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Vol 1 - Operation Maintenance Manual
Vol 1 - Operation Maintenance Manual
CONTENTS
1.0 Introduction
2.0 Safety
2.6. Atex
5.1. Introduction
5.2. Before Starting Engine
5.3. Inter Unit Connection
5.4. Start-up and Operating Procedures
5.5. Stopping the System
5.6. Engine Safety System Shutdowns
5.7. Final Rig Down
6.1. Introduction
6.2. Inspection
6.3. Unit Maintenance
6.4. Unit Cleaning
6.5. Compressor Maintenance
6.6. Maintenance Drive Belts
6.7. Maintenance Safety Valves
6.8. Maintenance Lifting Equipment
6.9. Maintenance Frame
6.10. Maintenance Hydraulics
6.11. Maintenance Pneumatics
6.12. Maintenance Electrical System
6.13. Engine Maintenance
6.14. Nitrogen Unit Troubleshooting Guide
6.15. Hydraulic Troubleshooting
6.16. SOS 3g System Maintenance
6.17. Oils & Filters
1.0 INTRODUCTION
NOV Hydra Rig UK equipment is engineered for simple operation and maintenance. This
equipment manual provides the operator with the information necessary to learn the
fundamentals of successful operation. Study this manual carefully before making any
attempt to operate the equipment. Pay special attention to any safety instructions. During
the operation or maintenance of this equipment, personnel safety should always be of the
utmost importance.
The equipment is designed and all components are carefully specified to provide maximum
performance and safety. Maintenance schedules outlined in this manual should be
considered as minimum requirements to maintain satisfactory performance. Maintenance
schedules should be followed as closely as possible. In the unlikely event of equipment
failure or decreased performance, maintenance personnel will find valuable
troubleshooting, circuit analysis and component information throughout the manual.
The abilities of operators or maintenance personnel to understand and use the system
schematics are vital when troubleshooting this equipment. Before operating, adjusting, or
replacing any components, be certain that the ramifications and consequences of those
actions are clearly understood by ensuring that the appropriate precautions are taken.
If problems cannot be readily resolved, it is strongly recommended that you contact NOV
Hydra Rig UK Service department. NOV Hydra Rig UK stands behind all equipment and is
willing and able to provide replacement parts and field service upon request.
1.2 Introduction
The Halliburton Zone 2 180K Nitrogen pumping and vaporising system has the following
identifications:
A skid mounted liquid nitrogen pumping and vaporizing system, to come complete as
described in the scope of supply.
The unit is designed and constructed for operations onshore and offshore and the final
assembly and design to be approved by D. N. V. This will include equipment designed to
meet, but not limited to, the requirements of D.N.V. 2.7-1, PED, C.E. marking and Zone 2
compliance.
Performance Specifications
Skid Dimensions
(ISO shipping compatible height and width)
Length: 4,572mm/180”
Width: 2,438mm/ 96”
Height: 2,600mm/102"
1. ACCEPTANCE Cooperation. Buyer shall cooperate with Seller, and at the request of Seller, Buyer shall use its best
Orders or other requests, whether oral or written, for the supply or sale of machinery or equipment efforts to supply to Seller such information (including documentary information) in connection with its
(“Equipment”), or for the supply or sale of spare or replacement parts (“Parts”), or for the provision of activities as may be required by Seller for any of the following purposes:
services (“Services”), or for the rental of machinery or equipment (“Rental”) to be provided by National a) To enable Seller to comply with the lawful demand or requirement for such information by
Oilwell Varco, L.P., on behalf of itself and its divisions and subsidiaries, or by its affiliates (“Seller”) to any appropriate government authority or to ensure that all requirements of the applicable
its customers (each a “Buyer”) (the “Order(s)”) are subject to Seller’s written acceptance by an law are being complied with;
authorized representative of Seller and any Orders so accepted will be governed by (a) the terms and b) To enable Seller to conduct, defend, negotiate or settle any claim arising out of, or in
conditions stated in these Terms and Conditions for provision of Equipment, Parts, Services or Rental connection with, such activities, whether or not such claim shall have become the subject
(the “Terms and Conditions”); (b) the written proposal submitted by Seller to Buyer (“Proposal”), if any; of arbitration or judicial proceedings;
(c) the written order acknowledgment issued by Seller to Buyer (“Acknowledgment”), if any; and, (d) c) To enable Seller to make any application (including, but without limitation, any claim for
any change orders identified as such and agreed to in writing by Seller (the Order, Terms and any allowances or relief) or representation in connection with, or to contest any
Conditions, Proposal, Acknowledgment, and any such change order, and any such additional terms as assessment on, or liability of Seller to any taxes, duties, levies, charges and contributions
agreed to in writing by an authorized representative of Seller collectively referred to herein as the (and any interest or penalties thereon); or
“Agreement”). Buyer’s submission of a purchase order (or other similar document) shall be deemed to d) To secure for Seller any beneficial tax treatment and legally minimize any tax obligations
be an express acceptance of these Terms and Conditions notwithstanding language in Buyer’s in connection with this Agreement.
purchase order (or other similar document) inconsistent herewith, and any inconsistent language in Seller’s request for such information and documents shall allow Buyer a reasonable time to prepare,
Buyer’s purchase order (or other similar document) is hereby rejected. Buyer’s purchase order (or provide and submit that information requested. The obligations set forth above shall exist for a period of
other similar document) is incorporated in this Agreement, only to the extent of specifying the nature six (6) years commencing with the date of agreement by Buyer of Seller's final statement of account
and description of the Equipment, Parts, Services or Rental and then only to the extent consistent with under the Agreement, and the Buyer shall retain and shall procure any subcontractor hereunder to
the Proposal or Acknowledgment. In the event of any conflict between a Proposal and an retain, all information and documents in connection with its activities under or pursuant to the
Acknowledgement, the Acknowledgment shall prevail. Agreement as shall enable the Buyer to comply with the above obligations.
Page 1 of 3 NOV Terms and Conditions for the Provision of Equipment, Parts, Services or Rental AAR 7/25/2011
months from date of purchase.
8. TITLE AND RISK OF LOSS
For purchased goods, ownership and risk of loss pass to Buyer upon the earlier of (a) Seller's delivery 12. LIABILITIES, RELEASES AND INDEMNIFICATION
of the goods, or (b) invoicing by Seller for the goods where Buyer is unable to accept delivery on the For purpose of this Article12, the following definitions shall apply:
scheduled date. Seller retains a security interest in the goods until the purchase price has been paid, “Seller Group” shall mean (i) Seller, its parent, subsidiary or related companies, (ii) its and their
and Buyer agrees to perform upon request all acts required to secure Seller's interest. Seller accepts working interest owners, co-lessees, co-owners, partners, joint venturers, if any, and their respective
no responsibility for any damage, shortage or loss in transit. Seller will attempt to pack or prepare all parents, subsidiary or related companies and (iii) the officers, directors, employees, consultants, agents
shipments so that they will not break, rust or deteriorate in shipment, but Seller does not guarantee and invitees of all of the foregoing.
against such damage. Claims for any damage, shortage or loss in transit must be made by Buyer on
the carrier. “Buyer Group” shall mean (i) Buyer, its parent, subsidiary or related companies, (ii) its and their
working interest owners, co-lessees, co-owners, partners, joint venturers, if any, and their respective
In the event of Rental, Buyer assumes all risk and liability whether or not covered by insurance, for loss parents, subsidiary or related companies and (iii) the officers, directors, employees, consultants, agents
or damage to the Rental machinery or equipment. Risk and liability passes to Buyer upon delivery by and invitees of all of the foregoing.
