CRYOGENIC MANUAL

CM 001

ISSUE 003

CRYOGENIC COLD END – PART No. 2LD000014

TITLE Bore 1.625” AND 1.375″ stroke. HYDRA RIG

SALES & SERVICE HYDRA RIG NOV

Telephone: 01493-666200 Excalibur Road
Fax: 01493-666249 Beacon Park
Email: hruksales@nov.com Gorleston
Norfolk. NR31 7RQ

ORIGINATOR S. Kent APPROVED N. Turner

th
DATE 20 January 2014 DATE 20 January 2014

REVISED S. Kent APPROVED N. Turner

DATE 30 June 2015 DATE 30 June 2015

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1.0 INTRODUCTION

The operating instructions in this manual describe the procedures for the operational
performance and maintenance of the Hydrarig NOV 2LD000014 Cold End. It is recommended
that the operator study this manual so as to obtain a complete understanding of the principles
of operation and general performance parameters of the pump and the related system.

A check must be made to ensure that lines and controls are installed correctly.

CAUTION

It is very important never to allow the cold end to operate without liquid supply. Damage to
the cold end will result.

1.1 Cryogenic Pumping - NPSH Requirements

The performance of the high pressure positive displacement cryogenic pump is directly
dependent, as are all such pumps, upon the net positive suction head (NPSH) quality of
cryogenic liquid, and characteristics of the suction feed system. According to service records
and reports of field engineers, more pump problems result from inadequate NPSH than from
any other single cause. NPSH difficulties can reduce pump capacities, and lead to incorrect
analysis of pumping problems. NPSH is expressed in terms of feet of head above vapour
pressure of the liquid being pumped. Reduction of pressure in the pump suction below the
vapour pressure of the liquid will cause “flashing”, a formation of vapour from the liquid. If this
vapour enters the pump cylinder, the pump will lose prime. The cylinder becomes vapour-
bound by the heat generated by compressing this vapour pressure of the liquids, thereby
compounding the problem.

CAUTION

Operation of the pump with one or more cylinders not primed may cause extensive damage
to the pump. A defrosted cold end or discharge line is an indication of prime loss.

1.2 Preventing Vapour Lock

The most common method used to remove this condition is to provide enough head (NPSH) on
the pump suction so that the pressure at the inlet of the pump is always greater than the
vapour pressure of the liquid. The term “available NPSH” is the head pressure available at the
required point due either to pressurisation or elevation of the liquid holder or sub-cooling the
liquid. (Sub-cooling means ‘cooling liquid below its normal boiling point at atmospheric
pressure’). The actual vapour pressure of a liquid cannot be changed without increasing or
decreasing the temperature of the liquid. The tendency in a cryogenic system is to continually
increase the temperature of the liquid, thereby increasing the vapour pressure of the liquid.
This condition places further demands on the artificially applied suction pressure (NPSH). The
remaining liquid may have its temperature reduced by allowing the liquid storage tank to be
vented to atmosphere thereby reducing tank pressure.

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1.3 Volumetric Efficiency and NPSH

The volumetric efficiency of the positive displacement pump is the percentage of liquid
displaced from the interior of the pumping cylinder or chamber by the piston. This function is
important to the efficiency in a cryogenic pumping unit in particular, as the residual liquid in the
cylinder has been raised to a high pressure, thereby increasing the energy level of the liquid.
The energy level of the residual liquid may also be considered heat energy, and, upon reducing
the pressure, the heat energy having raised the temperature of the liquid will result in a much
higher vapour pressure of this liquid. This higher liquid temperature will cause flashing in the
cylinder, reducing liquid flow into the pump suction if the NPSH is not greater than the resultant
vapour pressure of the liquid remaining in the cylinder.

In order to allow the pump to start smoothly and to run correctly, the NPSP required by the
pump design has to be built up.

NPSP = “Net Positive Suction Pressure” = excessive pressure above the actual vapour pressure
of the liquid in the suction nozzle of the pump. This pressure in the suction nozzle of the pump
is required to prevent local vaporisation of the liquid.

