Manual de Operación de Unidades de Nitrógeno

SPU-270F Nitrogen Skid
Operator’s Manual
Part No. 101812329

All information contained in this publication is confidential and proprietary property of
Halliburton Energy Services, Inc. Any reproduction or use of these instructions, drawings,
or photographs without the express written permission of an officer of Halliburton is for-
bidden.
© 2011 Halliburton
All Rights Reserved. Printed in the United States of America.
Part No. 101812329
Printing History:
First Printing (May 2011)
Contents
Section 1—Introduction/Operational Characteristics

Introduction................................................................................................... 1-1
Unit Features ................................................................................................ 1-2
Operational Characteristics ........................................................................ 1-10
Section 2—Nitrogen Safety

Nitrogen Properties....................................................................................... 2-1
Nitrogen Expansion ..................................................................................... 2-3
Nitrogen in the Air......................................................................................... 2-3
Safety Precautions for Handling Liquid Nitrogen ......................................... 2-5
Wear Protective Clothing ....................................................................... 2-5
Avoid Skin Contact ................................................................................. 2-5
First Aid Procedures for Cold Liquid Frostbite (Freeze Burns) .................... 2-7
Symptoms .............................................................................................. 2-7
Treatment ............................................................................................... 2-7
What Not to Do ....................................................................................... 2-8
Oxygen Deficiency Hazard .......................................................................... 2-8
Liquid Nitrogen Equipment Safety ............................................................... 2-9
Cryogenic Materials and Components ................................................... 2-9
Cryogenic Materials .......................................................................... 2-9
Cryogenic Components ................................................................. 2-10
Non-cryogenic Material and Components ............................................ 2-10
Non-cryogenic Materials ................................................................ 2-10
Non-cryogenic Components .......................................................... 2-10
Equipment Precautions ............................................................................. 2-11
Treating Iron Low-Temperature Limits ................................................. 2-12
Pressure Buildup from Trapped Liquid Nitrogen ....................................... 2-12
i
Section 3—Preliminary Checks
Set Pressures ...............................................................................................3-1
Calibrating the ANRCS Unipro™ II Controller ..............................................3-2
Pump A ...................................................................................................3-2
Pump B ...................................................................................................3-2
Fluid-Level and Pressure Checks ................................................................3-3
Section 4—Operating the Unit

Rig Up...........................................................................................................4-1
Introduction..............................................................................................4-1
Setup, Iron, and Bleed off........................................................................4-1
Check Valves ..........................................................................................4-4
Bleeder Tee.............................................................................................4-4
Replacement Parts for Bleeder Tees................................................4-5
Flowback of Energized Fluids .................................................................4-5
Conditioning Liquid Nitrogen.........................................................................4-5
Pumping Procedure.................................................................................4-6
Before Starting the Engine............................................................................4-6
Starting the Engine .....................................................................................4-13
Readings to Observe During Engine Warm-Up ....................................4-13
Preparing the Unit to Pump ........................................................................4-13
Pumping the Unit .......................................................................................4-21
Transitional Pumping.............................................................................4-22
Transitioning from Single-Pump Mode to Dual-Pump Mode...........4-22
Transitioning from Dual-Pump Mode to Single-Pump Mode..........4-23
Low-Rate Pumping................................................................................4-24
Gauges to Monitor during Pumping.......................................................4-24
After Pumping is Completed .......................................................................4-25
Section 5—Maintenance
Maintenance Specifications ..........................................................................5-1
Parts List.......................................................................................................5-2
Diagrams ......................................................................................................5-9
ii
Section 6—Troubleshooting
Introduction ...................................................................................................6-1
Engine Troubleshooting Guide .....................................................................6-2
Nitrogen Pumping System Troubleshooting Guide.......................................6-6
Tank Troubleshooting Guide ........................................................................6-7
iii
iv
SECTION
Section
1
Preface
Introduction/Operational
Characteristics
Introduction
Note The information contained within this manual is not intended for the purpose of
operator training. Any personnel operating this equipment should have the proper
level of training and competency requirements before attempting to operate it.
The SPU-270F nitrogen converter skid is a nitrogen pumping unit that converts low-pressure liquid
nitrogen to high-pressure gas using both a hot water bath and an exhaust vaporizer. This unit utilizes
two triplex pumps equipped with cryogenic fluid ends to attain a maximum combined pumping rate
of 270,000 scf/h.
The upper triplex pump is capable of 90,000 scf/h at a maximum allowable working pressure
(MAWP) of 15,000 psi.
The lower triplex pump is capable of 180,000 scf/h at a maximum allowable working pressure
(MAWP) of 10,000 psi. Hence, the limited max pressure at max rate is 10,000 psi (limited by the
maximum pressure capability of lower pressure-rated triplex).
Because this unit does not contain a source of liquid nitrogen, a self-contained liquid nitrogen storage
tank must be used to provide the product for pumping. The pressure-building system located on the
storage tank pressurizes the tank contents and pushes the liquid nitrogen through the low-pressure
piping to the pumping unit's high-pressure triplex pumps.
The pressure-building system in the storage tank takes liquid nitrogen from the bottom of the tank and
passes it through the pressure-building coil. After the liquid is vaporized to gas, it is then returned to
the top of the tank. The high expansion ratio of liquid nitrogen changing to gas causes the tank to
pressurize. The tank-pressure building systems are designed to maintain adequate tank pressure,
thereby ensuring sufficient net positive suction head is available at the inlet of the boost pump or LN2
fluid ends.
May 2011 Introduction/Operational Characteristics 1-1

SPU-270F Nitrogen Skid Operator’s Manual
The unit's high-pressure triplex pumps and fluid ends energize the liquid and push it through the
high-pressure piping to the liquid-nitrogen vaporizers, where it is converted from a
high-pressure/low-temperature liquid to a high-pressure/higher-temperature gas.
Unit Features
Figure 1.1 through Figure 1.6 show the basic configurations of the SPU-270F nitrogen converter
skid.
Figure 1.1—Front view of the SPU-270F converter unit.
1-2 Introduction/Operational Characteristics May 2011

Figure 1.2—Rear view of the SPU-270F converter unit.

Figure 1.3—Left-hand view of the SPU-270F converter unit.

Figure 1.4—Left-hand view of the SPU-270F converter unit (lift frame removed).

Figure 1.5—Right-hand view of the SPU-270F converter unit.

Figure 1.6—Right-hand view of the SPU-270F converter unit (lift frame removed).

Table 1.1—Unit Specifications

Unit Performance (Target)
Maximum rate at 10,000 psig: 270,000 scf/hr
Maximum rate at 15,000 psig: 90,000 scf/hr
Minimum rate at 15,000 psig: 350 to 400 scf/min
Minimum discharge temperature: 70°F
Weight and Dimensions
Maximum weight: 29,540 lbm
Maximum width: 8 ft, 6 in.
Maximum height (with drip pan): 9 ft, 6 in.
Maximum length: 14 ft, 6 in.
Engine
1. Caterpillar C-18 rated at 700 bhp at 2,100 rev/min
2. EPA Tier III emissions compliant
3. Electronic controls: see Controls
4. Dry-exhaust system (manifold, turbocharger, etc.)
5. Air-start
Pumps
1. One CS&P model ICPE-200 triplex with 1.625-in. bore cold ends rated for
10,000-psig maximum working pressure
2. One CS&P model ICPE-200 triplex with 1.250-in. bore cold ends rated for
15,000-psig maximum working pressure
3. One 1.5  2.5  6 centrifugal boost pump (Optional)
4. All driven hydraulically
Vaporizers
1. One CS&P exhaust: engine exhaust gas heat
2. One CS&P water pot: engine coolant, hydraulic, and lube systems waste heat
3. Diverter valve: used to split flow between vaporizers

Table 1.1—Unit Specifications (Continued)

Skid Base
1. Constructed of square/rectangular carbon-steel tubing
2. Bottom ISO container connections on a nonstandard (10-ft) pattern (size ID)
3. Separate removable drip pan with ISO container connections
Lifting Frame
1. Constructed of square/rectangular carbon-steel tubing
2. Attached to skid base with stainless-steel pins
3. Top corner lifting eyes: no top ISO-container connections
Controls
1. Primary nitrogen-rate control: manually operated hydraulic valve
2. Primary nitrogen-rate/volume instrument: NuFlo MC-II flow analyzer
3. Secondary nitrogen-rate control instrument: ANRCS with Unipro™ II controller
4. Engine control: electronic, including throttle and tachometer
5. Engine starting: air starter and air valves
6. Discharge-nitrogen valve: remotely operated with air actuator
7. Electrical control console: components sealed air-tight inside common enclosure
to minimize offshore corrosion
8. Mechanical control console: components inside common enclosure
9. All functions unless otherwise specified: analog gauge monitoring
10.All controls, valves, etc. unless otherwise specified: manually operated
Heat-Gathering Water System
1. One circulating coolant pump: Viking LL4126 (~200 gal/min)
2. One water-to-air intercooler: engine charge air cooling
3. One plate and frame heat exchanger: engine-jacket water cooling
4. One plate and frame heat exchanger: hydraulic heat-building oil cooling
5. One tube-and-shell heat exchanger: hydraulic-case drain-oil cooling
6. One tube-and-shell heat exchanger: triplex-pumps lube-oil cooling
7. One radiator: supplementary engine cooling

Table 1.1—Unit Specifications (Continued)

Tanks
1. 65-gal ASME-coded air tank: 4 seconds of air-start running
2. 100-gal aluminum fuel tank: 2.5 hours operating at full power
3. Optional remote-fuel connections with fuel-switching valve
4. 50-gal aluminum triplex-pump lubricating-oil tank: 2 triplex pumps
5. 70-gal aluminum hydraulic tank
6. Two expansion tanks: engine-water system and heat-gathering water system
Other Features
1. Hydraulic pumps and relief valves used to consume excess engine power for heat
building
2. Air compressor: engine driven
3. 24-V DC alternator: engine driven
4. Two batteries in sealed box: electricity supply for electronic controls
5. Connections for remote power supply
6. Painting: Halliburton red per three-coat offshore system (plus a clear coat)
Operational Characteristics
In general, flameless nitrogen units convert liquid nitrogen to gas by adding waste heat generated by
hydraulic, water, and engine-exhaust systems. The energy required for vaporization is dependent on
the nitrogen flow rates, which are generally expressed in standard cubic feet per minute (Scf/min). As
pumping rates increase, so do the energy requirements necessary for vaporization.
This nitrogen converter skid operates in much the same manner as other existing converters; however,
this SPU-270F has certain operating characteristics that are unique to its design. Details of the unique
operating characteristics are listed within the operating procedures of this manual.