Seller. Title to Rental machinery or equipment shall remain with Seller at all times. Buyer acquires no
ownership, title or property rights to the Rental machinery or equipment except the right to use the “Claims” shall mean all claims, demands, causes of action, liabilities, damages, judgments, fines,
Rental machinery or equipment subject to the terms of this Agreement. penalties, awards, losses, costs, expenses (including, without limitation, attorneys’ fees and costs of
litigation) of any kind or character arising out of, or related to, the performance of or subject matter of
9. LIMITED WARRANTY this Agreement (including, without limitation, property loss or damage, personal or bodily injury,
New Equipment/Parts. In the case of the purchase of new Equipment/Parts, and solely for the benefit sickness, disease or death, loss of services and/or wages, or loss of consortium or society).
of the original user, Seller warrants, for a period of eighteen (18) months from delivery or twelve (12)
months from installation, whichever is earlier, that new Equipment/Parts of its own manufacture shall a) Seller shall release, indemnify, defend and hold Buyer Group harmless from and against
conform to the material and technical specifications set forth in the Agreement. Goods manufactured by any and all Claims in respect of personal or bodily injury to, sickness, disease or death of
others are sold "as is" except to the extent the manufacturer honors any applicable warranty made by any member of Seller Group or Seller Group’s subcontractors or their employees, agents
the manufacturer. Secondhand goods are sold "as is". If the new Equipment/Parts fail to conform with or invitees, and all Claims in respect of damage to or loss or destruction of property
such specifications upon inspection by Seller, Seller will, at its option and as Buyer’s sole remedy, owned, leased, rented or hired by any member of Seller Group or Seller Group’s
either repair or replace such defective Equipment/Parts with the type originally furnished. subcontractors or their employees, agents or invitees.
b) Buyer shall release, indemnify, defend and hold Seller Group harmless from and against
Remanufactured to “As New” Equipment/Parts. Seller warrants to Buyer, that for a period of six (6) any and all Claims in respect of personal or bodily injury to, sickness, disease or death of
months from the date of delivery by Seller or installation of the Equipment/Parts, whichever is earlier, any member of Buyer Group or Buyer Group’s other contractors or their employees,
that reconditioned to “as new” Equipment/Parts will be free from defects in material and workmanship. agents or invitees, and all Claims in respect of damage to or loss or destruction of
If the reconditioned to “as new” Equipment/Parts fail to conform with such warranty upon inspection by property owned, leased, rented or hired by any member of Buyer Group or Buyer
Seller, Seller will, at its option and as Buyer’s sole remedy, either repair or replace such defective Group’s other contractors or their employees, agents or invitees.
Equipment/Parts with the type originally furnished. c) Each party covenants and agrees to support the mutual indemnity obligations contained
in Paragraphs (a) and (b) above, by carrying equal amounts of insurance (or qualified
Overhauled Equipment/Parts. Seller warrants that for a period of four (4) months from the date of self insurance) in an amount not less than U.S. $5,000,000.00.
delivery by Seller or three (3) months from installation, whichever is earlier, that overhauled d) Notwithstanding anything contained in this Agreement to the contrary, in all instances
Equipment/Parts will be free from defects in workmanship. If the overhauled Equipment/Parts fail to where Seller is providing Services at a well site, Buyer, to the maximum extent permitted
conform with such warranty upon inspection by Seller, Seller will, at its option and as Buyer’s sole under applicable law, shall release, indemnify, defend and hold Seller Group and Seller
remedy, either repair or replace such defective Equipment/Parts with the type originally furnished. This Group subcontractors harmless from and against any and all Claims asserted by or in
warranty expressly assumes that parts normally considered consumables (including, but not limited to favor of any person or party, including Seller Group, Buyer Group or any other person or
rubber goods, seals (rubber, polymer and/or metallic) and/or bearings, are replaced during overhaul. If party, resulting from: (i) loss of or damage to any well or hole (including but not limited to
Buyer requests that such parts not be replaced, Seller hereby disclaims any warranty for said the costs of re-drill), (ii) blowout, fire, explosion, cratering or any uncontrolled well
overhauled Equipment/Parts. condition (including but not limited to the costs to control a wild well and the removal of
debris), (iii) damage to any reservoir, geological formation or underground strata or the
Service. Seller warrants that the Services to be provided pursuant to this Agreement shall conform to loss of oil, water or gas therefrom, (iv) pollution or contamination of any kind (other than
the material aspects of the specifications set forth in the Agreement. Seller shall re-perform that part of surface spillage of fuels, lubricants, rig sewage or garbage, to the extent attributable to
the non-conforming Services, provided Seller is notified by Buyer prior to Seller’s departure from the the negligence of Seller Group, including but not limited to the cost of control, removal
worksite. and clean-up, or (v) damage to, or escape of any substance from, any pipeline, vessel or
storage facility.
Rental. Seller warrants that the Rental equipment to be provided pursuant to this Agreement shall e) NOTWITHSTANDING ANYTHING CONTAINED IN THIS AGREEMENT TO THE
conform to the material aspects of the specifications set forth in the Agreement. Provided Seller is CONTRARY, NEITHER PARTY SHALL BE LIABLE TO THE OTHER AND EACH
notified by Buyer prior to Seller’s departure from the worksite, Seller shall repair or replace non- PARTY RELEASES THE OTHER FOR ANY INDIRECT, SPECIAL, PUNITIVE,
conforming Rental equipment. In the event of failure or other non-performance of Seller’s Rental EXEMPLARY OR CONSEQUENTIAL DAMAGES OR LOSSES (WHETHER
equipment’s contributing to loss of hole, rental rates will apply during re-drill to equivalent TD. FORESEEABLE AT THE DATE OF THIS AGREEMENT, INCLUDING WITHOUT
LIMITATION, DAMAGES FOR LOST PRODUCTION, LOST REVENUE, LOST
Seller’s warranty obligations hereunder shall not apply if non-conformity or failure was caused by (a) PRODUCT, LOST PROFIT, LOST BUSINESS OR BUSINESS OPPORTUNITIES.
Buyer’s failure to properly store or maintain the equipment or parts; (b) the unauthorized modification, f) Seller’s total liability for all claims, damages, causes of action, demands, judgments,
repair or service of the equipment or parts by Buyer; (c) utilization of replacement parts not fines, penalties, awards, losses, costs and expenses (including attorney’s fees and cost
manufactured by Seller; or (d) use or handling of the equipment by Buyer in a manner inconsistent with of litigation) shall be limited to and shall not exceed the value of the Equipment, Parts,
Seller’s recommendations. Further, Seller’s warranty obligations under this Article 9 shall terminate if Services or Rental purchased under the Agreement.
(a) Buyer fails to perform its obligations under this or any other Agreement between the parties, or (b) if g) THE EXCLUSIONS OF LIABILITY, RELEASES AND INDEMNITIES SET FORTH IN
Buyer fails to pay any charges due Seller. Any third party warranties provided on equipment or parts PARAGRAPHS A. THROUGH F. OF THIS ARTICLE 12 SHALL APPLY TO ANY
not manufactured by Seller are assigned to Buyer, without recourse, at the time of delivery, provided CLAIM(S), LOSSES OR DAMAGES WITHOUT REGARD TO THE CAUSE(S)
such warranties are assignable. THEREOF, INCLUDING BUT NOT LIMITED TO PRE-EXISTING CONDITIONS,
WHETHER SUCH CONDITIONS BE PATENT OR LATENT, THE UNSEAWORTHINESS
THIS ARTICLE 9 SETS FORTH BUYER’S SOLE REMEDY AND SELLER’S EXCLUSIVE OF ANY VESSEL OR VESSELS, IMPERFECTION OF MATERIAL, DEFECT OR
OBLIGATION WITH REGARD TO NON-CONFORMING EQUIPMENT, PARTS, SERVICES OR FAILURE OF PRODUCTS OR EQUIPMENT, BREACH OF REPRESENTATION OR
RENTAL. EXCEPT AS OTHERWISE EXPRESSLY PROVIDED PURSUANT TO THE PROVISIONS WARRANTY (EXPRESS OR IMPLIED), ULTRAHAZARDOUS ACTIVITY, STRICT
OF THIS ARTICLE 9, SELLER MAKES NO OTHER WARRANTIES OR REPRESENTATIONS OF LIABILITY, TORT, BREACH OF CONTRACT, BREACH OF DUTY (STATUTORY OR
ANY KIND, EXPRESS OR IMPLIED, AND SELLER DISCLAIMS THE IMPLIED WARRANTIES OF OTHERWISE), BREACH OF ANY SAFETY REQUIREMENT OR REGULATION, OR
MERCHANTIBILITY AND FITNESS FOR A PARTICULAR PURPOSE. THE NEGLIGENCE OR OTHER LEGAL FAULT OR RESPONSIBILITY OF ANY
PERSON (INCLUDING THE INDEMNIFIED OR RELEASED PARTY), WHETHER SUCH
10. CHANGES NEGLIGENCE BE SOLE, JOINT OR CONCURRENT, ACTIVE OR PASSIVE.
Seller expressly reserves the right to change, discontinue or modify the design and manufacture of its h) Redress under the indemnity provisions set forth in this Article 12 shall be the exclusive
products without obligation to furnish, retrofit or install products previously or subsequently sold. remedy(ies) available to the parties hereto for the matters, claims, damages and losses
covered by such provisions.