The actual vapour pressure is thereby determined solely by the temperature in the suction
nozzle of the pump.

Vapour Pressure Determination

The necessary NPSP has to be maintained during start-up as well as under service conditions.
The necessary NPSP in the suction nozzle of the pump may be achieved or improved by:

a. Increasing the static liquid head (higher position of the tank).

b. Sub-cooling of the liquid.
c. Pressure increase in the tank.
d. Better insulation of the piping.
e. Reduction of pressure loss in piping.

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1.4 Priming

The priming of a positive displacement pump for cryogenic service will vary with respect to the
specific system suction characteristics. It is necessary for an operator to become familiar with
the characteristics of the pump itself and also the system in order to understand its operation.
The cryogenic pump must be chilled down until the temperature of the metal is the same
temperature as the incoming liquid or does not exceed the temperature of the liquid at its
established NPSH. Typically we recommend a differential pressure between the cold end
suction and tank return of 30-50 PSI. When using a conventional LN2 tank with approx. 25psi
tank pressure the boost pump pressure at the cold end should be in the region of 65-75 psi.
When the pump is started, the operator should pay very close attention to the discharge
pressure rise which could indicate pump prime. If there is no immediate indication of pumping
action, the pump must be stopped and further chilling should take place. A small volume of
nitrogen can be vented to atmosphere in order to assist with pump priming this make; the
starting procedure is much simpler.

1.5 System Variations

The operator should become familiar with the particular system characteristics as these can
vary between unit designs

1.6 Precautions

1.6.1 WARNING

All safety precautions for cryogenics and high pressure systems must be taken while
using this pump. Safety devices must not be tampered with as very high pressures may
result in systems containing a positive displacement pump.

1.6.2 CAUTION

a. Make sure that the boost pump system can provide the necessary NPSH.

b. Do not operate the pump dry - perform cool down procedure to cool down and
prime the pump.

c. Do not operate the pump without proper lubricating oil and adequate oil
pressure.

d. The pump discharge line must have a relief valve which does not exceed the
rated working pressure of the pump.

WARNING
This is a positive displacement pump. If the discharge system is closed off, extreme pressure
may result, therefore, a safety valve should always be included in the discharge system.

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2.0 ROTATION, STARTING AND OPERATION

2.1 Rotation

Pump rotation must be as indicated by rotational arrow. If there is any doubt, remove the
balance weight cover on the NP 200 and observe the pump connecting rod to determine the
correct rotation. Reverse rotation will not allow proper drive assembly lubrication and may
result in major damage. If in doubt, please contact the Service Department at Hydrarig NOV.

CAUTION

The rotation must be as indicated by rotational arrow on the pump crankcase, otherwise
serious damage may occur.

2.2 Pump Start-Up

Observe the following before starting the unit for the first time.

a. Check oil level of the pump.

b. Jog the drive to determine that the rotation is correct.

c. Increase the supply tank pressure to 25 – 30 psi above initial tank pressure.

2.3 Priming the Pump

Fully open the suction, discharge, by-pass and vent to top of tank valves. Follow the boost
pump priming procedure as noted in CM-004
When frost appears over the pump head and approximately two-thirds of the length of the cold
cylinder, (this make take cooling time of approximately fifteen minutes of venting to tank or
five minutes when venting to atmosphere) the pump will be cooled down sufficiently to begin
pumping.

If prime cannot be attained, or if prime is lost while pumping, it may be an indication of too low
a suction pressure. Raise the supply tank pressure another 5-10 psi. The pump requires a
minimum of 25 psi pressure above the vapour pressure of the liquid itself.
Once the pump has primed, the head valve positions are:

Suction valve – open

Discharge valve – open
Return to tank valve – open
Vent to atmosphere valve – closed
Metering valve- variable

The pump will then operate continuously at any pressure up to the maximum pressure rating.

WARNING
Should the pump exhibit unusual noises and/or erratic discharge pressure, stop the pump and
determine cause.

