Manual de Operación de Unidades de Nitrógeno
Manual de Operación de Unidades de Nitrógeno
Manual de Operación de Unidades de Nitrógeno
Operator’s Manual
© 2011 Halliburton
All Rights Reserved. Printed in the United States of America.
Printing History:
First Printing (May 2011)
Contents
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 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.
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 1.4—Left-hand view of the SPU-270F converter unit (lift frame removed).
Figure 1.6—Right-hand view of the SPU-270F converter unit (lift frame removed).
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.
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]).
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.
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 2.3 (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):
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.
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.
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.
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.
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 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
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.
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.
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.
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).
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.
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.
13
Preface
Preliminary Checks
Set Pressures
Pump A
Program 1.25-in. cold-end pumps with the following:
Pump B
Program 1.625-in. cold-end pumps with the following:
Note Additional ANRCS tuning and testing should be performed by E-Tech per Procedure
458.02510.
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).
14
Preface
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.
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.
Figure 4.1—Recommended test procedure for ensuring the check valves are in proper
operation.
Figure 4.2—Dual check valve and dual bleeder-tee setup for proper rigup operation.
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:
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:
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.
Pumping Procedure
After the liquid nitrogen is conditioned (when storage is venting no gas vapor from blow-down),
follow the steps below:
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
SPU-270F Nitrogen Skid Operator’s Manual
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.
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).
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 4.16—Tank blowdown and road-relief isolation valves and associated plumbing.
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).
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.
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.
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.
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).
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.
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.
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:
Diagrams
The following section contains diagrams used for maintenance of the SPU-270F nitrogen converter
skid.
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SPU-270F Nitrogen Skid Operator’s Manual
Figure 5.9—Triplex A and B and Viking drive control and gauge piping.
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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
SPU-270F Nitrogen Skid Operator’s Manual
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Maintenance
SPU-270F Nitrogen Skid Operator’s Manual
Figure 5.11—Boost pump control valve and pressure gauge pressure piping (international version).
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SPU-270F Nitrogen Skid Operator’s Manual
Figure 5.15—Air, water, and filter press indicator pressure gauge piping details.
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May 2011
Maintenance
Figure 5.16—Hydraulic drive and heat build pressure gauge piping details.
SPU-270F Nitrogen Skid Operator’s Manual
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Maintenance
SPU-270F Nitrogen Skid Operator’s Manual
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SPU-270F Nitrogen Skid Operator’s Manual
Figure 5.21—Low-pressure process valves and and piping exploded view (nonboosted version).
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May 2011
Figure 5.22—Low-pressure process valves and piping exploded view (boosted version).
Maintenance
SPU-270F Nitrogen Skid Operator’s Manual
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SPU-270F Nitrogen Skid Operator’s Manual
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Maintenance
SPU-270F Nitrogen Skid Operator’s Manual
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SPU-270F Nitrogen Skid Operator’s Manual
Figure 5.29—Skid lift points, ISO blocks, tiedowns, and pinning attachments.
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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:
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.
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.