11. RETURN OF MAKE TO STOCK GOODS
With Seller’s written approval, unused, incorrectly shipped or “Made to Stock” goods ordered 13. INSURANCE
incorrectly, in new condition and of current manufacture and catalog specifications may be returned by Upon written request, each party shall furnish to the other party certificates of insurance evidencing the
Buyer for credit (subject to a restocking fee), provided written request is received within one (1) year fact that the adequate insurance to support each party’s obligations hereunder has been secured. To
after the purchase date. Non-standard goods are not returnable for credit and such goods shall only be the extent of each party’s release and indemnity obligations expressly assumed by each party
accepted for return with the prior written agreement of Seller. Requests for return of goods must show hereunder, each party agrees that all such insurance policies shall, (a) be primary to the other party’s
the original purchase order number, invoice number, description of material, and date of purchase. insurance; (b) include the other party, its parent, subsidiary and affiliated or related companies, and its
Return of goods does not relieve Buyer of the obligation to make payment against Seller’s invoice, and and their respective officers, directors, employees, consultants and agents as additional insured; and,
any credit or refund allowed will be issued following Seller’s receipt of the goods. The credit allowed on (c) be endorsed to waive subrogation against the other party, its parent, subsidiary and affiliated or
returned goods, if any, is a merchandise credit and is applicable only against future purchases of Seller related companies, and its and their respective officers, directors, employees, consultants and agents.
goods. The credit given will be solely in Seller's discretion and may be based on the original or a
subsequently adjusted price. A charge will be assessed to clean-up, refinish and restock the goods, if 14. GOVERNING LAW
applicable. No rubber or electronic products or components may be returned for credit after six (6) Except for Equipment, Parts, Services or Rental provided, or to be provided, by Seller in North or South
Page 2 of 3 NOV Terms and Conditions for the Provision of Equipment, Parts, Services or Rental AAR 7/25/2011
America (the “America’s”), this Agreement shall be governed by and interpreted in accordance with the such information; (e) which is developed by the party receiving the Confidential Information as
laws of England and Wales, excluding conflicts and choice of law principles. All disputes arising out of evidenced by documentation, independently of the Confidential Information; or, (f) which is required to
or in connection with this Agreement shall be finally settled under the Rules of Arbitration of the be disclosed by the party receiving the Confidential Information pursuant to an order of a court of
International Chamber of Commerce by one or more arbitrators appointed in accordance with said competent jurisdiction or other governmental agency having the power to order such disclosure,
rules. Arbitration shall be held in London, England and shall be conducted in the English language. provided that the party receiving the Confidential Information uses its best efforts to provide timely
notice to the party disclosing the Confidential Information of such order to permit such party an
For Equipment, Parts, Services or Rental provided, or to be provided, by Seller in the America’s, this opportunity to contest such order. In the event that Seller owns copyrights to, patents to or has filed
Agreement shall be governed by and interpreted in accordance with the substantive laws of the State of patent applications on, any technology related to the Equipment, Parts, Services or Rental furnished by
Texas, excluding conflicts and choice of law principles. Any dispute, action or proceeding arising out of Seller hereunder, and if Seller makes any improvements on such technology, then Seller shall own all
or relating to this Agreement must be brought in a state or federal court sitting in Harris County, Texas, such improvements, including drawings, specifications, patterns, calculations, technical information and
and each of the parties hereby agrees to irrevocably submit itself to the exclusive jurisdiction of each other documents.
such court in any such action or proceeding and waives any objection it may now or hereafter have to
venue or convenience of forum. 18. INDEPENDENT CONTRACTOR
It is expressly understood that Seller is an independent contractor, and that neither Seller nor its
Seller retains the right to arbitrate any all disputes that may arise in connection with the provision of the principle, partners, employees or subcontractors are servants, agents or employees of Buyer. In all
Equipment, Parts, Services or Rental. cases where Seller’s employees (defined to include Seller’s and its subcontractors, direct, borrowed,
special, or statutory employees) are covered by the Louisiana Worker’s Compensation Act. La. R.S.
15. OWNERSHIP AND PATENT INDEMNITY 23:102 et seg., Seller and Buyer agreed that all Equipment, Parts, Services or Rental provided by
All software used in connection with the Equipment, Parts, Services or Rental, either purchased or Seller and Seller’s employees pursuant to this Agreement are an integral part of and are essential to
rented from Seller, is copyrighted and owned by Seller and licensed to Buyer. Seller warrants that the the ability of Buyer to generate Buyer’s goods, products, and services for the purpose of La. R.S.
use or sale of Equipment or Parts hereunder will not infringe patents of others by reason of the use or 23:106(A) (1). Furthermore, Seller and Buyer agree that Buyer is the statutory employer of all of
sale of such Equipment or Parts per se, and hereby agrees to hold Buyer harmless against judgment Seller’s employees for the purpose of La. R.S. 23:1061(A) (3).
for damages for infringement of any such patent, provided that Buyer shall promptly notify Seller in
writing upon receipt of any claim for infringement, or upon the filing of any such suit for infringement, 19. ADDITIONAL RENTAL TERMS AND CONDITIONS
whichever first occurs, and shall afford Seller full opportunity, at Seller’s option and expense, to answer Unless otherwise indicated, the rental rates contained in Seller’s Proposal are on a per day basis and
such claim or threat of suit, assume the control of the defense of such suit, and settle or compromise such rates shall apply to each piece of equipment or part rented. Seller represents that it has fully
same in any way Seller sees fit. Seller does not warrant that such Equipment or Parts: (a) will not inspected the Rental equipment and parts as detailed in the Agreement and that said equipment and
infringe any such patent when not of Seller's manufacture, or specially made, in whole or in part, to the parts are in good condition and repair, and are fully acceptable for use as specified in the Agreement.
Buyer’s design specifications; or (b) if used or sold in combination with other materials or apparatus or Furthermore, Seller represents that the Rental equipment and parts are not subject to any
used in the practice of processes, will not, as a result of such combination or use, infringe any such encumbrances or liens, and that Seller has full title to the equipment and parts, and thus, Seller is
patent, and Seller shall not be liable and does not indemnify Buyer for damages or losses of any nature authorized to enter into and execute this Agreement.
whatsoever resulting from actual or alleged patent infringement arising pursuant to (a) and (b) above.