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3.0 HIGH PRESSURE PUMP MAINTENANCE – Refer to Drawing 2LD000014

3.1 Removal of the Cold End

3.1.1 Disconnect suction, vent and discharge lines.

3.1.2 Remove the coupling clamp from the cold and power ends.

3.1.3 Back off the cold end lock nut (item 14).

3.1.4 If necessary, use a strap wrench to unscrew the cold end from the installation.

3.2 Disassembly of Cold End

A sturdy 6” vice mounted to a heavy duty bench is required. The vice jaws will require aluminium or
fibre soft jaws to prevent damage to the cold end.

The follows tools will be required:

• T645-00024 Cold end tool kit

• Soft hammer
• Small punch
• Engineers hammer
• Solvent based degreasing cleaner, quick to dry and must not leave a residue.
• Lint free rag and cleaning paper
• Large propane blowtorch
• Heat resistant gloves
• Surface lapping plate
• Diamond lapping powder and oil
• Fine grinding paste
• Hydraulic or mechanical press.
• Nitrogen cylinder with HP regulator to reduce pressure to 100-120 psi, 0-150psi gauge,
valve and hoses

3.2.1 Hold the cold end in the vice, using the soft jaws and squeezing on the body lock nut
(item 14) to prevent damage to the threads. Relieve jamming pressure of setscrews
(item 26); then, remove head jam ring (item 19) from cylinder. Remove setscrews
(item 26) from head jam ring. Note: The ends of the set screws may be damaged due to
the burring or swelling of the end of the screw. The damaged area will need to be
removed before attempting to unscrew the setscrew through the jam ring otherwise it
may seize or damage the threads.

3.2.2 Remove the discharge fitting (item 20), gaskets (item 7 and 12) and the poppet (item
15).

3.2.3 Remove pump head (item 23), head gasket (item 8), suction plate (item 22), and
suction spring (item 3).

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3.2.4 Remove the cold end from the vice and turn the cold end the other way up. Unscrew
the assembled packing nut (item 18) using the special wrench in the tool kit, assembly
consists of retaining ring, packing gland, self-lubricating bush and scraper, from cylinder
and disassemble. The bush is a press fit so will require a hammer and punch to remove
it (Items 9, 11, 18 and 27). Remove the orange O ring (item 25).

3.2.5 Remove the cold end from the vice and reposition horizontally in the vice. Push the
piston (item 24) form the bottom and remove it from the top of the cold end. Remove
the cold end from the vice and hold it vertically over the bench so the hat seals (item
10), hat seal spacers (item 17) and Belleville springs (item 2) fall out.

3.2.6 We advise that the cylinder sleeve (item 13) is removed for inspection to check for
cracks, scoring, wear and pitting. This may ne be necessary for a routine repair, but
should be removed for a more severe failure.

Note: The cylinder sleeve is a shrink fit in the body and requires rapid heating of the body to
release the sleeve.

3.2.7 To remove the sleeve, place the cold end body, upside down on a heat proof bench,
using the large blow torch, rapidly heat the circumference of the cold end body mid-
way up, (the area where the sleeve is located), the sleeve will be heard to drop once it
is released, quickly lift up the cold end body using the gloves and set to one side to
cool. The rapid heating allows the body to expand faster that the sleeve and allows it to
fall free. If it is heated to slowly, both items will heat up and the sleeve will not fall out.
If this happens allow the assembly to fully cool before trying again.

Note: Take care not to overheat the body.

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3.3 Inspection

All parts need to be cleaned thoroughly and inspected before use. A solvent based degreasing and
cleaning agent is most effective, providing that no residue is left on the components.

All seals, gaskets, rider rings and piston rings should be discarded every time the cold end is
disassembled.

All internal and external threads should be closely inspected for any damage; minor damage can be
repaired using a thread file. Any major damage will require the part to be scrapped and new
components used.

Once cleaned the following should be checked:

3.3.1 Cylinder Body

The external thread on the body is extremely important, very minor damage can be cleaned with
thread files. This thread is not a standard sized thread; the tolerances are tightened to ensure that
when the cold end is attached to the triplex pump a tight fit is achieved. Any damage has the potential
to cause the cold end to ‘pick-up’ on the pump causing both parts to require replacing.