SECTION
Section
12
Preface
Nitrogen Safety
Nitrogen Properties
Nitrogen (N2) is a nontoxic, colorless, and odorless gas naturally occurring in the atmosphere (78%
of air is nitrogen). Nitrogen is brought to the work site in liquid form in cryogenic tanks at -320°F
(-196°C). The nitrogen is then pumped through a cryogenic pump and forced into a vaporizer. While
passing through the vaporizer, the liquid nitrogen absorbs the suffucient heat needed to vaporize into
gas. The nitrogen gas is then forced out of the vaporizer and down the service piping to perform the
prescribed job function.
Because nitrogen is an inert gas, it cannot react with hydrocarbons to form a combustible mixture. In
addition, nitrogen is only slightly soluble in water and other water-based liquids, which allows it to
remain in bubble form when commingled with these fluids. Nitrogen does not support life functions,
and it is a poor conductor of heat. Table 2.1 (Page 1-2) lists some of the important properties of
nitrogen at atmospheric pressure (14.7 psia [101 kPa absolute]).
May 2011 Nitrogen Safety 2-1

Table 2.1—Physical Properties of Nitrogen (at 14.7 psi [1.01 bar])

Boiling Point -320.42°F (-195.79°C)
Liquid Weight Density 6.745 lbm/gal (0.8082 kg/L)
Gas Weight Density 0.0724 lbm/scf (1.160 kg/scm)
Gas Density Relative to Air at
0.97
70°F (21°C)
Gas Density Relative to Air at
3.8
-320°F (-195.79°C)
Heat Required to Convert Liquid
184 Btu/lbm
to a Gas at 70°F (21°C)
Expansion Ratio of Liquid to
1 to 697a
Gas
Solubility in Water 2.35 parts nitrogen in 100 parts water at 32°F (0°C);
1.55 parts nitrogen in 100 parts water at 68°F (20°C)
a
1 gal of liquid nitrogen at -320°F expands to 93.11 scf of gas at 70°F.
1 L of liquid nitrogen at -196°C expands to 0.697 scm of gas at 21°C.
Table 2.2—Nitrogen Converter Data
Pounds Standard Cubic Gallons of

Unit (lbm) Feet (Scf) Gasa Liquid
One pound 1.0 13.80 0.1481
One ton 2,000 27,605 296.5
One gallon liquid 6.745 93.11 1.0
One cubic ft liquid 50.46 696.5 7.48
aOne Scf is at 14.7 psia and 70°F.
2-2 Nitrogen Safety May 2011

Nitrogen Expansion
Nitrogen expands greatly as it absorbs heat from the environment. Nitrogen expands 697 times its
volume in going from a liquid at -320.4°F to a gas at 70°F, as shown in Figure 2.1.
Figure 2.1—Liquid nitrogen at -320°F (-196°C) expands its volume

697 times when heated to 70°F (21°C).
Nitrogen in the Air

Air contains 78% nitrogen, 21% oxygen and 1% other rare gases (Figure 2.2, Page 2-4). Nitrogen
gas is colorless, odorless, and non-toxic or irritating. Nitrogen gas neither burns nor supports
combustion, will not support life functions, and is a poor conductor of heat.
Oxygen is the component of air, which supports combustion as well as supports life functions and
makes up 21% of the air you breath.

Figure 2.2—Air contains 78% nitrogen, confirming that nitrogen

gas is colorless and odorless and is not toxic or irritating.
Figure 2.3 (Page 2-5) shows the extraordinarily cold nature of liquid nitrogen. You can see the
temperature at which the following items boil (below sea level):
• Carbon dioxide at -109.3°F

• Oxygen at -297.3°F
• Nitrogen at -320.4°F
• Absolute zero at -459.7°F
• Water at +212°F
Liquids can boil both on the positive and negative side of the temperature spectrum.

Figure 2.3—Cryogenic thermometer showing the extraordinarily

cold nature of liquid nitrogen.
Safety Precautions for Handling Liquid Nitrogen
Wear Protective Clothing

• Face shield and safety glasses
• Loose-fitting insulated leather welder gauntlet-type glove
• Long-sleeved shirts or coveralls
• Cuffless trousers
• Hard hat without rain gutter
• Proper foot protection (i.e., high-top boots with steel toes)
• Hearing protection
Avoid Skin Contact

• Liquid leaking from equipment
• Cold equipment surfaces
• Liquid leaking from loose connections (defective seals)

Liquid nitrogen is hazardous! Contact of human tissue with severe cold will destroy tissue in a manner
similar to high-temperature burns. Freeze burns will result from contact with the actual liquid or
contact with the cold surfaces of piping and equipment containing the liquid. An increased dimension
of hazard is added when the liquid nitrogen is under pressure. These facts emphasize the need for
protective clothing and safety attitudes by the nitrogen equipment operator or personnel working
around nitrogen (Figure 2.4). Safety glasses or goggles and a face shield should be worn if liquid
spraying or splashing may occur, or if cold gas could leak forcefully from equipment. Clean, insulated
gloves that can be easily removed and long sleeves are recommended for hand and arm protection.
Cuffless trousers should be worn outside boots or overshoes to shed spilled liquid. Hearing protection
should also be used.
Liquid nitrogen causes immediate eye damage that is usually beyond repair. The severe nature of eye
injuries emphasizes the extreme importance of wearing eye protection (Figure 2.5, Page 2-7).
DANGER One drop of liquid nitrogen to the eyeball will damage the eyeball
instantaneously. This damage is usually beyond repair.
Figure 2.4—(Left) Improper PPE and (right) proper PPE.

Figure 2.5—Always protect your eyes when working around nitrogen.
First Aid Procedures for Cold Liquid Frostbite (Freeze Burns)
Symptoms
• Skin pink just before frostbite develops
• Skin changes to white or grayish-yellow as frostbite develops
• Initial pain that quickly subsides
• Victim feels cold and numb; he or she is often not aware of frostbite
Treatment
1. Immediately flood or submerge the affected body area with large quantities of clear, lukewarm
(NOT HOT) water, preferably 95 to 105°F.
2. Cover the frostbitten part with a warm hand or woolen material. If fingers or hand is frostbitten,
have victim hold hand in his or her armpit, next to body.
3. Bring victim inside as soon as possible.
4. Gently wrap the part in blankets if lukewarm water is not available or is impractical to use.
5. Let circulation reestablish itself naturally.
6. When the part is warmed, encourage the victim to exercise fingers and toes.
7. Give victim a warm, nonalcoholic drink.
8. Get patient to a physician for treatment.

What Not to Do
• Do not rub the injured tissue with snow or ice. Rubbing frostbitten tissue increases the risk of
gangrene.
• Do not use hot water, hot water bottles, or heat lamps over the frostbitten area.
Oxygen Deficiency Hazard

Refer to Halliburton Health and Safety Standard C2S3, “Pressure Containment Failure” for more
information.
Warning OXYGEN DEFICIENCY HAZARD. One full breath of pure nitrogen will
not allow blood to receive oxygen. Loss of consciousness may result. Maintain
proper ventilation to prevent asphyxiation.
The displacement of breathing air is a potential hazard when spent liquid nitrogen is discharged as a
gas. Cold nitrogen gas will displace warmer air containing vital oxygen for breathing. As seen in Table
2.3, oxygen is necessary for people to function correctly.
A slight oxygen deficiency results in deeper respiration, faster pulse, and poor coordination. As the
oxygen deficiency increases, one's judgment becomes so poor, he or she may not know to move to a
well ventilated area. Because nitrogen is odorless, a victim may not be aware of the oxygen-deficient
air. Maintain proper ventilation to prevent asphyxiation. Use confined-space entry procedures to enter
any area that may contain nitrogen. See Table 2.3.
Table 2.3—Symptoms of Oxygen Deficiency

Amount of Oxygen in the Air Symptoms
21% Normal
Deeper breathing, faster pulse, poor
14%
coordination
12% Giddiness, poor judgment, blue lips
Nausea, vomiting, ashen complexion,
10%
approaching loss of consciousness
Death within 8 minutes; at 6 minutes,
8% 50% will die; at 4 minutes, all should
recover with treatment
4% Coma in 40 seconds, convulsions, death

Always be cautious when there is a nitrogen gas cloud present (Figure 2.6). Although, in most cases, the
gas cloud is condensed water vapor, never enter a gas cloud unless you are certain that it is not oxygen
deficient. If an oxygen deficient atmosphere is suspected, use company Confined Space Entry procedures
along with the appropriate breathing apparatus before entering. Additionally, entering a gas cloud with
reduced or little visibility will greatly increase the chances of injury from trip hazards or other hidden
dangers.
Figure 2.6—Gas cloud.
Liquid Nitrogen Equipment Safety
Cryogenic Materials and Components

Most construction materials are adversely affected by the extreme low temperature of liquid nitrogen. It
is imperative that the components engineered for use in cryogenic service be chosen from suitable
approved materials.
Cryogenic Materials
• Copper and its alloys (such as brass)
• Austenitic stainless steels (300 series)
• Aluminum (open-ended only and low pressure)

Cryogenic Components
• Inner tank of nitrogen storage vessel
• Nitrogen low-pressure piping
• Nitrogen fluid ends
• Nitrogen high-pressure piping up to the vaporizer outlet
Non-cryogenic Material and Components

Most of the components of nitrogen pumping units are constructed of materials that cannot withstand
cryogenic temperatures. Do not expose these components to extreme cold.
Non-cryogenic Materials
• Carbon steels
• Martensitic stainless steels (400 series)
• Most rubber and plastic products
Non-cryogenic Components
• Treating iron: Made of carbon steel. Liquid nitrogen should never be allowed to enter or flow
through it.
• The outer tank surface of a storage vessel and other components will crack when liquid nitrogen
lands on the surface (such as when overfilling occurs) because these devices are made from carbon
steel.
• Outer tank (casing) of a nitrogen storage vessel
• Trailer frame
• Power train
• Structural components
• Hydraulic lines
• Tires
• High-pressure hoses

Equipment Precautions
Warning HIGH-PRESSURE HAZARD. Carbon steel becomes brittle at approximately

-40°F (-40°C). Keep liquid nitrogen out of carbon steel to avoid breakage from
rapid contraction.
Treating iron will not withstand cryogenic temperatures . Allowing liquid nitrogen in the carbon steel
treating iron is one of the most dangerous mistakes an operator can make.
Carbon steel becomes brittle at approximately -40°F. When this occurs, any shock could cause treating
iron to break like glass (Figure 2.7).
Carbon steel cannot withstand rapid contraction. Nitrogen can shrink the inside of treating iron so fast
that it separates from the outside, causing severe breaks. This is comparable to the way glass explodes
when engulfed in fire. The outside of the glass expands more rapidly than the inside, which causes the
material to separate.
Iron becomes brittle at -40°F.
Iron cannot withstand rapid contraction.
Figure 2.7—Liquid nitrogen can severely damage iron.
Treating iron must not be hit or moved while frozen as this can cause the iron to crack. Treating iron at
-40°F or below, allowed to warm up will go back to its natural state and must be requalified before
reusing.
Treating iron should be visually inspected before each job for cracks.