THIS ARTICLE STATES THE ENTIRE RESPONSIBILITY OF SELLER CONCERNING PATENT Buyer represents that it shall use the Rental equipment and parts in a careful and proper manner and
INFRINGEMENT. shall comply with all laws, ordinances and regulations relating to the possession, use and maintenance
of the equipment and parts in accordance with Seller's approved procedures. In the event the parties
16. REGULATORY COMPLIANCE agree that the Buyer shall operate the Rental equipment and parts, Buyer further represents that the
By acceptance of delivery under this Agreement, Buyer warrants it has complied with all applicable Rental equipment and parts will be operated by skilled employees trained in the use of the Rental
governmental, statutory and regulatory requirements and will furnish Seller with such documents as equipment and parts. Buyer shall keep the Rental equipment and parts free and clear of all liens and
may be required. Seller warrants and certifies that in the performance of this Agreement, it will comply encumbrances arising in connection with Buyer’s operations and/or use of the Rental equipment and
with all applicable statutes, rules, regulations and orders in effect at the time of Agreement execution, parts. Buyer, at its sole cost, shall provide and maintain insurance against the loss, theft, damage or
including laws and regulations pertaining to labor, wages, hours and other conditions of employment, destruction of the Rental equipment and parts. The coverage shall be in an amount not less than the
and applicable price ceilings if any. Seller will not provide any certification or other documentation nor new replacement price of the Rental equipment and parts. NOV shall provide equipment and parts
agree to any contract provision or otherwise act in any manner which may cause Seller to be in prices at execution of this Agreement.
violation of applicable United States law, including but not limited to the Export Administration Act of
1979 and regulations issued pursuant thereto. No provision in this Agreement shall be interpreted At the expiration of the applicable rental term, Buyer will at its sole cost return the Rental equipment to
or applied which would require any party to do or refrain from doing any act which would the facility designated by Seller, in working condition (reasonable wear and tear excepted). Upon
constitute a violation of, or result in a loss of economic benefit under, any anti-boycott receipt of the returned Rental equipment, Seller will service and inspect the Rental equipment. In the
including but not limited to any such law of the United States. All Orders shall be conditional upon event Seller determines that the Rental equipment is materially damaged or not in working condition
granting of export licenses or import permits which may be required. Buyer shall obtain at its own risk (reasonable wear and tear excepted), any service work required to bring the Rental equipment to good
any required export license and import permits and Buyer shall remain liable to accept and pay for working condition will be charged back to the Buyer. Such charges may include service, inspection,
material if licenses are not granted or are revoked. and spare parts.
Page 3 of 3 NOV Terms and Conditions for the Provision of Equipment, Parts, Services or Rental AAR 7/25/2011
OPEN 180K NITROGEN UNIT
2.0 SAFETY
The hazards associated with liquid nitrogen are exposure to the cold temperatures which
can cause severe skin burns, over pressurisation due to expansion of small amounts of
liquid vaporising into large volumes of gas in inadequately vented equipment and
asphyxiation due to displacement of oxygen in the air in confined work areas.
(Asphyxiation is dealt with in the next section on gaseous nitrogen).
Bodily contact with liquid nitrogen is of major importance but a well-ventilated working
environment is even more essential. Nitrogen is odourless, colourless, and tasteless. The
human senses cannot detect it within the air. Without proper ventilation nitrogen can
expand, displacing enough oxygen in the working atmosphere to cause dizziness,
unconsciousness or even death when inhaled. Always store liquid nitrogen containers in
well-ventilated facilities or outdoors.
At this extreme temperature, liquid nitrogen can produce an effect on the skin
similar to a burn.
Delicate tissues, such as those of the eye, can be damaged by an exposure to these
cold gases which is too brief to affect the skin of the face or the hands.
Never allow any unprotected part of the body to touch the uninsulated pipes or
vessels containing liquid nitrogen; the extremely cold material may stick fast and
tear the flesh when you attempt to withdraw it. Even non-metallic materials are
dangerous to touch at low temperatures. In addition to the hazards of frost bite or
flesh sticking to cold materials, objects that are soft and pliable at room
temperatures, such as rubber or plastics, are easily broken because they become
hard and brittle at these extremely low temperatures.
Carbon steels become brittle at low temperatures and may easily fracture when
stressed.
Personnel should be thoroughly familiar with the material’s properties and safety
considerations if they must be in the area where liquid nitrogen is being used.
Loose fitting gloves of impermeable material should be worn when handling
anything that comes into contact with cold liquids and vapour or whenever the
possibility of exposure to liquid nitrogen spill exists. (Customer personnel, under
normal circumstances, will not be exposed to the hazards of cold temperatures).
The inherent hazard of nitrogen is in a pressurised system where the potential energy of
the containment will on release, accidental or otherwise, be cause for concern.
Unless adequate precautions are taken, persons can be exposed to oxygen deficient
atmospheres if they enter equipment or areas which have contained, or have been purged
with, nitrogen.
Atmospheres containing less than 10% oxygen can produce permanent brain damage or
death.
The danger of nitrogen displacing oxygen in the atmosphere within the vicinity of
operations must be brought to the attention of all personnel involved in the opening up of
plant/equipment/pipelines etc. that have been inerted or where liquid nitrogen is being
used.
Initial symptoms of asphyxiation include nausea and vomiting, breathing becomes slow,
deep and difficult, and then becomes noisy with frothing at the mouth, and then finally
stops. Casualty’s colour will be flushed at first, becoming blue especially at the head, neck,
face and lips. The casualty will gradually lose consciousness.
Persons exposed to such atmospheres and suffering from the above symptoms may be
unable to help themselves or warn others of their predicament. The symptoms are an
inadequate warning of the hazard.
Breathing a pure nitrogen atmosphere will produce immediate loss of consciousness and
almost immediate death.
When pumping at LOW and HIGH discharge pressure the operator should remember the
unit is capable of producing pressures up to 10,000 PSIG. The following safety procedures
should be taken and observed.
1. Inspection of all piping and valves to insure pressure rating and integrity.
3. Restrict personnel access to system and line area. Warning signs and barriers
should be employed.
4. All system safety devices should be inspected and in known working order.
These are few examples and are not intended to be considered the only safety measures
employed or required for safe pumping operations. It is the responsibility of the system
operator to insure his and others safety.
The following are general safety precautions. These precautions are not related to any
specific procedures and do not appear repeatedly in this publication. Personnel must
understand and apply these precautions during all phases of operation and maintenance of
this equipment. Specific precautions will be included in the text for certain potentially
hazardous operations in the form of WARNING or CAUTION statements. Some of the
warnings appear in the text of this publication but are presented here for emphasis.
Safety Practices – Overall good safety practices should be adhered to at all times when
starting up, operating, shutdown, and maintenance of this equipment. It is the equipment
owner’s operator’s responsibility to establish good safety practices, personnel training, and
enforce observance of safety practices.
Unit Operation – Personnel should not operate the unit unless they are thoroughly familiar
with the equipment manual, all unit operating controls, and functions. Reading the
equipment manual does not qualify any individual to operate this equipment.
Unauthorised Personnel – Keep unauthorised personnel away from the unit when
operating, servicing, or performing maintenance.
High Pressure – Ensure pressure in piping connected to the unit has been bled to zero (0)
pressure before attempting to disconnect any component.
Lifting – Equipment used in lifting and moving items from the unit must be of sufficient
rating to handle the weights involved.
Compressed Air Usage – Use of compressed air can create an environment of propelled
foreign particles. Air pressure should be reduced to less than 30 PSIG and used with
effective chip guarding and personal protective equipment. Never direct compressed air to
the body or towards other people.
Moving Parts – Keep hands, hair, clothing, jewellery, rags, and tools away from moving
parts when the unit is in operation.
Visibility – Do not attempt to operate equipment with obstructed visibility. Always ensure
suitable lighting provisions are available.
Pre-Start – Before starting the unit ensure that all operating controls are in the proper
position (e.g. off, on, neutral).
Work Areas – Keep work areas clean and clear of obstructions, hand tools and other
objects when operating the unit.
Transporting the Unit – Ensure all components are secured before transporting the unit to
another location.
Read and understand this manual before operating NOV HydraRig UK equipment.
Use this manual as a guide for system operation in conjunction with common sense
and operator experience.
While working with NOV HydraRig UK equipment follow the field’s rules and
regulations
While working with NOV HydraRig UK equipment wear appropriate work clothing
and personal protective equipment as required.
Let only qualified and experienced personnel operate NOV HydraRig UK equipment.
(Please note that rigging up and rigging down is also a part of unit operations.) This
will help prevent damage to the equipment and reduce the possibility of dangerous
situations arising.
The equipment has been designed and built for particular purposes. Do not
attempt to use the equipment for other purposes outside its design scope. This
may lead to damage and/or dangerous situations.
2.5.2. Transport/Installation
· When lifting the unit by crane, make sure that you cannot get trapped between
the load and a wall, fixed object etc.
· If possible, position yourself so that you are visible to the crane operator. If not,
make sure to have a flagman to give signs to the crane operator.
· Never walk under a hanging load!
· Make sure that lifting gear to be used is sufficiently dimensioned and certified.
· Never leave an “operation-ready” unit unattended.