The suction fitting thread should also be checked to ensure the thread form is in good order; again, any
damage has the potential to cause the cold end to leak.

The area inside the bore of the cold end has to be checked for any signs of corrosion, the small band
located just above the suction port is where the wedge seal extrudes to provide a seal. Any corrosion
on this area has the potential to cause the cold end to fail. Light surface corrosion can be removed
using a fine grade emery paper or wire wheel. Any deep pitting/corrosion will require the body to be
replaced.

3.3.2 Piston

The shaft of the piston should be checked for any signs of scoring and pitting, any light marking can be
polished using a fine grade emery paper. Deep scoring will cause the hat seals to fail so the piston will
require replacing.

The grooves at the top of the piston should be checked for any signs of damage. If the cold end has
overheated or been used for a long time, the rider rings and piston rings can wear out. If this happens
the piston will run against the cylinder sleeve and damage both.

The clamp end of the piston also needs checking for signs of damage. If damaged, the pony rod adaptor
may not fit properly which will cause the cold end to not run completely true in the triplex pump.

3.3.3 Sleeve

The sleeve is made from hardened carbon steel, therefore it will quite often corrode. Any light
corrosion can be removed using emery paper. The bore needs careful inspection to ensure that no
pitting, cracks or scoring has occurred. It is possible to use a fine grade honing tool to clean any light
damage in the bore, any significant damage will require replacement. The sleeve is machined to
extremely tight tolerances so only minimum honing should be attempted.

On occasion it is possible for the discharge port of the cold end to become blocked, if this occurs the
sleeve has the potential to crack. When inspecting, be vigilant for any signs of hairline cracks.

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3.3.4 Pump Head

The pump head should be inspected for any signs of damage to the poppet sealing area in the bore and
also the plate valve sealing face. The serrations on the top of the head also need checking to ensure
that the gasket will provide a good seal.

After each use the poppet sealing face will require lapping to ensure that a good sealing face is present.

Using the lapping tool from the tool kit (Part number CRT1029) and some fine grinding paste spin the
pump head from side to side until any scoring has been removed. When looking in the bore a light grey
area should be visible, with no scoring.

The plate valve sealing face will also require lapping and polishing after each use. Any light scoring
should be removed when run on a lapping machine until a uniform light grey finish is achieved. If any
scoring is still visible it is possible that the plate valve will not seal. Repeat the lapping process until no
scoring can be seen. Once lapped the pump head should be polished to a mirror finish using a liquid
diamond compound on a felt pad. This will allow for a perfect sealing face.

3.3.5 Plate Valve

The plate valve should be inspected for any signs of scoring on the sealing face. After each use the plate
valve should be lapped and polished in the same way as the pump head.

If the cold end has been in normal operation it is normally more cost effective to replace rather than try
and lap and polish this part. Lapping and polishing is normally only attempted when the cold end has
not run for a long period of time.

3.3.6 Discharge Fitting

The discharge fitting should be inspected for any signs of damage and/or corrosion, particular attention
should be given to the autoclave sealing area and the serrations on which the discharge gasket seals.

3.3.7 Jam Ring

The threads on the jam ring should be inspected for any signs of damage. As stated earlier, it is possible
to clean minor damage with a thread file but any significant damage and the part should be replaced. It
is prudent to run a 5/16” tap in each of the threaded holes to clear any debris before attempting to
insert the cap head screws. Hydrarig NOV recommends that the cap head screws are replaced on each
occasion the cold end is serviced.

3.3.8 Suction Spring

Hydrarig NOV recommends that the suction spring is replaced every time the cold end is serviced. If this
is not possible, a visual inspection should ensure that the ends of the spring are not folded over and
that the wire is still is a good condition.

3.3.9 Discharge poppet

The discharge poppet should be inspected for any signs of wear, if the cold end has been run for
extended periods. Hydrarig NOV recommends that the poppet is replaced. It is possible to lap and
polish the poppet to ensure that the sealing face is in good condition, but it is more cost effective to
replace on each occasion that the cold end is serviced.