Treating Iron Low-Temperature Limits

The lowest permissible operating temperature for carbon steel piping is 35°F (2°C). Operation at
temperatures below this limit must use stainless steel or a low-temperature alloy. The reason for this
limit is that at low temperatures, carbon steel becomes brittle. At -40°F (-40°C), a sudden impact or
pressure pulse could cause a minor crack to turn into a major failure.
After carbon steel has warmed up, it returns to its previous state. However, all iron that has been
frosted up, should be inspected for damage and requalified before being used again.
Caution CONTRACTION HAZARD. Do not frost hoses.
High-pressure hoses will not withstand cryogenic temperatures. Therefore, the temperature of the
fluids flowing through hoses should also be maintained above 35°F (2°C).
Pressure Buildup from Trapped Liquid Nitrogen
Warning HIGH-PRESSURE HAZARD. Manifolds can contain compressed nitrogen.

Be sure manifolds are properly ventilated or have sufficent pressue reliefs.
Nitrogen to be used as a gas is most often stored and transported as a liquid for economy and
convenience. Nitrogen is easier to pump as a liquid than a gas. Because of its very low boiling point,
there is a continuous, unavoidable, and inexhaustible heat leak into liquid nitrogen. This increase in
heat causes the liquid to vaporize or boil at a constant temperature.
Nitrogen expands to 697 times its initial volume in going from a liquid at -320.4°F to a gas at 70°F.
One cubic foot of liquid nitrogen (50.46 lbm) at -320.4°F exerts 0 psi. When this same volume warms
to 70°F, it can exert 42,500 psi while contained in the same space. If you had a container of liquid
nitrogen and left the valve open, the following would result with 50.46 lbm of liquid nitrogen at minus
320°F and 0 psi—the liquid would just boil away. (Figure 2.8, Page 2-13) With a closed valve, the
same 50.46 lbm of liquid nitrogen heated to 70°F would build pressure to 42,500 psi, as mentioned
above.
Important It is important to note the pressure difference with temperature increase in a

closed container.
As another example of a high-pressure hazard, a 12-ft section of 3-in. treating iron full of nitrogen at
10,000 psi has the same energy as 90 lbm of nitroglycerin.

Figure 2.8—Trapped liquid nitrogen will absorb heat and can exert pressure
in excess of 21 tons per square inch.
Because trapped liquid nitrogen will continually absorb heat and can exert pressure in excess of 21 tons
per square inch, it is easy to explain why our pumping systems are designed using a primary safety relief
valve and storage vessels have both primary and secondary relief systems. If there is any place nitrogen
can be trapped within a system, a line safety or pop-off is used. Similarly, to prevent the hazard of high
pressure buildup, which can result from trapped liquid or very cold vapors between two valves in series,
it is essential to install a relief valve in any section of line or equipment that carries liquid and that may
be isolated by closed valves.


SECTION
Section
13
Preface
Preliminary Checks
Set Pressures
Table 3.1—Set Pressures

Min Typ Max
Hydraulic System
Hydraulic tank capacity, gal 70
Hydraulic oil temp, °F 160 180
Triplex A Drive Circuit (Sundstrand Pump)
Charge circuit, psi 450
Triplex A flushing relief, psi (verify flow through
350
case > 11 gal/min w/ flowmeter on A or B)
Triplex A drive circuit, psi 5,000
Triplex pump crankshaft, Pump A, rev/min 900 1,000
Triplex pump rate limit, scfm 1,500
Triplex B Drive Circuit (Sundstrand Pump)
Charge circuit, psi 450
Triplex B flushing relief, psi (verify flow through
350
case > 11 gal/min w/ flowmeter on A or B)
Triplex B drive circuit, psi 5,000
Triplex pump crankshaft, Pump B 900 1,000
May 2011 Preliminary Checks 3-1

Table 3.1—Set Pressures (Continued)

Triplex pump rate limit, scfm 3,000
Viking Water Pump Drive Circuit (Parker PAVC Pump)
Compensator circuit pressure, psi 2,750
Water pump speed, rev/min 520 560 600
Lube-Oil Pump Circuit (Barnes Pump)
Triplex lube pump pressure, psi 80 110
Heat-Building Circuit (Barnes Charge Pump and Parker VOAC
Heat-Build Pumps)
Heat-build charge pressure, psi 90 105 110
Heat-build flushing relief, psi 80 95 100
Heat-build relief pressure, psi 4,500
Calibrating the ANRCS Unipro™ II Controller

Calibrate the ANRCS Unipro II controller by referring to manual 458.02506.
Pump A
Program 1.25-in. cold-end pumps with the following:
• 2nd Freq 750.

• 2nd Rate 1382.2876.
• PPI 32.5547.
Pump B
Program 1.625-in. cold-end pumps with the following:
• 2nd Freq 750.

• 2nd Rate 2336.065.
• PPI 19.26316.
Note Additional ANRCS tuning and testing should be performed by E-Tech per Procedure
458.02510.
3-2 Preliminary Checks May 2011

Fluid-Level and Pressure Checks

1. Check the engine-oil level (Figure 3.1, Page 3-4).
2. Check the hydraulic-pump drive oil level (Figure 3.1, Page 3-4).
3. Check engine coolant level. Check the level at the engine expansion tank and fill the tank to 1/2 in.
from the bottom of the sight glass (Figure 3.2, Page 3-5).
4. Check air-filter restriction indicator (Figure 3.3, Page 3-6).
5. Check the hydraulic-oil tank level and fill to middle of sight glass (Figure 3.4, Page 3-7).
6. Check the lube-oil level of the high-pressure pumps (Figure 3.4, Page 3-7).
7. Check the saturation pressure on both high-pressure pumps for the proper pressure. The proper
pressures, which vary depending on the temperature of the bulbs in the low-pressure piping, can be
found in Table 3.2 (Page 3-8).
8. Drain any accumulated water from the bottom of the hydraulic tank.
9. Drain any accumulated water from the bottom of the fuel tank.
10.Check the fuel level (fill to the bottom of the fill neck).

Figure 3.1—Dipsticks for engine-oil and hydraulic-pump drive oil.

Figure 3.2—Engine coolant, circulating coolant, and hydrualic oil levels.

Figure 3.3—Air-filter restriction indicators.

Figure 3.4—Sight glass location on lube-oil tank..

Table 3.2—Liquid Saturation Pressure

Saturated Pressure Temperature
psig bar °F °C
0 0 -320.4 -195.78
5 0.34 -315.8 -193.22
10 0.69 -312.0 -191.11
15 1.03 -308.7 -189.28
20 1.38 -305.8 -187.67
25 1.72 -303.2 -186.22
30 2.07 -300.9 -189.94
35 2.41 -298.7 -183.72
40 2.76 -296.7 -182.61
45 3.1 -294.8 -181.56
50 3.45 -293.1 -180.61
Table 3.3—Nitrogen Unit Prejob Checklist

√ = OK F = Fail N/A = Not applicale
Documents
1 Verify HES and location stickers are clearly identified on nitrogen pump.
Frame
1 Verify nitrogen unit is clean.
2 Verify drip pans are clean and plugs installed.
3 Verify all gates are properly secured on unit with safety pins.
4 Verify proper weight is clearly identified on nitrogen unit.
5 Verify unit is equipped with proper-rated lift sling and safety shackles.
Visually inspect lift sling and safety shackles for damage and replace if neces-
6
sary.
7 Visually inspect lift sling and safety shackles for proper installation (cotter pins).

Table 3.3—Nitrogen Unit Prejob Checklist (Continued)

Verify sling one-year pull-test certification and record CWR
8 Date:
the following: No.:
9 Verify employee(s) can hook up to lift-sling configuration from the ground.
Visually inspect lift eyes for cracks or damage. Notify Equipment Team Leader
10
if evident.
Hydraulic System/Engine/Cryogenic Pump
1 Verify proper engine-oil level (dip stick).
2 Verify proper engine-water level (expansion-tank sight glass).
3 Verify proper hydraulic-oil level (sight glass).
4 Visually inspect fuel, oil, and hydraulic filters for leaks. Replace if needed.
5 Verify proper cryogenic-pump power-end lube-oil level (dip stick).
6 Visually inspect all hydraulic hoses for leaks/wear. Replace if necessary.
7 Visually inspect fan, air compressor, and water-pump belts for proper tension.
8 Verify an extra set of fan and air-compressor belts are attached to the unit.
9 Verify and extra set of water-pump belts are attached to the unit. (SPU-90)
Verify unit is equipped with liquid-nitrogen suction hoses (two) and proper con-
10
nections.
11 Verify engine fuel tank is full and visually inspect for damage or leaks.
12 Verify engine starts and system gauges function properly.
13 Verify emergency kill functions properly. Start unit and activate emergency kill.
Verify all cryogenic and discharge valves are closed on unit. Install proper
14
plugs/caps.
Visually inspect nitrogen power-end coupling for damage. Verify allen screw is
15
torqued.
Control Panel/Unipro™II Controller

Verify all control-panel gauges are in proper working condition. Replace if nec-
1
essary.
2 Verify control-panel rate/pressure-control valves function properly.
3 Visually inspect power cord for damage/wear. Replace if necessary .
Visually inspect temperature, pressure, and flow meter cables for damage/
4
wear.