· Do not operate damaged equipment. This may lead to further damage and/or
dangerous situations.
· Respect and maintain your working environment. Dispose of waste correctly.
· Keep the unit and connected components clean. Accumulated dirt can hamper
unit operations and might jeopardize safety.
· Keep all safety guards in position while operating ASEP equipment. Removal of
any safety guards may lead to accidents.
· When engaged in maintenance and/or performing checks on the unit:
§ First consider your safety and that of others.
§ Make sure that the equipment is switched off completely and use a decal or
similar to prevent unauthorized starting during maintenance or check up.
§ Never work on a hydraulic and/or pneumatic system under pressure.
Always relieve the system to prevent dangerous situations.
§ Never attempt to move heavy parts without aid of a mechanical device
§ Do not allow heavy objects to rest in an unstable position.
§ Use the right tools for the task..
With the engine certified according to ATEX regulations apply the following: The diesel
engine, including driven parts, has been manufactured and assessed according to ATEX. All
driven parts have been tagged with a unique identification number. ONLY trained
personnel may service the assembly.
Failure to follow this may impair suitability for Zone 2. In its explosion safe version the unit
is suitable for use in gas hazardous classified locations however limited to Group II Zone 2
(acc. IEC) or Class I Division 2 (acc. NEC). Hereto the unit is designated amongst other as
Ex ia IIB T4.
The design and manufacturing has been based on European Directive nr. 94/9/EC following
conformity assessment procedure relating to internal control of production according
Annex VIII of the Directive. The construction is documented in a confidential Technical
Construction File held at the offices of NOV HydraRig UK. Let only qualified `EX` personnel
trained to a level as described in IEC 60079-14 and IEC 60079-17 perform maintenance on
NOV HydraRig UK equipment.
Maintenance should also be performed with the right tools and under controlled
circumstances. Performing maintenance under the proper conditions will prevent damage
to the equipment and prevent dangerous situations arising.
Maintenance can be described as and is not limited to: installing and removing parts from
the unit filling up the fluid levels on the unit trouble shooting any malfunctions that may
occur on the unit before, during and after operations calibrating and adjusting setting on
the units hydraulic, pneumatic, mechanical, electrical and diesel systems.
Parts that have not been approved or supplied by NOV HydraRig UK cannot be relied upon
to be of the correct material strength, correct dimensions, finish or quality.
NOV HydraRig UK cannot be held responsible for any damage arising from the use of such
parts and guarantee claims may be refused.
Therefore, pay special attention to safety when operating and maintaining each
system, including:
WARNING
For conditions that may result in injury to personnel
operating the system.
CAUTION
For conditions that may cause damage to the equipment or
interfere with the normal processing and ruin the product.
CORROSIVE
Liquids or adhesive that can cause injury to the operator,
and can damage the machine.
DANGEROUS ELECTRICITY
The machine, or parts of the machine are under high
voltage.
EARTH CONNECTION
This icon indicates that this equipment requires an earth
connection. Always make sure this connection is in place
before and after maintenance.
EXPLOSIVE
Substances may explode – be extremely careful when
handling or disposing of these materials.
FLAMMABLE
Substances are flammable.
ENTRAPMENT
Do not place any part of your body between any units that
can close.
HOT SURFACE
Do not touch object, this may cause serious burns.
MOVING MACHINERY
Make sure no body-parts, clothing or jewelry can get
caught in the machinery.
LOW TEMPERATURES
Do not touch any cold surface, may result in serious injury.
CLEANING
Clean your hands after this procedure.
BREATHING PROTECTION
Wear a full respiratory mask if working
with toxic vapors.
EAR PROTECTION
Wear ear protection during this
procedure.
2.7.3. Responsibilities
Supervisor
Employee
2.8.1.1. Responsibilities
Supervisor
Employee
2.8.2.1. Responsibilities
Supervisor
1. Maintains an awareness of the approximate noise levels in work
places for which he/she is responsible.
2. Requests a survey from the Local Health Authority when a change in
equipment or procedure may increase employee exposure to noise.
3. Ensures that all employees are aware of the requirements for
hearing protection in any area that has been identified as having
levels which exceed permissible exposure limits.
4. Ensures that appropriate protective devices are worn and that any
other control measures are observed.
Employee
1. Complies with the recommendations of the Local Health Authority
and supervisor for controlling noise exposure.
2. Makes proper use of the hearing protection devices provided by the
Health and Safety Branch.
3. Reports any suspected change in noise levels of equipment to the
Local Health Authority so that a survey can be made.
4. Participates in audiometric testing or other hearing conservation
programs as required by company policy.
2.8.3.1 Responsibilities
Supervisor
Employee
2.8.4.1. Responsibilities
Supervisor
Employee
Always treat all circuits as if they are live until you have
personally disconnected the power.
Keep your clothing, hands and feet dry at all times.
2.8.5.1 Responsibilities
Supervisor
Employee
Securely tuck all long hair under a cap when working around
moving mechanical parts.
2.8.6.1 Responsibilities
Supervisor
1. All work hazards must be anticipated and all safeguards utilized.
2. Ensures that all employees are properly trained and instructed in the
safe operation of mechanical equipment and aware of all hazards
associated with the use of these devices.
3. Initiates any necessary administrative action required to enforce
safety practices.
Employee
1. Follows the company’s mechanical safety policies and procedures
and instructions of responsible supervisor and/or Local Health
Authority.
2. Brings to the attention of the supervisor and/or Local Health
Authority potential hazardous situations such as discrepancies
between instruction, procedures, policies and manual, faulty
equipment, misapplication of device, etc.
3. Mechanical equipment known to be malfunctioning must be
repaired or replaced before use. The repair must be initiated as soon
as possible after the malfunction is noted.
CAUTION
It is illegal to pollute drains, sewers or the ground. Clean up all split fluids and/or
lubricants. Used fluids and/or disposed of in accordance with local regulations.
Use authorised waste disposal sites. All waste products should be disposed of in
accordance with all the relevant regulations. The collection and disposal of used
oil should be in accordance with any local regulations. Never pour used engine oil
into the sewers, drains or on the ground.
Handling
New Oil-There is no special precautions needed for the handling or use of new oil,
beside the normal care and hygiene practices.
Here are precautions to protect your health when handling used engine oil:
First aid-Oil
Eyes
In the case of eye contact flush with water for 15 minutes. If irritation persists, get
medical attention.
Swallowing
If oil is swallowed do not induce vomiting. Get medical advice.
Skin
In the case of excessive skin contact, wash with soap and water.
Spillage
Absorb on sand or a locally approved brand of absorbent granules. Scrape up and
remove to a chemical disposal area.
Fires
Extinguish with carbon dioxide, dry chemical or foam. Fire fighters should use self-
contained breathing apparatus.
If you require medical treatment for any problems arising from incorrect use of NOV
HydraRig UK equipment, please read the following headings.
1. Notify your colleagues that you require treatment for injury and/or
assistance to release a trapped body part.
2. Make sure any injury is correctly treated.
2.9.3. Burns
1. Immediately apply water to the skin area contaminated with acid spill (use a
shower if available).
2. Notify your colleagues or foreman that you require treatment for acid
burns.
1. Signal your foreman or work colleagues that you have eye damage and
indicate the cause.
2. If the eye damage is caused by contaminating spray, rinse your eye(s) with
an eye bath filled with water.
2.10.1 General
· While working with equipment follow the field's rules and regulations.
· When lifting the unit by crane or forklift, make sure that you cannot get trapped
between the load and a wall or a fixed object, etc.
· If possible, position yourself so that you are visible to the crane operator. If not,
make sure a flag man is available to give signs to the crane operator.
· Never walk under hanging load!
· Make sure that lifting gear to be used is sufficiently dimensioned.
· All lifting equipment used with this equipment must have the correct
certification and be marked accordingly. The lifting equipment may only be used
by instructed personnel.
· Before each lift it must be checked that the shackles are mounted in a correct
manor.
· The equipment must be checked yearly for deformation and wear.
NOTE Definitions listed relate to the context in which these terms are used in this manual. A
more general definition of terms is given in the “Glossary of Terms for Fluid Power NFPA
Recommended Standard T2.70.1”.