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3.3.10 Packing Nut

The packing nut should be inspected for any signs of damage to the threads and any distortion. Once
again any minor thread damage can be removed with a thread file. When assembling the cold end it is
possible for the packing nut to become distorted, this will cause the bushing/rider ring to not sit
correctly over the piston.

The retainer ring groove should also be checked, to ensure the retainer fully enters which will, in turn,
stop the scraper ring from dislodging from its correct position.

All other cold end components require a visual inspection for any signs of damage and/or corrosion.
The spacer seals, ring seal and Belleville springs rarely require replacing.

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3.4 Reassembly of the cold end

Note: When assembling any cold end it is important to ensure that all parts are cleaned prior to
installing, the best way to complete this is to use solvent based quick dying cleaner that leaves
no residue followed by wiping any residue with a clean paper or clean soft rag.

3.4.1 This is a basic guide to aid assembly to provide the individual person with the information
required to rebuild cold ends to as new condition.

3.4.2 The cold ends must be rebuilt in a very clean, dry and dust free environment.

3.4.3 Lay the components out on the bench in the order that they will be assembled. Ensure that any
protective coatings are removed and that all parts are clean and free from any grease, dust or
moisture.

3.4.4 Take the packing gland nut (item 18) insert the self-lubricating bush (item 9), this can normally
be achieved by pushing in by hand, on some occasions a vice or press is needed.

3.4.5 Turn the packing nut over and insert the scraper ring ( item11), to aid assembly it can be useful
to remove the edge on the inside of the bore of the scraper ring with a hand scraper. Press the
retainer ring (iteme27) into the groove on the packing nut and check that the scraper ring
cannot be removed.

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3.4.6 Take the jam ring (item19) and the setscrews (item 26) and coat with anti-seize compound over
the entire length of the threaded section also into each internal thread of the jam ring. Screw a
cap head into each of the bores until they are just short of protruding all the way through; leave
two opposing cap head higher than the rest to aid assembly.

3.4.7 The piston rider rings need to be hand sized to the sleeve for the best possible fit. Take the
piston (item 24), chamber sleeve (item 13), 2 x rider rings (item 5), 4 x expander rings (item 6)
and 8 x piston rings (item 4).

3.4.8 Place the piston horizontally in a vice using a soft rag to ensure that the piston does not get
damaged.

3.4.9 Place one of the rider rings into the first groove on the piston, take the cylinder sleeve and push
over the piston/rider ring.

3.4.10 The sleeve should be able to move over its entire length with some resistance, if this cannot be
done by hand the rider ring is too large, remove the rider ring and use a hand scraper to scrape
a small amount evenly out of the inside surface/bore. Replace the rider ring onto the piston and
try again. Repeat this process until the liner moves smoothly over the piston/rider ring. If the
sleeve passes over the rider ring with little or no resistance it will have to be replaced as the
rider ring would be too small.

3.4.11 Once the first rider ring has been checked, move it to the bottom groove on the piston and try
the liner again. Assuming that the sleeve still runs smoothly over the entire length, take the
second rider ring and repeat this process in the first rider ring groove, until the sleeve runs
smoothly over both rider rings.

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3.4.12 Take the cylinder body (item 21) and sleeve (item 13) and start heating the body with the blow
torch or heat gun until the body has been heated sufficiently to allow the sleeve to be dropped
into place. Make sure the sleeve is the correct way up! The serration and plate valve recess
should be visible when installed. A distinct noise should be heard when the sleeve bottoms out
in the body, if the sleeve does get stuck before ‘bottoming out’ a sharp tap with a hammer may
be enough to help it locate in the correct position. The sleeve will heat up quickly; if it does it
becomes impossible to push into the correct position. The propane torch will have to be used
to heat up the body until the sleeve drops out, once it has been allowed to cool the body can be
re-heated and the sleeve can be dropped in again.

3.4.13 Place the body to one side to cool. A fan can be used to speed the process.

Important: The body must never be quenched in water.