Table 3.3—Nitrogen Unit Prejob Checklist (Continued)

5 Power up and verify Unipro™ II controller functions properly.
6 Verify Unipro II controller switches and rate-control valve functions properly.
Visually inspect magnetic pick up(s) on drive-shaft sprocket(s) for damage or
7
wear.
Required Paperwork
Verify nitrogen unit has been properly tested against call sheet. Attach a copy of test
1
chart to prejob checklist.
2 Complete prejob checklist and place in job file before shipping unit to location.
Comments (Attach Additional Sheets if Necessary)

SECTION
Section
14
Preface
Operating the Unit
Rig Up
Introduction
It is very important to ensure that the iron being used is inspected and tagged. Serious accidents can
occur because of cracked or weakened iron or iron not rated for the correct pressure and service.
Treating iron should be inspected both before and after a job for signs that a failure might be ready to
happen. If liquid was suspected to have gotten into the iron, it is extremely important that this is done
because treating iron becomes brittle at -40°F.
Setup, Iron, and Bleed off

When laying treating iron, it is good practice to make sure that the pipe is clean of debris and foreign
matter. Make sure that new seals are used and lubricate the threads when putting the iron together.
All iron should be banded with serial number and inspection date. Iron should be visually checked
before every job. See the Manifold Equipment Qualification Global Standard ST-GL-HAL-PSL-501.
It is mandatory that a minimum of two check valves are used when rigging up. There should be at least
one check valve for isolating each pumping unit and an additional check valve in the primary nitrogen
dicharge line. It is also good practice to label or mark the check valves to identify which one was in
line first. The following test procedure (Figure 4.1, Page 4-2) should be used to ensure check valves
are in proper operating condition before starting a job.
May 2011 Operating the Unit 4-1

Figure 4.1—Recommended test procedure for ensuring the check valves are in proper
operation.
4-2 Operating the Unit May 2011

Figure 4.2—Dual check valve and dual bleeder-tee setup for proper rigup operation.
Figure 4.3—Recommended configuration for treating-line layouts.

Check Valves
A maintenance schedule should be established to routinely inspect check valves and all
high-pressure manifold components. Check valves should be taken apart and serviced at least
once a month or sooner by an approved treating-iron vendor. The Manifold Equipment
Qualification Global Standard ST-GL-HAL-PSL-501 shows the proper thread condition. If
damage is found, repair parts can be ordered from Duncan. The following are the SAP numbers
for the parts needed to repair the check valves used in nitrogen service:
• Spring (SAP 100000996).

• Dart (SAP 100001008).
• O-rings (SAP 100000967).
Before they are placed back into service, rebuilt check valves should be pressure tested in the
open position to the rated working pressure. The check valves should also be pressure tested in
the closed position to their rated working pressure. A regularly scheduled maintenance program
can help reduce the potential for an accident.
Figure 4.4—High-pressure check valve (dart type).
Bleeder Tee
The primary acceptable bleeder-tee valve is an autoclave high-pressure needle valve. These can
be obtained from Duncan manufacturing using the following SAP numbers:
• Bleeder tee (SAP 100049155).

• Autoclave valve (SAP 100048678).
• Autoclave adapter (SAP 100049159).

Replacement Parts for Bleeder Tees

• Part No. 252.10208 (SAP 100049158): The replacement (Butech) valve for the old tees comes with
a male NPT inlet and a female NPT outlet.
• Part No. 252.01420 (SAP 100011197): The new (autoclave) tees, including the bleeder valve.
• Part No. 252.01403 (SAP 100048678): The replacement (autoclave) valve for the new tees.
The part number in the manifold book for the 1 1/2-in. bleeder tee has not been updated since the early
1990s. The part number in the book reflects a 1/2-in. NPT thread on the body of the tee with a 15,000-psi
Butech valve with 1/2-in. NPT threads. This is not the correct tee to order.
The correct tee has an API thread cut into the tee with an autoclave adaptor and valve rated at 30,000 psi.
This tee is listed on the Surface Manifold Equipment homepage.
1/2-in. NPT threads will hold 15,000 psi because the tee is heat-treated. These tees return from rebuild
and testing still rated at 15,000 psi. The problem with using the NPT threads is that a lower-pressure valve
could be screwed onto a tee with 1/2-in. NPT threads, but with the autoclave threads operators are forced
to use an autoclave valve.
Flowback of Energized Fluids

Under normal circumstances, it is not the responsibility of Halliburton personnel to flow fluids back after
stimulation. However, situations might arise that make it necessary for Halliburton to assist with or
advise of a flowback procedure. Because of the many variations in rig up of flowback manifolds and
flowback procedures, a specific procedure is impractical; therefore, general guidelines must be applied
to make all possible rig ups safe. Fluids containing nitrogen and carbon dioxide have a tremendous
amount of energy to dissipate on flowback, so close adherence to specific flowback guidelines is
essential.
Conditioning Liquid Nitrogen

Liquid nitrogen is "blown down" before pumping because there is a continuous, unavoidable, and
inexhaustible heat leak into liquid nitrogen. As the liquid nitrogen becomes warmer, the pressure within
the liquid nitrogen (saturation pressure) increases. By first blowing down the tank, the liquid nitrogen is
forced to boil, releasing the gas within the liquid and lowering the liquid-nitrogen temperature back
toward -320.4°F. The boiling stops when the nitrogen reaches -320.4°F. Blowing down the tank before
building pressure is done in accordance with the first law of pumping liquid nitrogen.

Pumping Procedure
After the liquid nitrogen is conditioned (when storage is venting no gas vapor from blow-down),
follow the steps below:
1. Close the blow-down valve.

2. Build tank pressure.
3. Open the main liquid withdrawl valve from the storage tank.
Before Starting the Engine

1. Turn both of the high-pressure pump-rate controls counterclockwise to their minimum set-
tings (Figure 4.5, Page 4-7; Item 42 and 48).
2. Turn both remote/local switching valve handles to the neutral position (straight down) (Figure
4.5, Page 4-7; Item 29 and 41).
3. Turn the hydraulic heat control counterclockwise to its minimum setting (Figure 4.5, Page
4-7; Item 36).
4. Connect an auxiliary air supply into the unit air tanks or the remote rig air connection, if
necessary (Figure 4.8, Page 4-11).
5. Turn the master power switch located on the engine skid to the ON position (Figure 4.9, Page
4-12).

Figure 4.5—Operator control panels and discharge pressure guages.

Figure 4.6—Electronic control and instrumentation panel layout.

Figure 4.7—Hydrualic controls and instrumentation panel layout.

4-10
Table 4.1—Operator Control Panels and Discharge Pressure Gauges Components List
Item Component Description Item Component Description Item Component Description
No. No. No.
Pump B Auto/Manual Switching Valve
1 Murphy Power View 21 Pump A Auto Control Switch 41
Handle
2 Voltage Gauge 22 Pump A Manual Control Switch 42 Pump B Rate Control Knob
Operating the Unit

3 Fuel Gauge 23 Air Horn Switch Push Button 43 Pump B Saturation Pressure Gauge
4 Unipro II 24 Water Pump Hydraulic Pressure Gauge 44 Pump B Suction Pressure Gauge
5 Pump B Auto Control Switch 25 Air Pressure Gauge 45 Tank Return Pressure Gauge
6 Pump B Manual Control Switch 26 System Water Pressure Gauge 46 Boost Pump Control Valve Handle
7 Auto/Manual Rate Control Tuning Knob 27 System Water Temperature Gauge 47 Boost Pump Hydraulic Pressure Gauge
8 All Stop Switch 28 Hi/Lo Diverter Valve Switch 48 Pump A Rate Control Knob
Pump A Auto/Manual Switching Valve
9 Emergency Kill Switch 29 49 Pump A Saturation Pressure Gauge
Handle
10 Keyswitch Power to ECM 30 Pump A Charge Pressure Gauge 50 Pump A Suction Pressure Gauge
Hydraulic Filter Differential Pressure
11 Ethernet Serial Out Port Connection 31 Pump A MC II Flow Analyzer 51
Gauge
Pump A Hydraulic Drive Pressure
12 Secondary Cement Rate Port Connection 32 52 Hydraulic Oil Temperature Gauge
Gauge
13 ECM Power Switch 33 Heat Building Charge Pressure Gauge 53 Triplex Lube Oil Pressure Gauge
14 Primary Cement Rate Port Connection 34 Unit Discharge Temperature Gauge 54 Triplex Lube Oil Temperature Gauge
Exhaust Vaporizer Discharge Tempera- Triplex Lube Filter Differential Pressure
15 Control/Sensor Power Switch 35 55
ture Gauge Gauge
16 Engine Throttle Knob 36 Hydraulic Heat Control Knob 56 Discharge Valve Switch Handle
Heat Building Hydraulic Pressure Primary Unit Discharge Pressure
17 Engine Start Switch 37 57
Gauge Gauge
18 Engine Ignition Switch 38 Pump B Charge Pressure Gauge 58 Pump A Discharge Pressure Gauge
19 Skid Light Switch 39 Pump B MC II Flow Analyzer 59 Pump B Discharge Pressure Gauge
Pump B Hydraulic Drive Pressure
20 Electronic Console Master Power Switch 40
Gauge
May 2011
Figure 4.8—Air-line connection on air tank.

Figure 4.9—Master power switch and remote rig air connection.

Starting the Engine

1. Check to be sure the system air pressure is at least 90 psi (Figure 4.5, Page 4-7; Item 25).
2. Verify that the emergency kill switch is in the RUN position (pulled up) (Figure 4.5, Page 4-7;
Item 9).
3. Set the ignition switch to the RUN position (push up) (Figure 4.5, Page 4-7; Item 18).
4. Start the engine by pressing down on the start switch (Figure 4.5, Page 4-7; Item 17).
Readings to Observe During Engine Warm-Up

• Engine-oil pressure should indicate 30 to 50 psi (Figure 4.5, Page 4-7; Item 1).
• Engine-water temperature should be climbing slowly (Figure 4.5, Page 4-7; Item 1).
• Lube-oil pressure should be 90 psi (Figure 4.5, Page 4-7; Item 54).
• System-air pressure should be 120 psi (Figure 4.5, Page 4-7; Item 25).
• Triplex A and B charge pressure should be at least 350 psi (Figure 4.5, Page 4-7; Item 30 and 38).
• Heat-building charge pressure should be at least 80 psi (Figure 4.5, Page 4-7; Item 33).
Preparing the Unit to Pump

Note Engine should be running at this point.
1. With engine running at 1,500 rev/min, warm all fluids before pumping.
Note Engine should not be run for extended periods of time without nitrogen being pumped.
Unchecked temperature rises can occur within hydraulic and circulating water systems,
resulting in premature component failure.
2. Ensure that the insides of all transfer hoses are clear of debris. All liquid-nitrogen transfer hoses
need to be properly purged using nitrogen gas from the supply tank (Step 6).
3. Connect the liquid-nitrogen transfer hose from the inlet suction connection of the skid (Figure
4.10, Page 4-14) to the outlet connection of the storage tank (Figure 4.11, Page 4-15). Then,
connect the liquid-nitrogen transfer hose from the outlet or return to tank on the skid unit to the
inlet or gas-return connection on the liquid-nitrogen storage tank.
4. Open the blow-down valve of the storage tank until the tank pressure reaches 0 psi and no gas
vapor is venting from the blow-down line (Figure 4.12, Page 4-16). If present, close the
road-regulator valve.