ABSOLUTE – A measure having as its zero point or base the complete absence of the entity being
measured.
ABSOLUTE PRESSURE – The pressure above zero absolute, i.e., the sum of atmospheric and gage
pressure. In vacuum related work it is usually expressed in millimetres of mercury (mm Hg).
ACCUMULATOR – A container in which fluid is stored under pressure as a source of fluid power.
ACTUATOR – A device for converting hydraulic energy into mechanical energy. A motor or
cylinder.
AERATION – Air in the hydraulic fluid. Excessive aeration causes the fluid to appear milky and
components to operate erratically because of the compressibility of the air trapped in the fluid.
AMPLIFIER – A device for amplifying the error signal sufficiently to cause actuation of the stroke
control. Several types of servo amplifiers are used at the present time: electronic (DC, AC, phase
sensitive, and magnetic) and mechanical.
ANNULAR AREA – A ring shaped area - often refers to the net effective area of the rod side of a
cylinder piston, i.e., the piston area minus the cross-sectional area of the rod.
ATMOSPHERIC PRESSURE – Pressure exerted by the atmosphere at any specific location. (Sea
level pressure is approximately 14.7 pounds per square inch absolute).
BACK CONNECTED – A condition where pipe connections are on normally unexposed surfaces of
hydraulic equipment. (Gasket mounted units are back connected).
BACK PRESSURE – A pressure in series. Usually refers to pressure existing on the discharge side of
a load. It adds to the pressure required to move the load.
BAFFLE – A device, usually a plate, installed in a reservoir to separate the pump inlet from return
lines.
BREATHER – A device which permits air to move in and out of a container or component to
maintain atmospheric pressure.
CARTRIDGE
2. The pumping unit from a vane pump composed of the rotor, ring, vanes and one or both
side plates.
CAVITATION – A localised gaseous condition within a liquid stream which occurs where the
pressure is reduced to the vapour pressure.
CHAMBER – A compartment within a hydraulic unit. May contain elements to aid in operation or
control of a unit. Examples: spring chamber, drain chamber, etc.
CHARGE (supercharge)
CHARGE PRESSURE – The pressure at which replenishing fluid is forced into the hydraulic system
(above atmospheric pressure).
CHECK VALVE – A valve which permits flow of fluid in one direction only.
CHOKE – A restriction, the length of which is large with respect to its cross-sectional dimension.
CLOSED CENTRE VALVE – One in which all ports are blocked in the centre or neutral position.
CLOSED CENTRE CIRCUIT – One in which flow through the system is blocked in neutral and
pressure is maintained at the maximum pressure control setting.
CLOSED LOOP – A system in which the output of one or more elements is compared to some other
signal to provide an actuating signal to control the output of the loop.
COMMAND SIGNAL (or input signal) – An external signal to which the servo must respond.
COMPENSATOR CONTROL – A displacement control for variable pumps and motors which alters
displacement in response to pressure changes in the system as related to its adjusted pressure
setting.
COMPRESSIBILITY – The change in volume of a unit volume of a fluid when it is subjected to a unit
change in pressure.
CONTROL – A device used to regulate the function of a unit (see Hydraulic Control, Manual
Control, Mechanical Control, and Compensator Control).
COOLER – A heat exchanger used to remove heat from the hydraulic fluid.
COUNTERBALANCE VALVE – A pressure control valve which maintains back pressure to prevent a
load from falling.
CRACKING PRESSURE – The pressure at which a pressure actuated valve begins to pass fluid.
CUSHION – A device sometimes built into the ends of a hydraulic cylinder which restricts the flow
of fluid at the outlet port, thereby arresting the motion of the piston rod.
CYLINDER – A device which converts fluid power into linear mechanical force and motion. It
usually consists of a movable element such as a piston and piston rod, plunger rod, plunger ram,
operating within a cylindrical bore.
DEADBAND – The region or band of no response where an error signal will not cause a
corresponding actuation of the controlled variable.
DECOMPRESSION – The slow release of confined fluid to gradually reduce pressure on the fluid.
DELIVERY – The volume of fluid discharged by a pump in a given time, usually expressed in gallons
per minute (gpm).
DE-VENT – To close the vent connection of a pressure control valve permitting the valve to
function at its adjusted pressure setting.
DIFFERENTIAL CURRENT – The algebraic summation of the current in the torque motor; measured
in MA (milliamperes).
DIFFERENTIAL CYLINDER – Any cylinder in which the two opposed piston areas are not equal.
DIRECTIONAL VALVE – A valve which selectively directs or prevents fluid flow to desired channels.
DISPLACEMENT – The quantity of fluid which can pass through a pump, motor or cylinder in a
single revolution or stroke.
DITHER – A low amplitude, relatively high frequency periodic electrical signal, sometimes
superimposed on the servo valve input to improve system resolution. Dither is expressed by the
dither frequency (Hz) and the peak-to-peak dither current amplitude (ma).
DOUBLE ACTING CYLINDER – A cylinder in which fluid force can be applied to the movable element
in either direction.
DRAIN – A passage in, or a line from, a hydraulic component which returns leakage fluid
independently to reservoir or to a vented manifold.
EFFICIENCY – The ratio of output to input. Volumetric efficiency of a pump is the actual output in
gpm divided by the theoretical or design output. The overall efficiency of a hydraulic system is the
output power divided by the input power. Efficiency is usually expressed as a percent.
ERROR (signal) – The signal which is the algebraic summation of an input signal and a feedback
signal.
FEEDBACK (or feedback signal) – The output signal from a feedback element.
FEEDBACK LOOP – Any closed circuit consisting of one or more forward elements and one or more
feedback elements.
FILTER – A device whose primary function is the retention by a porous media of insoluble
contaminants from a fluid.
FLOODED – A condition where the pump inlet is charged by placing the reservoir oil level above
the pump inlet port.
FLOW CONTROL VALVE – A valve which controls the rate of oil flow.
FLOW RATE – The volume, mass, or weight of a fluid passing through any conductor per unit of
time.
FLUID
1. A liquid or gas.
2. A liquid that is specially compounded for use as a power-transmitting medium in a
hydraulic system.
FOLLOW VALVE – A control valve which ports oil to an actuator so the resulting output motion is
proportional to the input motion to the valve.
FORCE – Any push or pull measured in unit weight. In hydraulics, total force is expressed by the
product P (force per unit area) and the area of the surface on which the pressure is applied. F = P
x A.
FREQUENCY – The number of times an action occurs in a unit of time. Frequency is the basis of all
sound. A pump or motor’s basic frequency is equal to its speed in revolutions per second
multiplied by the number of pumping chambers.
FRONT CONNECTED – A condition wherein piping connections are on normally exposed surfaces of
hydraulic components.
FULL FLOW – In a filter, the condition where all the fluid must pass through the filter element or
medium.
GAUGE PRESSURE – A pressure scale which ignores atmospheric pressure. Its zero point is 14.7 psi
absolute.
HEAD – The height of a column or body of fluid above a given point expressed in linear unit. Head
is often used to indicate gage pressure. Pressure is equal to the height times the density of the
fluid.
HEAT – The form of energy that has the capacity to create warmth or to increase the temperature
of a substance. Any energy that is wasted or used to overcome friction is converted to heat. Heat
is measured in calories or British Thermal Units (BTU’s). One
BTU is the amount of heat required to raise the temperature of one pound of water one degree
Fahrenheit.
HEAT EXCHANGER – A device which transfers heat through a conducting wall from one fluid to
another.
HORSEPOWER (HP) – The power required to lift 550 pounds one foot in one second or 33,000
pounds one foot in one minute. A horsepower is equal to 746 watts or to 42.4 British Thermal
Units per minute.
HYDRODYNAMICS – Engineering science pertaining to the energy of liquid flow and pressure.
KINETIC ENERGY – Energy that a substance or body has by virtue of its mass (weight) and velocity.
LAMINAR (FLOW) – A condition where the fluid particles move in continuous parallel paths.
Streamline flow.
LEVERAGE – A gain in output force over input force by sacrificing the distance moved. Mechanical
advantage or force multiplication.