3.4.15 Going back to the piston, spin the rider rings round to ensure the splits are 180˚ from each
other.

3.4.16 Place the piston vertically in the vice, ensuring that it is still protected from damaged by a soft
rag, install the 4 expander rings (item6) into the grooves in the piston; spin them round so that
all 4 gaps are in a line.

3.4.17 Install one piston ring (item 4) into the bottom groove so that the gap is approximately 120˚
from the gap in the expander ring. Take another piston ring and install in the same groove,
again so that it is approximately 120˚ from the other gaps. This is to ensure there is not a
complete channel for the liquid to travel along.

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3.4.18 Repeat above process for all the other grooves in the piston.

IF YOU ARE REPAIRING MULTIPLE COLD ENDS, YOU MUST ENSURE THAT THE BODIES, SLEEVES AND
PISTONS ARE KEPT IN ORDER OR THEY WILL NOT FIT TOGETHER CORRECTLY ON ASSEMBLY!!!!

3.4.19 Ensure the cylinder sleeve has cooled to room temperature.

3.4.20 Apply a small band of anti-seize compound onto the external thread of cylinder body
approximately ¾ of the way from the top. Screw on the lock nut (item 14) until it locates on the
anti-seize.

3.4.21 Clean the entire piston assembly with the solvent cleaner.

3.4.22 Place the insertion tool/ ring compressor horizontally in the vice with the larger funnel end
facing you, insert the piston complete with expander rings, piston rings and rider rings into the
insertion tool clamp end first until the lower rider ring is near the bottom of the insertion tool.
Place the tool and piston into the bore of the cylinder body ensuring that it sits in the counter
bore of the sleeve. Using a press, push the piston assembly into the sleeve until the top of the
piston clears the counter bore.

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3.4.23 Put the cylinder body in a vice, holding on the lock nut with the main bore facing upwards.

3.4.24 Using a pair of internal circlip pliers in the poppet bore hold the pump head (item 23) and insert
into the body, ensuring that it locates in the counter bore of the sleeve. If the sleeve has been
inserted in the correct position the measurement from the top of the pump head to the top of
the body should read 32mm.

3.4.25 Remove the pump head with the circlip pliers.

3.4.26 Compress the suction spring (item 3) by hand to ensure it is square. Twist the wire until the
coils compress ‘in-line’ and no wire bulges out of the side.

3.4.27 Insert the spring into the counter bore of the sleeve.

3.4.28 Using a pair of internal circlip pliers place the plate valve (item 22)on the suction spring,
ensuring that the face of the plate valve is clean and free of any dirt. Still using the circlip pliers
press the plate valve up and down on the spring, make sure the plate valve freely enters the
counter bore and does not jam up at any point. Do not touch the surface of the plate valve.

3.4.29 Pick up the pump head and insert the head gasket (item 8) into the groove. Top tip!!Tap the
gasket on the bench to make it slightly oval, this will allow you to press it into the groove and
still be able to lift the pump head without the gasket falling off.

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IMPORTANT: ENSURE THAT WHEN DOING THIS THAT YOU DO NOT TOUCH THE SEALING FACE OF
THE PUMP HEAD AND PLATE VALVE!!!!

3.3.30 Again using a pair of circlip pliers, pick up the pump head. Place in the bore of the cylinder so it
sits on the plate valve and compresses the spring into the counter bore of the sleeve.

3.3.31 To ensure everything has located correctly a measurement should be taken, this measurement
should be between 30 and 32mm from the top of the pump head to the top of the cylinder
body.

3.3.32 Using a length of aluminum wire, (through the ¾” NPT bore of the body and the small bores on
the pump head) gently press down on the plate valve. There should be free movement, an
audible click can be heard as the plate valve seals on the pump head. If there has been a
problem during assembly the plate valve may not move. If this happens remove the pump head
and plate valve. The most common problem is that the ends of the suction spring have folded in
causing the plate valve to jam.

3.3.33 Place the poppet valve (item 15) into the bore on the pump head.

3.3.34 Please note that we no longer install a discharge spring into our cold ends, any repairs that
come in with a discharge spring included can be repaired without a spring.