5. Close the storage-tank blow-down valve (Figure 4.12, Page 4-16) once the liquid in the tank
is fully conditioned for pumping. This occurs when no vapor is present in the venting exhaust
gas and the tank pressure gauge reads 0 psi.
Figure 4.10—Tank withdrawl and return piping.

Figure 4.11—Skid supply and return piping.

Figure 4.12—Tank vent and road relief piping.
6. Open the storage-tank pressure-building inlet valve (Figure 4.13, Page 4-17). 

If the tank is equipped with a pressure-building regulator, the regulator should maintain
pressure at 65 to 75 psi for non-boosted systems and 25 to 35 psi for boosted systems (Figure
4.13, Page 4-17).
Note If the liquid-nitrogen tank is not equipped with a pressure-building regulator, the
operator must be present at the tank while the pressure-building inlet valve is open to
monitor and control tank pressure.
7. Open the storage-tank supply and return valves (Figure 4.10, Page 4-14).
8. Open the main suction and tank return valves on skid (Figure 5.22, Page 5-31).
9. Open the prime valves for the pump(s) being used on skid (Figure 5.22, Page 5-31).
10. Open the blowby metering valves for the pump(s) being used on skid (Figure 4.14, Page 4-18).
11. If using both pumps, open each individual pump suction valve to allow the fluid ends (pumps)
to cool down with an even layer of frost (Figure 5.22, Page 5-31).

Figure 4.13—Pressure-building system piping.

Figure 4.14—Blowby metering valves.
12. Observe the saturation-pressure gauge (Figure 4.15, Page 4-19) (Table 3.2). The pressure
should be slowly falling as the fluid ends steadily cool. Wait for the saturation pressure to drop
below 10 psi and be sure a thick and even layer of frost at least 1/4-in. thick appears on all cold
ends before bringing pumps online.
Note As the pumps and piping begin to cool down and saturation pressure continues to
drop, a greater-than-desired amount of liquid nitrogen will begin exiting the priming
system into the atmosphere. Corrective action must be taken to ensure only gas with
small amounts of liquid exits the priming system metering. This is done by partially
closing (pinching) the priming valve(s) and/or blowby vent valve(s).
13. Once the saturation pressure has fallen below 10 psi and the fluid ends have been properly
cooled and contain an appropriate layer of frost, the blowby metering valves can be closed to
within a 1/4 turn of being completely shut (Figure 4.14, Page 4-18).
14. Visually inspect the fluid ends to ensure that a proper layer of frost is present and monitor the
saturation pressure to verify pressure is being maintained below 10 psi. Once both have been

verified, begin rotating the pump(s) by turning the rate-control knob(s) clockwise (Figure 4.5,
Page 4-7; Item 42 and 48).
Note If operating manually, rotate the pumps by switching the remote/local switching-valve
handle to point to the local operating position.

If operating in automatic mode, rotate the pumps by switching the remote/local
switching-valve handle to point to the remote position.
Note All the instructions that follow pertain to manually operating the unit.
Figure 4.15—Properly frosted fluid ends.

Figure 4.16—Tank blowdown and road-relief isolation valves and associated plumbing.

Pumping the Unit

Note This procedure is for rates above 1000 scfm. For rates below 1000 scfm, see “Low-Rate
Pumping” on Page 4-24
1. Increase the speed of the engine to full throttle (2,100 rev/min) (Figure 4.5, Page 4-7; Item 16).
2. Increase boost-pump discharge pressure by turning the boost-pump rate-control knob
counterclockwise to achieve 65- to 75-psi boost-pump discharge pressure (assuming the boost
pump has been properly primed) (Figure 4.5, Page 4-7; Item 46).
3. Depending on the job requirements, perform the following:
a. If rates require 1,500 scf/min or less, ensure the pump-isolation valve (Figure 5.24, Page
5-33) on Pump B (bottom triplex with 1.625-in. cold ends) is closed and open the isolation
valve on Pump A. Bring Pump A online by turning the rate control clockwise and closing
the Pump A priming valve. (Figure 5.24, Page 5-33).
b. If rates require more than 1,500 scf/min but less than 3,000 scf/min, ensure the isolation
valve on Pump A (top triplex with 1.25-in. cold ends) is closed and open the isolation valve
on Pump B. Bring Pump B online by turning the rate control clockwise and closing the
Pump B priming valve.
c. If rates require more than 3,000 scf/min, open both isolation valves (Figure 5.24, Page
5-33). Bring both pumps online by turning the rate controls clockwise at the same time
(Figure 4.5, Page 4-7; Item 42 and 48). As pumps are being brought online, begin closing
both prime valves and verify that discharge pressures of both pumps are equal (Figure 4.5,
Page 4-7; Item 58 and 59).
4. If transitional pumping is required, see the next section “Transitional Pumping” on Page 4-22. If
transitional pumping is not required, proceed to Step 5.
5. Open the discharge "customer" valve when positive pressure is shown on the discharge-pressure
gauge by pressing in on the discharge valve switch (Figure 4.5, Page 4-7; Item 56).
Important Verify discharge "customer" valve is open by monitoring the main

discharge-pressure gauge.
6. Observe the nitrogen-discharge temperature gauge (Figure 4.5, Page 4-7; Item 4 and 34).
Maintain a temperature between 70 and 100°F whenever nitrogen is being pumped. This
temperature is controlled by the hydraulic heat-control and nitrogen-diverter valve. To raise the
circulating-water temperature, turn the hydraulic heat control clockwise; to lower the
temperature, turn the control counterclockwise.

7. While maintaining the required discharge temperature (Figure 4.5, Page 4-7; Item 4 and 34),
turn the rate control clockwise to increase the high-pressure pump speed until the required rate
is achieved (Figure 4.5, Page 4-7; Item 42 and 48).

Adjust the blowby metering valves for pumps in operation to control saturation pressure.
Saturation pressure should be maintained below 10 psi.
Transitional Pumping
Certain applications might dictate the need for transitional pumping. This operation requires the
operator to bring a set of fluid ends (i.e., single triplex) online or offline while the other is continuing
to pump. An example of this application might be a nitrogen ramp where the job design starts or
finishes at a rate too low or too high for one or both pumps to safely operate.
Note The transitional pump referred to here is the pump or set of cold ends being brought
on or offline. 

The online pump is referred to here as the pump or set of cold ends currently pumping
during the transition procedure.
Transitioning from Single-Pump Mode to Dual-Pump Mode
Note Use this procedure only after applying Steps 3a or 3b previously detailed.
1. To transition to dual-pump mode after either Step 3a or 3b has been applied in single-pump
mode, the operator must first cool down and prime the transitional cold ends:
a. Open the suction valve and prime valve for that pump.
b. Cool down pumps until a thick, even layer of frost is present.
2. Prime the pumps by slowly rotating them only after the saturation pressure is 10 psi or less.
3. Continue to pump at a low rate while maintaining low saturation pressure.
4. Begin to close the prime valve while monitoring that pump's discharge-pressure gauge.
5. Once the prime valve is completely closed, the discharge-pressure gauges for both Pumps A
and B must be observed.
6. When the transitional-pump pressure is equal to or greater than the online-pump pressure,
immediately begin to rotate the transitional pump's isolation-valve handle until fully opened.
Pump pressures will equalize once the isolation valve is fully opened.

7. After verifying pressure equalization on the discharge-pressure gauges for both Pump A and B,
adjusting to the desired rate can begin. If necessary, adjust the boost pump to maintain 65 to 75
psi suction pressure at the inlet of the fluid ends.
Caution It is important to be aware that a sudden buildup of pressure can occur during
this transition if the transition pump's isolation valve is not promptly opened or
while pumping at too high of a rate before opening the isolation valve.
8. On completion of the transitional-pumping process, normal pumping operations can be

continued (see Step 6 previously listed). Proceed to Step 6 of the "Pumping the Unit" procedure.
Transitioning from Dual-Pump Mode to Single-Pump Mode
Note Use this procedure only after applying Step 3c previously detailed.
1. To transition to single-pump mode after Step 3c has been applied in dual-pump mode, select the
set of fluid ends (triplex pump) to transition offline based on job-design criteria (refer to Steps
3a and 3b).
2. Once the desired triplex pump has been selected for offline transition, the rate of the transitional
pump must be slowed until that pump can be safely brought offline.
3. After this is complete, begin to close the transitional pump's isolation valve while monitoring that
pump's discharge-pressure gauge to verify pressure rise.
4. Once the transitional-pump isolation valve is fully closed and a positive discharge-pressure
increase is established, stop the transitional pump by turning the rate-control knob
counterclockwise. The transitional pump is now offline.
5. Slowly open the transitional-pump’s prime valve to safely vent the remaining pump-discharge
pressure. After venting excess pressure, close the transitional pump’s suction valve. If necessary,
adjust the online-pump rate to the desired set point. Also, adjust the boost pump flow-control
valve, if necessary, to maintain 65- to 75-psi suction manifold pressure.
6. On completion of the transitional-pumping process, normal pumping operations can be
continued (see Step 6, previously listed). Proceed to Step 6 of the "Pumping the Unit" procedure.