LIFT – The height a body or column of fluid is raised; for instance, from the reservoir to the pump
inlet. Lift is sometimes used to express a negative pressure or vacuum. The opposite of head.
LINEAR ACTUATOR – A device for converting hydraulic energy into linear motion - a cylinder or
ram.
MANUAL CONTROL – A control actuated by the operator, regardless of the means of actuation.
Example: Lever or foot pedal control for directional valves.
MECHANICAL CONTROL – Any control actuated by linkages, gears, screws, cams or other
mechanical elements.
METER-OUT – To regulate the flow of the discharge fluid from an actuator or system.
MOTOR – A device which converts hydraulic fluid power into mechanical force and motion. It
usually provides rotary mechanical motion.
OPEN CENTRE CIRCUIT – One in which pump delivery flows freely through the system and back to
the reservoir in neutral.
OPEN CENTRE VALVE – One in which all ports are interconnected and open to each other in the
centre or neutral position.
ORIFICE – A restriction, the length of which is small in respect to its cross-sectional dimensions.
PASSAGE – A machined or cored fluid conducting path which lies within or passes through a
component.
PILOT VALVE – An auxiliary valve used to control the operation of another valve. The controlling
stage of a 2-stage valve.
PISTON – A cylindrically shaped part which fits within a cylinder and transmits or receives motion
by means of a connecting rod.
PLUNGER – A cylindrically shaped part which has only one diameter and is used to transmit thrust.
A ram.
POPPET – That part of certain valves which prevents flow when it closes against a seat.
POSITIVE DISPLACEMENT – A characteristic of a pump or motor which has the inlet positively
sealed from the outlet so that fluid cannot recirculate in the component.
POTENTIOMETER – A control element in the servo system which measures and controls electrical
potential.
POWER PACK – An integral power supply unit usually containing a pump, reservoir, relief valve and
directional control.
PRECHARGE PRESSURE – The pressure of compressed gas in an accumulator prior to the admission
of liquid.
PRESSURE – Force per unit area; usually expressed in pounds per square inch (psi).
PRESSURE DROP – The difference in pressure between any two points of a system or a
component.
PRESSURE LINE – The line carrying the fluid from the pump outlet to the pressurised port of the
actuator.
PRESSURE OVERRIDE – The difference between the cracking pressure of a valve and the pressure
reached when the valve is passing full flow.
PRESSURE PLATE – A side plate in a vane pump or motor cartridge on the pressure port side.
PRESSURE REDUCING VALVE – A valve which limits the maximum pressure at its outlet regardless
of the inlet pressure.
PROPORTIONAL FLOW – In a filter, the condition where part of the flow passes through the filter
element in proportion to pressure drop.
PUMP – A device which converts mechanical force and motion into hydraulic fluid power.
RAM – A single-acting cylinder with a single diameter plunger rather than a piston and rod. The
plunger in a ram-type cylinder.
REGENERATIVE CIRCUIT – A piping arrangement for a differential type cylinder in which discharge
fluid from the rod end combines with pump delivery to be directed into the head end.
RELIEF VALVE – A pressure operated valve which by-passes pump delivery to the reservoir, limiting
system pressure to a predetermined maximum value.
RETURN LINE – A line used to carry exhaust fluid from the actuator back to sump.
ROTARY ACTUATOR – A device for converting hydraulic energy into rotary motion - a hydraulic
motor.
SEQUENCE
SEQUENCE VALVE – A pressure operated valve which, at its setting, diverts flow to a secondary line
while holding a predetermined minimum pressure in the primary line.
SERVO MECHANISM (servo) – A mechanism subjected to the action of a controlling device which
will operate as if it were directly actuated by the controlling device, but capable of supplying
power output many times that of the controlling device, this power being derived from an external
and independent source.
SERVO VALVE
SINGLE ACTING CYLINDER – A cylinder in which hydraulic energy can produce thrust or motion in
only one direction. (May be mechanical or gravity returned).
SPOOL – A term loosely applied to almost any moving cylindrically shaped part of a hydraulic
component which moves to direct flow through the component.
STROKE
SUCTION LINE – The hydraulic line connecting the pump inlet to the reservoir or sump.
SUMP – A reservoir.
SWASH PLATE – A stationary canted plate in an axial type piston pump which causes the pistons to
reciprocate as the cylinder barrel rotates.
TACHOMETER (AC) (DC) – A device which generates an AC or DC signal proportional to the speed
at which it is rotated and the polarity of which is dependent on the direction of rotation of the
rotor.
THROTTLE – To permit passing of a restricted flow. May control flow rate or create a deliberate
pressure drop.
TORQUE – A rotary thrust. The turning effort of a fluid motor usually expressed in inch pounds.
TORQUE MOTOR – A type of electromechanical transducer having rotary motion used in the input
stages of servo valves.
TRANSDUCER (or feedback transducer) – An element which measures the results at the load and
sends a signal back to the amplifier.
TURBULENT FLOW (TURBULENCE) – A condition where the fluid particles move in random paths
rather than in continuous parallel paths.
TURBINE – A rotary device that is actuated by the impact of a moving fluid against blades or vanes.
UNLOAD – To release flow (usually directly to the reservoir), to prevent pressure being imposed
on the system or portion of the system.
UNLOADING VALVE – A valve which by-passes flow to tank when a set pressure is maintained on
its pilot port.
VACUUM – Pressure less than atmospheric pressure. It is usually expressed in inches of mercury
(in. Hg) as referred to the existing atmospheric pressure.
VALVE – A device which controls fluid flow direction, pressure, or flow rate.
VELOCITY
1. The speed of flow through a hydraulic line. Expressed in feet per second (fps) or inches per
second (ips).
2. The speed of a rotating component measured in revolutions per minute (rpm).
VENT
1. To permit opening of a pressure control valve by opening its pilot port (vent connection) to
atmospheric pressure.
2. An air breathing device on a fluid reservoir.
VOLUME
WOBBLE PLATE – A rotating canted plate in an axial type piston pump which pushes the pistons
into their bores as it “wobbles”.
WORK – Exerting a force through a definite distance. Work is measured in units of force multiplied
by distance. For example, pound-foot.
Hydraulic pump power and liquid nitrogen vaporizing heat are supplied via a diesel power
pack. The system converts waste engine heat used in the nitrogen vaporizing.
During normal operation liquid nitrogen flows from a storage vessel through the
centrifugal charge pump where the suction pressure to the triplex pump is boosted to
meet the required inlet conditions. The liquid nitrogen is then pressurized by the
reciprocating pistons of the triplex pump to the required downstream pressure. The high
pressure liquid then flows through the nitrogen / water heat exchanger where it is
vaporized and the gaseous nitrogen temperature is raised to a minimum of 20 degrees
Celsius.
The heat balance between the hydraulically loaded engine and the nitrogen vaporization
circuit is obtained by transferring the heat through a plate heat exchanger. The engine
water temperature is maintained in all conditions by thermostatically controlling the water
flow either back to the engine water pump or to an air blast radiator.
Skid and Frame designed to BS EN 12079, DNV certifications note 2.7-1. Upper frame
manufactured from 100 x 100mm box section steel. Base section includes ISO twist lock
blocks set on STD ISO 10’ x 8’ container size. 350mm x 150mm on 2000mmm centres
forklift pockets are integral to the base skid
Power Unit: CAT 3406C DITA Turbocharged and after cooled - 490 BHP at 2100 rpm.
Engine conforms to BP 200 requirements for the protection of Diesel engines working in 3G
T3 (Zone 2) areas. Engine meets Tier 1 for emissions for land based and off-shore
operation. Engine Zone 2 protection equipment includes, exhaust gas heat exchanger, air
inlet shut down valve and engine protection system with exhaust flame traps.
Engine loading is achieved using a Denison hydraulic vane pump, the applied load is
controlled by remote activation of the sequence valve.
Closed loop: This system uses separate hydraulic pumps for triplex drive and heat load. A
closed loop piston pump drives the triplex and a large double vane pump provides the heat
load. This allows the heat load to be applied independently to the operation of the triplex.