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3.3.35 Insert the wedge seal (item 12) ensuring that it fits onto the 45˚ chamfer on the pump head.

3.3.36 Place the discharge gasket (item7) on the top of the pump head.

3.3.37 Insert the discharge fitting (item 20) into the cylinder body ensuring that it locates securely into
the bore of the pump head.

3.3.38 Apply some anti-seize to the external thread of the jam ring and screw into the cylinder body.
Use a piece of flat bar to tighten against the 2 cap head screws that were left higher than the
rest. Be careful as the cap heads are quite soft and bend easily.

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3.3.39 Using a ¼” allen key screw in setscrews (item 26). Tighten opposite screws in sequence to
ensure that the discharge fitting presses down squarely. Torque to 20ft/lbs, to set the gaskets.

3.3.40 Unscrew all cap heads again, use a piece of flat bar to re-tighten the jam ring. There will be
more movement because by tightening the cap heads you have compressed the gaskets into
the serrations and also compressed the wedge seal.

NOTE: Do not allow the head to move during this process and it may disturb and unseat the gaskets.

3.3.41 Once the jam ring is tight again tighten all the cap heads working your way round going from
opposite to opposite, use a torque wrench set to 20ft/lbs. You will need to do this 3-4 times to
ensure the gaskets are fully compressed and all of the screws are evenly torqued.

3.3.42 Remove the body from the vice and turn 180˚ upside down.

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3.3.43 Take the two Belleville springs (item 2) and place into the bore over the shaft of the piston. The
Belleville springs are dished and should be opposing with the contact area in the center. Refer
to the drawing for correct orientation.

3.3.44 Use the installation tool to push the springs down until they ‘bottom out’.

3.3.45 Insert one of the spacer seals (item 17) into the bore, again use the installation tool to press the
spacer to the bottom of the bore. When installing the spacer seals ensure that the wider end of
the bore is facing upwards. Refer to the drawing for the correct orientation.

3.3.46 Place one of the hat seals (item 10) over the end of the piston. Ensure that it is pointing down.
Place the next spacer seal on top of the hat seal again making sure that is also the correct way
round. Press the two components into the bore using the installation tool.

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3.4.47 Repeat this process until all spacer seals and hat seals have been used. The final hat seal will not
have a spacer on top and can be pressed down on its own.

3.4.48 Place the ‘o-ring’ (item 25) over the piston, gently press down until it sits round the bore and
flat to the hat seal.

3.4.49 Insert the ring seal (item16) so that the 45˚ chamfer sits over the ‘o-ring’, ensure this is in place
by pressing down with the installation tool.

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3.4.50 Finally, coat the packing nut assembly with anti-seize and place over the piston. Use the packing
nut spanner and fully tighten by hand, this will compress the hat seals into the spacer seals.
When tight ‘back-off’ the nut a small amount. The packing nut should be tight enough to
compress the Belleville washers, but not too tight to squash the hat seals.

The cold end is now ready for testing.

3.5 Testing procedure

3.5.1 Hold cold end in vice - piston facing down, ensure that there is a maximum of 2 inches (50mm)
below the piston, as it will move when pressure is applied. If too much room is left under the
piston it can shoot straight out of the cold end!

3.5.2 Plug 9/16” autoclave port in the discharge fitting.

3.5.3 Plug ¼” NPT port on the side of the cylinder body

3.5.4 Use a ¾” NPT x JIC12 fitting in the suction port of the cold end, attach the nitrogen bottle.

3.5.5 Pressurize the cold end to 100-120psi. Turn off the nitrogen valve.

3.5.6 Watch the attached gauge for any signs of decreasing value.

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3.5.7 If the gauge shows a leak try the following:

• Tighten cap heads again to 20 ft/lbs, they can loosen over time
• Tighten packing nut (ensure nitrogen is off before undoing the vice, otherwise
• Piston will shoot out of cold end!)
• Check all fittings are tight.

3.5.8 If no leak is readily apparent a small amount of solvent or soapy water can be put over the
sealing areas to see if any bubbling occurs which will indicate a leak.