Low-Rate Pumping
For low-rate operations, reduce engine rev/min to any acceptable level that will balance heat in water
and oil systems while maintaining adequate N2 discharge temperatures. For example, reduce the
engine speed to the 1,100 to 1,250 rev/min range for N2 discharge rates of approximately 350 scfm.
Lower engine speeds might also be necessary for other low-rate jobs. A rule of thumb would be to
increase engine rev/min to any acceptable level that will generate enough heat in the circulating water
loop, by means of heat exchange with the engine and hydraulic systems, up to and including use of the
high/low diverter circuit, without the need for using the auxiliary heat-build systems.
Previous testing would indicate that the breakover N2 rate point to bring the engine to full throttle
without the use of additional heat load would be somewhere above 1000 scfm. Also, for any low-rate
run in which the temperatures of the fluids and discharge continue rise, the procedure would be to
reduce the engine rev/min to a point that results in an N2 discharge-temperature drop to acceptable
levels with corresponding circulating fluid(s) temperature stabilization. Use of a heat builder to adjust
or fine tune discharge temperatures is acceptable during these low-rate runs as long as the hydraulic
oil, intake manifold inlet, and circulating-water temperatures remain at acceptable levels.
The temper valve should not be used to temper gas discharge at low pump rates because doing so does
nothing to solve the heat imbalance occurring in the water and hydraulic systems. The only way to
drive the systems toward an energy balance is to reduce the engine rev/min and turn off additional
heat-build systems to reduce the excess heat being generated by the engine and hydraulic systems,
thereby reducing the excess heat being transferred into the circulating-water circuit. There will be a
reduced rev/min that will eventually result in an energy balance between the systems. If the rev/min
is dropped too much, N2 discharge temperatures will begin to fall below the acceptable range,
preceded by a substantial constant drop in system water temperature. This can be remedied by
increasing the engine rev/min to a point where discharge and water temperatures stabilize and might
also be fixed by activating the high low diverter or engaging the heat-build pumps, or a combination
of the two.
It is recommeded that activating these auxiliary systems only be used as a temporary solution to falling
temperatures until engine speed can be brought to a level that will stabilize systems as well as the N2
discharge temperature without the use of the auxiliary heat builders.
Gauges to Monitor during Pumping

1. Check that the nitrogen-discharge temperature is maintained between 70 and 100°F (Figure
4.5, Page 4-7; Item 4 and 34).
2. Check that Pump A and Pump B discharge-pump pressures match (if operating in dual pump
mode) (Figure 4.5, Page 4-7; Item 58 and 59).
3. Check the main discharge-pressure gauge to verify treating pressures match job design
(Figure 4.5, Page 4-7; Item 57).

4. Check that the circulating-water temperature stays between 100 and 165°F (Figure 4.5, Page 4-7;
Item 27).
5. Check that the saturation-pressure gauge does not rise above 20 psi (Figure 4.5, Page 4-7; Item
43 and 49).
6. Check that the suction pressure is at least 65 psi (Figure 4.5, Page 4-7; Item 44 and 50).
7. Monitor all other gauges on the control panel for their normal ranges (Figure 4.5, Page 4-7).
After Pumping is Completed

1. Turn off the high-pressure pump(s) by turning its rate-control valve knob(s) counterclockwise
(Figure 4.5, Page 4-7; Item 42 and 48).
2. Switch remote/local valve handle(s) to the neutral position (Figure 4.5, Page 4-7; Item 28 and
41).
3. Turn off the boost pump by turning the rate-control knob clockwise (Figure 4.5, Page 4-7; Item
46).
4. Close the discharge valve by pulling up on the discharge-valve handle (Figure 4.5, Page 4-7; Item
56).
5. Open the prime valves (Figure 5.22, Page 5-31).
6. Reduce heat by turning the hydraulic heat-control knob counterclockwise to its minimal setting
(Figure 4.7, Page 4-9).
7. Reduce engine speed to 1,200 rev/min (Figure 4.5, Page 4-7; Item 16).
8. Close the tank supply and return valves, as well as pressure-building inlet valve (Figure 4.10,
Page 4-14 and Figure 4.13, Page 4-17).
9. Open the supply tank blow-down valve (Figure 4.12, Page 4-16).
10. Close all inlet/suction valves on skid, as well as skid tank return valve (Figure 5.22, Page 5-31).
11. Open all applicable line bleeds (Figure 5.22, Page 5-31).
12. Open the road relief-regulator valve on the supply tank (if equipped) (Figure 4.12, Page 4-16).
13. Reduce engine rev/min to idle before engine shutdown. Shut down the engine only after the
cryogenic piping has begun to thaw or the engine has idled for 10 minutes.
14. After all liquid nitrogen has evaporated from the pump(s) and piping, close all remaining valves
on the skid. See low- and high-pressure piping diragrams (Figure 5.22 through Figure 5.25).
15. Close the supply-tank blow-down valve and make sure the road-relief regulator valve has been
opened, as per Step 11.

Note Verify that all valves are closed on unit.
16. Double check that all skid and tank valves are in proper positions and all of the nitrogen has
been evacuated from the systems.
17. Close all control-panel lids, switch the master power on the skid to the OFF position, and
rig-down the unit.

SECTION
Section
15
Preface
Maintenance
Maintenance Specifications
The maintenance schedule for this unit should be set by the local shop foreman. The foreman works
with the maintenance coordinator to evaluate the conditions and the equipment to find the best
maintenance time intervals. The minimum maintenance schedule listed here is for reference only.
Always check with the local shop foreman to find out the proper lubricant (oil, grease, etc.) to use in
the various components of the unit.
Table 5.1—Oil Change Schedule

Description Frequency
Engine oil SAE 15W-40 Change every 350 hr
Gear box pump drive
Change every 1,400 hr
(funk box) oil 80/90W
Nitrogen pump drive
lube oil 20W 50 or SAE Change every 1,400 hr
30 nondetergent
Hydraulic oil Shell Tellus
Change every 1,400 hr
Plus ISO 46 Product
Change hydraulic-oil filters
Code 5061244 or com-
every 350 hr
patible substitute
May 2011 Maintenance 5-1

Table 5.2—Pressure Setting and Values

Item Pressure Value
Engine oil 10 to 50 psi (0.69 to 3.45 bar)
Coolant water Approximately 100 psi ( 6.89 bar) at 560 rev/min
Hydraulic coolant pump Approximately 1,500 psi (103.42 bar)
Heat building charge Minimum 50 psi (1.52 bar)
Lube oil 90 psi (6.21 bar)
LN2 suction Minimum 65 psi (4.48 bar)
Saturation 10 psi (0.69 bar) or less
System air 100 to 120 psi (6.89 to 8.27 bar)
Hydraulic heat building Value determined by hydraulic heat control
Pumps A and B charge 350 psi (24.13 bar)
Pumps A and B drive Value determined by rate control
Table 5.3—Temperature Settings and Values

(Minimum and Maximum allowable values)
Item/System Temperature
Engine coolant 170 to 190°F (77 to 87°C)
Hydraulic oil 130 to 180°F (54 to 82°C)
Coolant water 70 to 180°F (21 to 82°C)
Lube oil 100 to 180°F (38 to 82°C)
Liquid-nitrogen discharge 70 to 100°F (21 to 38°C)
Parts List
The following parts list is for SAP No. 101665140. This unit is a 102-in. wide boosted
(international) pumping skid. For more detailed information on simiar units, see the following:
• Nonboosted 102-in. wide unit (101664826).

• Boosted 96-in. wide unit (101904723).
• Nonboosted 96-in. wide unit (101909546).
5-2 Maintenance May 2011

Table 5.4—Components List

Find No. SAP/Matl No. Reference No. Qty Description
STOCKABLE MODULE, POWER PACK-
AGE, 700 BHP CATERPILLAR C18, 24
1000 101697174 101697174 1.0 VOLT, AIR START, SKID, NITROGEN
CONVERTER, DUAL TRIPLEX, SPU-270
FLAMELESS
ASSEMBLY, ATTACHMENT, LIFT FRAME
TO SKID BASE, SKID, NITROGEN CON-
3000 101697036 101697036 1.0
VERTER, DUAL TRIPLEX, SPU-270
FLAMELESS
WELDMENT, DRIP PAN, SKID, NITRO-
3100 101665207 101665207 1.0 GEN CONVERTER, DUAL TRIPLEX,
SPU-270 FLAMELESS
ASSEMBLY, ELECTRONIC EQUIPMENT
ENCLOSURE W/ OPERATOR PANEL,
4000 101756439 101756439 1.0
WELLNITE SPU-270 FLAMELESS
NITROGEN SKID
ASSEMBLY, ENCLOSURE, HYDRAULIC
CONTROLS AND INSTRUMENTATION,
4100 101765633 101765633 1.0
SKID, NITROGEN CONVERTER, DUAL
TRIPLEX, SPU-270 FLAMELESS
PUMP ASSEMBLY, TRIPLEX, LIQUID
NITROGEN, LEFT HAND, CS&P MODEL
5000 101697072 101697072 1.0 ICPE-200-GR WITH 1 1/4 BORE X 1 3/8
INCH STROKE FLUID ENDS AND BACK
SWEPT GEARBOX
PUMP ASSEMBLY, TRIPLEX, LIQUID
NITROGEN, LEFT HAND, CS&P MODEL
5100 101697074 101697074 1.0 ICPE-200-GR WITH 1 5/8 BORE X 1 3/8
INCH STROKE FLUID ENDS AND BACK
SWEPT GEARBOX
INSTALLATION, ENGINE AND COOL-
ANT PUMP, SKID, NITROGEN CON-
9500 101697077 101697077 1.0
FLAMELESS
INSTALLATION, TRIPLEX PUMP ASSEM-
BLIES AND COMPONENTS, SKID,
9510 101697078 101697078 1.0
NITROGEN CONVERTER, DUAL TRI-
PLEX, SPU-270 FLAMELESS

Table 5.4—Components List (Continued)

INSTALLATION, HEAT EXCHANGERS
AND COOLANT PIPING ALONG WITH
9520 101697079 101697079 1.0 HARDWARE AND MOUNTS, SKID,
INSTALLATION, HYDRAULIC COMPO-
NENTS AND PIPING, SKID, NITROGEN
9530 101697100 101697100 1.0 CONVERTER, DUAL TRIPLEX, SPU-270
FLAMELESS WITH BOOST PUMP
OPTION
INSTALLATION, TRIPLEX LUBE PIPING
AND COMPONENTS, SKID, NITROGEN
9540 101697081 101697081 1.0
CONVERTER, DUAL TRIPLEX, SPU-270
FLAMELESS
INSTALLATION, LOW PRESSURE
NITROGEN PIPING, SKID, NITROGEN
OPTION
INSTALLATION, HIGH PRESSURE
NITROGEN PIPING, SKID, NITROGEN
OPTION
INSTALLATION, PIPING, BLOWBY AND
PURGE, SKID, NITROGEN CON-
9570 101697084 101697084 1.0
FLAMELESS
INSTALLATION, FUEL TANK AND FUEL
TANK COMPONENTS AND MOUNTS
9580 101697085 101697085 1.0 ALONG WITH FUEL PIPING, SKID,
INSTALLATION, AIR TANK AND AIR
TANK COMPONENTS AND MOUNTS
ALONG WITH PNEUMATIC PIPING AND
9590 101697086 101697086 1.0
REMOVABLE CROSS MEMBERS, SKID,


INSTALLATION, ACCESS PANELS AND
COMPONENTS, SKID, NITROGEN CON-
9600 101697087 101697087 1.0
FLAMELESS
INSTALLATION, CONTROL STAND AND
COMPONENTS, SKID, NITROGEN CON-
9610 101697088 101697088 1.0
FLAMELESS
INSTALLATION, WORK PLATFORM AND
FOOT STEP ALONG WITH MOUNTING
9620 101697089 101697089 1.0 COMPONENTS AND HARDWARE, SKID,
INSTALLATION, DRIP PAN AND COMPO-
9630 101697090 101697090 1.0 NENTS, SKID, NITROGEN CONVERTER,
DUAL TRIPLEX, SPU-270 FLAMELESS
INSTALLATION, ELECTRONIC EQUIP-
MENT W/ OPERATOR PANEL, CABLING
9650 101756503 101756503 1.0
AND SENSORS, WELLNITE SPU-270
FLAMELESS NITROGEN SKID
INSTALLATION, PRESSURE AND TEM-
PERATURE TRANSMITTERS ALONG
WITH MAGNETIC PICKUPS AND AUXIL-
9660 101697093 101697093 1.0 IARY COMPONENTS INCLUDING MAN-
UAL EMERGENCY SHUTDOWN CABLE,
SKID, NITROGEN CONVERTER, DUAL
INSTALLATION, NITROGEN HOSE
TUBES AND HOSE ALONG WITH
9670 101697094 101697094 1.0 MOUNTING HARDWARE AND COMPO-
NENTS, SKID, NITROGEN CONVERTER,
INSTALLATION, TOOL BOX AND COM-
PONENTS, SKID, NITROGEN CON-
9680 101697095 101697095 1.0
FLAMELESS
INSTALLATION, FIRE EXTINGUISHER,
9700 101697096 101697096 1.0 SKID, NITROGEN CONVERTER, DUAL


INSTALLATION, PAINT DECALS AND
FINAL PREP, SKID, NITROGEN CON-
9710 101697097 101697097 1.0
FLAMELES
INSTALLATION, GRATING AND COMPO-
9720 101697098 101697098 1.0 NENTS, SKID, NITROGEN CONVERTER,
Table 5.5—Critical Components List

Equipment Type SAP No. Manufacturer Model
Engine package 101697174 Halliburton
Engine 101668482 Caterpillar C18
Instln pump drive and
101697176
hydraulic pumps
Pump drive 101714711 Funk 57414C
Hydraulic drive pump 1 101517255 Sundstrand Sauer 90L130HF5DE80R4F1F03G
Hydraulic drive pump 2 101517255 Sundstrand Sauer 90L130HF5DE80R4F1F03G
Hydraulic heat-build pump
101697068 Volvo - Parker F12-125-MS-SV-S
1
Hydraulic heat-build pump
101697068 Volvo - Parker F12-125-MS-SV-S
2
Hydraulic charge and lube
101697069 Barnes G2009W2E15V28VTB12X63
pump
Hydraulic pump for Viking
101697070 Parker PAVC38BL4
drive
Instln alternator 101697177
Alternator 101439509 Leece-Neville 8LHA3096U
Instln starter, pneumatic 101697178
Starter 100049770 Ingersoll I-R 150 SERIES
Instln radiator 101697179
Radiator 100046427 Young —
Fan 101769709 Crowley —

Table 5.5—Critical Components List (Continued)

Jacket water-heat
101697063 WTT America WP8-70
exchanger
Thermatic valve 120009620 AMOT 3BOCF
Instln exhaust vaporizer 101697180
Exhaust vaporizer 101697059 CS&P 427-05273-00007
Instln charge air 101697181
Water to charge air cooler 101697062 Bell Intercooler W09001
Lift-frame and skid-base
101397036
attachment assembly
Skid-base weldment 101665206 Halliburton
Lift-frame weldment 101665171 Halliburton
Drip-pan weldment 101665207 Halliburton
Electronic equip-
101756439 Halliburton
ment-enclosure assembly
Unipro II assembly 100062112 Halliburton
Gauge-panel and hydrau-
lic control-enclosure 101765633 Halliburton
assembly
Triplex-pump assembly
with 1 1/4-in. bore fluid 101697072 Halliburton
ends
Triplex-pump power end
with cold 101665204 CS&P
ends
1 1/4 -in. Bore fluid end 101697215 CS&P
1 1/4- in. Bore fluid end 101697215 CS&P
1 1/4- in. Bore fluid end 101697215 CS&P
Hydraulic-drive motor 101697067 Volvo-Parker F12-110-MS-SV-S
Discharge-manifold block 101697209 Autoclave Engineers 201D-1687
Triplex-pump assembly
with 1 5/8-in. bore fluid 101697074 Halliburton
ends
Triplex-pump power end
101665208 CS&P
with cold ends
1 5/8-in. Bore fluid end 101697216 CS&P


1 5/8 -in. Bore fluid end 101697216 CS&P
1 5/8-in. Bore fluid end 101697216 CS&P
Hydraulic-drive motor 101697067 Volvo-Parker F12-110-MS-SV-S
Discharge-manifold block 101697209 Autoclave Engineers 201D-1687
Instln engine and coolant
pump
Coolant-pump assembly 101697077 Halliburton
Pump-rotary gear 101697071 Viking LS4126A W/RELIEF at 150 psi
Motor-hydraulic geroler 100021777 Parker 110A-054-BS-0
Instln heat exchangers
Heat-exchanger weld-
ment
Hydraulic-oil to water heat
101697064 WTT America WP10-84
exchanger
Water-bath vaporizer 101697061 CS&P 851-01430-00007
Shell and tube-heat
100048828 Thermal Transfer SA1648-6-6-0
exchanger 8-in. diameter
Shell and tube-heat
100048829 Thermal Transfer SA1224-4-6-0
exchanger 6-in. diameter
Valve assembly three-way
101764394 Worcester 3 INCH-D5166/DCR90
diverter
Electronic actuator 101764417 RCS DCR90-15-7-24VDC-2AUX
Instln hydraulic compo-
nents
Relief-valve assembly 1 100048287 Sun Hydraulic RVIS-LWV-KCS/S
Relief-valve assembly 2 100048287 Sun Hydraulic RVIS-LWV-KCS/S
Instln high-pressure com-
ponents
Valve 1 in. medium-pres-
101517270 Autoclave Engineers 20SM16072-LT-WO
sure two-way angle
100011198 Autoclave Engineers 20SM16071-LT-WO
sure two-way straight
Valve 9/16 in.
medium-pressure 100048711 Autoclave Engineers 20SM9072-LT-WO
two-way angle


100048680 Autoclave Engineers 20DV16077-LT-WO
sure three-way diverter
Valve safety 9/16 in.
100048693 Autoclave Engineers 15RV9072-K-316-12000#
12,000 psi
100048554 Autoclave Engineers 20RVP9072-K-316-17000#
17,000 psi
100048554 Autoclave Engineers 20RVP9072-K-316-17000#
17,000 psi
Hub 1-in. medium pres-
sure
Gaseous nitrogen-mani-
fold block
LoTorc® plug-valve 100049204 Halliburton
assembly
Pneumatic actuator 100011125 Matryx MODEL 200-SPECIAL
Instln fuel tank and piping 101697085
100-gal Aluminum fuel
101313300 Tank Craft 4010047
tank
Instln air tank and air-tank
comp.
Air tank, air start system 100054646 Halliburton
Diagrams
The following section contains diagrams used for maintenance of the SPU-270F nitrogen converter
skid.

Figure 5.1—Left-hand view of skid (lift frame removed).

Figure 5.2—Right-hand view of skid (lift frame removed).

Figure 5.3—Circulating water piping.

Figure 5.4—Triplex A and B drive circuit motor piping.

Figure 5.5—Triplex A nd B drive circuit case drain piping.

Figure 5.6—Viking drive circuit hydrualic piping.

Figure 5.7—Hydraulic build cicuit hydraulic piping.

May 2011
Maintenance
Figure 5.8—Heat build, boost pump, and overall hydraulic system drain piping.
5-17
5-18
Maintenance
Figure 5.9—Triplex A and B and Viking drive control and gauge piping.
May 2011
May 2011
Figure 5.10—Boost pump control, along with Triplex A and B discharge pressure and case drain filter differential pressure gauge piping.
Maintenance
5-19
5-20
Maintenance
Figure 5.11—Boost pump control valve and pressure gauge pressure piping (international version).
May 2011
Figure 5.12—Hydraulic heat control/air plumbing.

Figure 5.13—Triplex A auto/manual rate control plumbing.

Figure 5.14—Triplex B auto/manual rate control plumbing.

5-24
Maintenance
Figure 5.15—Air, water, and filter press indicator pressure gauge piping details.
May 2011
May 2011
Maintenance
Figure 5.16—Hydraulic drive and heat build pressure gauge piping details.
5-25
5-26
Maintenance
Figure 5.17—System temperatures and low-pressure nitrogen gauge piping details.
May 2011
Figure 5.18—Air piping schematic.

Figure 5.19—Air piping schematic.

Figure 5.20—Lube oil plumbing detail.

5-30
Maintenance
Figure 5.21—Low-pressure process valves and and piping exploded view (nonboosted version).
May 2011
May 2011
Figure 5.22—Low-pressure process valves and piping exploded view (boosted version).
Maintenance
5-31
Figure 5.23—Blowby piping exploded view.

May 2011
Maintenance
Figure 5.24—High-pressure process valves and piping exploded view.
5-33
5-34
Maintenance
Figure 5.25—High-pressure relief valves and piping exploded view.
May 2011
Figure 5.26—Electrical schematic.



5-38
Maintenance
Figure 5.29—Skid lift points, ISO blocks, tiedowns, and pinning attachments.
May 2011
SECTION
Section
16
Preface
Troubleshooting
Introduction
In many instances a component or system may develop a problem for which there is no immediate
clear cause. It is recommended that, to avoid needless disassembly, the following procedures be taken
to isolate the portion of the circuit where the problem exists. Review the safety summary before
troubleshooting any problems. The procedures are as follows:
1. Operate the system or circuit to confirm the problem actually exists.

2. Check for obvious problems first.
3. Check the oil level in the hydraulic reservoir to ensure that it is full.
4. Check to ensure hydraulic filters are clean.
5. Check to ensure all system gauges, valves, and other components are functioning correctly.
6. Check to see what recent repair or maintenance has been performed. Inspect these areas for
possible problem causes.
Important It should be emphasized that cleaning the equipment before inspection will
make the job easier, take less time, and will reduce the chances of
contamination.
Common equipment malfunctions are presented in the following sections:
• Engine Troubleshooting Guide (Page 6-2).