3.5.9 Ideally there will be no movement in the gauge when nitrogen valve is shut. This is not always
the case however. A small decrease in pressure is allowed. When the cold end is assembled on
the triplex pump and is running they do ‘run themselves in’ as the piston moves up and down
the hat seals.

3.6 Installation of Cold End Assembly

Replacement cold end assemblies have been cleaned for service at the factory. Extreme
caution should be exercised to prevent contaminating any internal fitting or tubing connection
during replacement.

3.7 Head Clearance Adjustment

The drive is designed for adaptation with several different cold ends. It is necessary, in all
configurations, to maintain a head clearance between .020 and .090 inches. This clearance is
pre-set at the factory, but must be adjusted if the cold end is removed and/or replaced.

DO NOT TURN THE POWER END / COLD END ASSEMBLY HYDRAULICALLY UNTILL THE
FOLLOWING INSTALLATION PROCEDURE HAS BEEN CARRIED OUT.

a) Turn the power end until the connecting rod is at Top Dead Centre.

NOTE – HR200 POWER END

1. Remove the hydraulic drive motor

2. Insert special tool part number into the spline drive.
3. Place ratchet and socket on the end of the special tool and turn the power end
to achieve Top Dead Centre.

For cold ends which are threaded into the drive and are held in place with a locknut, set
headspace as follows:

b. Screw the cold end assembly into the immediate housing until it bottoms out.

c. Unscrew the cold end assembly until the vent port is vertically up. If less than 180°
rotation is required to position the vent port vertically, turn the cold end one more
complete turn.

d. Rotate the pump crankshaft by hand to verify that the cold end piston does not hit the
cylinder head at top dead centre position.

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e. If the shaft cannot be rotated because of interference, unscrew the cold end assembly
one complete turn only; then check again.

f. Tighten the lock nut.

4.0 LUBRICATION

Ambient Temperature Non-Oxygen Service

-40°F to +45°F SAE 10W

+10°F to +85°F SAE 30W
+60°F to 130°F SAE 40W

The lubrication system is a self-contained design, and is trouble-free if the proper grade of oil is
used. Oil levels should be checked at least once a week to safeguard against damage to the
drive end. It is recommended that the oil be changed after the first twenty (20) hours of
service. Thereafter the oil should be changed every 500 hours, or once every six (6) months
whichever comes first.

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5.0 HIGH PRESSURE PUMP TROUBLE SHOOTING
This section contains a brief troubleshooting guide to be used to locate probable malfunctions.
Trouble
Failure to prime, loss of
prime while pumping or low
flow.
Leaking low pressure seals.
Leaking crosshead oil seal.
Excessive drive noise or high
drive temperature.
Excessive drive noise or high
temperature.
Low Discharge Pressure
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Probable Cause Remedy
Insufficient suction head. Verify proper operation of boost pump
and the two related solenoid valves. If
pump and valves operate satisfactorily,
review the section on NPSP to verify the
condition of the liquid supply.
Open vent valve to tank.
Vent line closed.
Warm to 150° to 225°F and purge with
Foreign material in cold end. dry gas.
Increase pump suction to minimum of
Loss of suction pressure. 25 psi over vapour pressure.
Clean suction filter.
Dirty filter.
Repeat priming procedure. Check NPSH.
One cylinder not primed.
Worn packing. Replace low pressure seals.
Worn seal. Replace oil seal in intermediate.
Loss of Oil. Drain and replenish oil. Rotate pump by
Worn parts. hand and check for noise or abnormality
of operation.
Overloaded. Reduce discharge pressure. Discharge
system restricted.
Worn or damaged parts. Repair drive assembly.
Insufficient NPSH. Verify proper operation of boost pump
and check liquid flow by opening boost
pump prime valve slightly until flow is
verified.
Worn piston rings. Replace piston rings.
Damaged suction valve. Repair valve; relap valve.
Damaged discharge poppet. Replace poppet.
Insufficient NPSH. Verify proper operation of boost pump
system, and check liquid condition in
supply tank.
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