• Nitrogen Pumping System Troubleshooting Guide (Page 6-6).
• Tank Troubleshooting Guide (Page 6-7).
May 2011 Troubleshooting 6-1

Note These guides are summarized lists of troubles, probable causes, and remedies.
Should a series of malfunctions occur, suspect a lack of daily scheduled
inspections and maintenance to be a contributing factor.
Note The following troubleshooting guides are simple checks that field maintenance
can make. Any detailed engine problems should be performed by an authorized
engine repair facility. Field maintenance personnel should possess a good
understanding and working knowledge of the properties and dangers of nitrogen
and high pressure pumping equipment before attempting to troubleshoot this unit.
Engine Troubleshooting Guide

Table 6.1—Problem A: Engine Starter Not Turning Over
Probable Cause Remedy
Check electrical connections.
Check alternator out feed.
Low voltage
Check disconnect switches.
Charge battery.
Starter not engaging or does not remain
Low air pressure or air valve sticking.
engaged
Seized bearings Replace bushings.
Table 6.2—Problem B: Engine Cranks But Will Not Start

Slow cranking speed Refer to Table 6.1.
Using starting aid (ether) below 15°F. Check
Low ambient temperature engine manual to be certain ether starting is
approved.
Check fuel tank level, fuel filters, fuel lines,
Engine not getting fuel
valves, supply and return, and fuel pump.
Check normal kill cylinder to see if it is stuck in Repair or remove and replace normal kill cyl-
Kill position inder.
Poor quality fuel, incorrect fuel or water in fuel Drain fuel, change filters, and replace fuel.
Improper oil viscosity Drain oil, change filters, and replace oil.
Check the emergency kill “flapper” to see if it
Reset emergency kill “flapper.”
is in closed position.
6-2 Troubleshooting May 2011

Table 6.3―Problem C: Engine Misfiring

Poor quality fuel Drain fuel, change filters, and replace fuel.
Check for air in fuel system mainly on suction
Air in fuel system
side of fuel pump.
Check for fuel leaks and replace defective
Broken or leaking fuel lines
parts.
Check fuel flow. Replace fuel lines as neces-
Restrictions in fuel lines
sary.
Check fuel level and kinks in fuel lines.
Low fuel pressure
Change fuel filters.
Contact authorized engine repair representa-
Defective fuel injectors or pump
tive.
Table 6.4―Problem D: Engine Stalls

Fuel tank vent plugged Check tank vent and repair as necessary.
Low fuel supply Refer to Table 6.3, Item 5.
High parasitic loading (e.g., LN2 pump
Check for engine loading during starting.
hydraulic pump speed control.)
Table 6.5―Problem E: Erratic Engine Speed

Air leaks in fuel suction line Check for air leaks and repair as necessary.
Engine governor problems Contact authorized repair representative.

Table 6.6—Problem F: Low Power

Check air pressure in air inlet manifold.
Restrictions in air intake system, clogged air
Replace air filter and make necessary repairs
filter
to air system.
Poor fuel quality Refer to Table 6.12, Item 6.
Emergency kill “flapper” partially closed Check “flapper.” Reset or repair as necessary.
Normal kill cylinder partially extended Reset cylinder or repair as needed.
Table 6.7―Problem G: Engine Overheating

Determine cause, replace defective parts, and
Coolant level low
replace coolant.
Expansion tank cap Replace expansion cap.
Defective thermostat Replace thermostat.
Defective coolant pump Replace coolant pump.
Fan not engaging fully (full rev/min) or turning Inspect fan and fan belt. Repair as necessary.

Table 6.8―Problem H: Low Engine Oil Pressure

Oil leakage, low level Check for leaks and repair as necessary.
Incorrect oil viscosity Drain oil, change filters, and replace oil.
Defective oil gauge Replace oil gauge.
Clogged oil filter Replace oil and filters.
Defective oil pump Contact authorized repair representative.
Excessive engine wear Contact authorized repair representative.
Table 6.9―Problem I: Oil in Coolant

Defective oil-cooler core or seals Contact authorized repair representative.
Blown head gasket Contact authorized repair representative.
Table 6.10―Problem J: Coolant in Oil

Defective oil-coolant core or seals Contact authorized repair representative.
Blown head gasket Contact authorized repair representative.
Defective coolant pump Contact authorized repair representative.
Cylinder sleeve seals failure Contact authorized repair representative.

Nitrogen Pumping System Troubleshooting Guide
Table 6.11―Problem A: Low Flow Rate to Unit From LN2 Tank

Low tank pressure Increase tank pressure.
Supply valve not fully open Open valve fully on LN2 tank and skid.
Return valve closed or partially closed Open valve fully on LN2 tank and skid.
Suction strainer on LN2 tank clogged Clean or replace strainer.
Strainer(s) on skid clogged Clean or replace strainer(s).
Clogged piping or transfer hoses Inspect piping and hoses to ensure free flow.
Table 6.12—Problem B: Moisture In Stem Packing

Moisture in stem packing Thaw valve and dry out packing.
Table 6.13―Problem C: Boost Pump Will Not Turn

Hydraulic valve closed at boost pump Open valve.
Turn the shaft coupling with a pipe wrench. Do
Locked up from ice formation not use excessive force. If pump will not turn,
thaw out and dry out pump.
Suction valve to hydraulic pump closed Open valve.
Disconnect motor supply hose. Plug hose and
cap motor. If pump does not build pressure,
Defective hydraulic pump
then check system relief valve. If relief valve is
all right, remove and replace pump.
Defective motor Replace motor.
Defective sequence valve Replace sequence valve.

Table 6.14―Problem D: Triplex Pump Will Not Rotate

Improperly adjusted cold end Adjust cold end properly.
Over pressure shutdown is active or tripped Reset to operating position.
Check pump drive coupling to ensure drive
Replace damaged or broken drive coupling.
components are not slipping off input shaft
Check main system pressure. If pressure Disconnect motor supply hose. Plug hose and
rises above what is normally required to drive cap motor. If pump does not build pressure,
Triplex, one of the following is locked up: then check system relief valve. If relief valve is
Hydraulic drive motor all right, remove and replace pump.
Reduction gear box
Triplex pump
Tank Troubleshooting Guide
Table 6.15―Problem A: Low Flow Rate To Pumping Skid

Low suction pressure Build pressure on LN2 tank.
One or more valves required for liquid supply Check supply and return valves to make sure
not fully open they are fully open.
Check for ice or contamination in LN2 supply
Ice or contamination in supply line filters
filters/strainers.
Table 6.16―Problem B: Frozen Valve Stem

Thaw and dry valve packing and packing
Moisture in stem packing
gland with dry nitrogen gas.

Table 6.17―Problem C: Valve Leaking Vapor And Liquid

Disassemble valve and repair or replace as
Foreign material or ice on valve seat
required.
Table 6.18―Problem D: Tank Will Not Build Or Maintain Pressure

Line to pressure-building coil obstructed, iced,
Clear obstruction and/or open valve.
or valve closed
Low liquid level Fill tank.
Leak to atmosphere Locate leak and repair.
Table 6.19―Problem E: Excessive Tank Pressure

Defective pressure gauge Check indicator. Replace if necessary.
Road relief not functioning Repair or replace road relief as required.
Pressure building valve open Close valve.

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SPU-270F Nitrogen Skid

Part No. 101812329

Part No. 101812329

Section 1—Introduction/Operational Characteristics

Section 2—Nitrogen Safety

Section 4—Operating the Unit

May 2011 Introduction/Operational Characteristics 1-1

Figure 1.1—Front view of the SPU-270F converter unit.

1-2 Introduction/Operational Characteristics May 2011

Figure 1.2—Rear view of the SPU-270F converter unit.

May 2011 Introduction/Operational Characteristics 1-3

Figure 1.3—Left-hand view of the SPU-270F converter unit.

1-4 Introduction/Operational Characteristics May 2011

May 2011 Introduction/Operational Characteristics 1-5

Figure 1.5—Right-hand view of the SPU-270F converter unit.

1-6 Introduction/Operational Characteristics May 2011

May 2011 Introduction/Operational Characteristics 1-7

Table 1.1—Unit Specifications

1-8 Introduction/Operational Characteristics May 2011

Table 1.1—Unit Specifications (Continued)

May 2011 Introduction/Operational Characteristics 1-9

Table 1.1—Unit Specifications (Continued)

1-10 Introduction/Operational Characteristics May 2011

May 2011 Nitrogen Safety 2-1

Table 2.1—Physical Properties of Nitrogen (at 14.7 psi [1.01 bar])

Table 2.2—Nitrogen Converter Data

Pounds Standard Cubic Gallons of

2-2 Nitrogen Safety May 2011

Figure 2.1—Liquid nitrogen at -320°F (-196°C) expands its volume

Nitrogen in the Air

May 2011 Nitrogen Safety 2-3

Figure 2.2—Air contains 78% nitrogen, confirming that nitrogen

• Carbon dioxide at -109.3°F

2-4 Nitrogen Safety May 2011

Figure 2.3—Cryogenic thermometer showing the extraordinarily

Safety Precautions for Handling Liquid Nitrogen

Wear Protective Clothing

Avoid Skin Contact

May 2011 Nitrogen Safety 2-5

Figure 2.4—(Left) Improper PPE and (right) proper PPE.

2-6 Nitrogen Safety May 2011

Figure 2.5—Always protect your eyes when working around nitrogen.

First Aid Procedures for Cold Liquid Frostbite (Freeze Burns)

May 2011 Nitrogen Safety 2-7

Oxygen Deficiency Hazard

Table 2.3—Symptoms of Oxygen Deficiency

2-8 Nitrogen Safety May 2011

Figure 2.6—Gas cloud.

Liquid Nitrogen Equipment Safety

Cryogenic Materials and Components

May 2011 Nitrogen Safety 2-9

Non-cryogenic Material and Components

2-10 Nitrogen Safety May 2011

Warning HIGH-PRESSURE HAZARD. Carbon steel becomes brittle at approximately

Iron becomes brittle at -40°F.

Iron cannot withstand rapid contraction.

Figure 2.7—Liquid nitrogen can severely damage iron.

May 2011 Nitrogen Safety 2-11

Treating Iron Low-Temperature Limits

Caution CONTRACTION HAZARD. Do not frost hoses.

Pressure Buildup from Trapped Liquid Nitrogen

Warning HIGH-PRESSURE HAZARD. Manifolds can contain compressed nitrogen.

Important It is important to note the pressure difference with temperature increase in a