The triplex pump drive is obtained using a Denison P14 variable flow high pressure piston
hydraulic pump.
The Triplex pump power end: A Hydra Rig model number NP 200 complete with integral
reduction drive and Rexroth hydraulic drive motor.
NOV Hydra Rig UK designed and built 1 5/8” cold end pumps D.N.V. approved, 10,000 psi
working pressure, 180,000 scf/h flow.
NOV Hydra Rig UK designed and built 1 1/2” x 2 1/2” x 6” centrifugal charge pump.
NOV Hydra Rig UK designed and built high pressure vaporizer, used to convert the waste
heat obtained from the power pack and hydraulic circuits to useful heat for liquid nitrogen
conversion.
Non slip material on all ladder rungs and a harness point at the top of each ladder.
A local panel contains all the instrumentation and controls to ensure compliance to
the standards applicable to meet Zone 2 and CE marking regulations.
The control panel and enclosure constructed from stainless steel and the panel sub
divided by circuits to allow for ease of operation of all the valves and controls. The
gauges to read in both psi and bar for pressure and Celsius and Fahrenheit for
temperature.
· Engine controls; start, stop, emergency stop, engine rpm/hour meter, oil
pressure, water pressure, air pressure, water temperature, engine speed
control.
· Shut down indicators for high exhaust temperature, high water temperature,
low oil pressure, over-speed and discharge overpressure.
All the cryogenic piping of either type 316 or 304 stainless steel. Piping installed
with sufficient flexibility to avoid damage during cool down or transportation. The
system and cryogenic valves conform to the requirements of the PED directive.
· Cryogenic long stem ball valves for the liquid nitrogen circuit.
· Stainless Steel fuel and hydraulic tanks.
· Tempering line around the nitrogen vaporizer to control the gaseous
nitrogen discharge temperature.
· Stainless steel floor in all areas exposed to possible cryogenic spillage.
· High pressure safety shut down system.
· Discharge relief valve set at 11,000 psi and a gas line check valve for unit
protection.
· The control panel mounted on the end of the skid assembly.
· Engine equipped with an air start system.
· Cryogenic suction, boost pump bypass and return fittings 1-1/2 “CGA.
· Vent valves on LN2 inlets
· Hydraulically operated discharge valve 2 x 1 valve with a “Danfoss” actuator.
· OPP vent connection point ( ¼” BSP male with cap)
· Slings provided.
· Stainless steel nuts and bolts where possible.
· Tool box, large enough to store boost pump, cold ends, fuel filters, vee belts
and other small spares.
Two off operating and maintenance manuals in accordance with DNV complete
with schematics, parts lists and trouble shooting procedures. Two off separate
quality manuals to be supplied containing all records applicable to both the FAT
document and the requirements for D.N.V. and C.E. Marking.
4.2.6 Testing
The equipment furnished field tested and in field ready condition. The Customer
Acceptance testing performed with the customer representative witnessing. A pre-
test performed before the customer acceptance test. Customer shall provide a
minimum of 2 tanks of LN2 for testing, or NOV Hydra Rig to supply and to recharge.
Testing carried out to meet your customer acceptance testing requirements and
incorporates the following:
· 1/2 hour at full rate and 1,500 psi back pressure and showing a minimum of
20 degree C discharge temperature.
· 1 hour at full rate and 10,000 psi back pressure.
· Chart recording taken on the above tests.
· Start up and testing data taken and recorded in a test report.
· Customer representative to include a customer test report.
The following supplied prior to the unit release note being issued:
The system comprises the following components whose actions are further described in
4.4.
a. Diesel Engine: Caterpillar 3406C DITA producing 490 HP @ 2100 RPM providing all
necessary power. The engine is fitted with Zone II equipment comprising exhaust
gas heat exchanger, air inlet shutdown valve and engine protection devices.
b. Centrifugal Charge Pump: (boost pump) supplies the main nitrogen triplex pump
with a positive head of liquid nitrogen.
c. Triplex Pump: A positive displacement pump which increases the LN2 pressure to a
maximum operating pressure of 10,000 PSIG; consisting of the following:
ii. WARM END(s): The mechanical drive and plunger section of the triplex
pump assembly.
d. LN2 Vaporiser: This part of the system converts the liquid nitrogen to a gas by
absorbing heat from the coolant loop circuit.
f. Coolant Loop Circuit: Water/Glycol system that collects unit generated heat for LN2
vaporisation.
a. Power Unit
Caterpillar 3406C DITA producing 490 HP @ 2100 RPM: Engine speed is controlled
mechanically and governed via manual control cables. Engine power is accessed via
the power take off.
To insure that positive pressure of liquid nitrogen is available for pumping and
vaporisation. The centrifugal charge (boost) pump is used to maintain a pressure of
40-100 PSIG on the suction of the cold end. This is necessary to maintain net
positive suction head across the cold end vent or return pressure. Typically, cold
end(s) require between 30-40 PSIG NPSH to pump efficiently.
c. Triplex Pump
The triplex pump cold end(s) receive the liquid nitrogen at a pressure of 40-100
PSIG. The three positive displacement cold end chambers are capable of
pressurising the liquid nitrogen to a maximum pressure of 10,000 PSIG.
d. Heat Exchanger
There are three basic types of heat exchangers utilised, shell and tube heat
exchanger, plate heat exchanger and air blast exchanger, all function virtually the
same. A heat exchanger normally has two or three isolated fluid paths. As two
different temperature fluids flow through these paths, the higher temperature fluid
gives up heat to lower temperature fluid.
e. LN2 Vaporiser
ii. Hydraulic heat exchanger. The coolant fluid will absorb additional heat from
the hydraulic oil. In cold weather a reverse heat exchange is possible, i.e.
the coolant loop exchanges heat into the hydraulic oil. This is desirable in
cold weather because it allows a more rapid unit warm up allowing
operations to start sooner.
iii Engine Cooling System: The engine water cooling system produces a large
percentage of the heat required to warm up the vaporisation coolant circuit.
The amount varies depending upon the horsepower draw or engine load.
Most of the controls and indicators needed to control the system are contained on the
engine control panel and nitrogen control panel. The following is a brief description of the
panel control areas and their purpose as shown in the following diagram.
2 & 27.Flow Rate – indicates customer requirements in either cubic metre or feet
per hour of nitrogen gas discharge.
15. Push to Activate – safety button has to be operated before discharge valve
can be operated.
26. GN2 Discharge Valve (Open/Closed) - utilises Activate button (15) & valve
(26) which must be depressed for the discharge control valve to operate this
is a two handed operation to prevent accidental operation of the valve.
29. Nitrogen Over Pressure Indicator– indicates nitrogen gas discharge pressure
above maximum system pressure.
19, 20. Hydraulic Load Control – controls the load on hydraulic system.
9. Boost Pump Pressure Gauge – indicates pressure from the boost pump
10. Hydraulic Pressure Gauge – indicates hydraulic pressure driving the boost
pump.
21. Boost Pump Speed Control – adjusts the speed of the boost pump by
controlling the hydraulic pressure.
15. Permissive Override – press and hold until oil pressure rises and stabilises.
Use in-conjunction with air starter.
17. Air Start – push button which operates engine air starter motor to start
engine.
22. Low Oil Pressure – illuminates when engine oil pressure drops below safety
limit.
Refer to the General Arrangement and Control Panel drawings respectively for an overview
of the system.
There are two water circuits. The first is an internal circuit for the engine. The
second is the main circuit which absorbs the heat from the various sources and
vaporises the liquid nitrogen. Both circuits will be described starting from the
water pump in the direction of flow.
The engine water pump takes water from the circuit, and after passing it
through the engine and the exhaust gas cooler, passes it through the shell
and tube where the heat is transferred to the nitrogen vaporiser water
circuit. The water then returns to the suction of the engine water pump. If
this returning water is above 65°C it is diverted by a thermostat, through a
radiator to dissipate the excess heat.
There are three hydraulic pumps mounted via a splitter box to the rear of the
engine, a Denison P14 closed loop mounted on the centre pad, a Denison T6EDC
mounted on the left hand pad and a Tandem Gear Pump and single vane pump
mounted on the right hand pad.
a. The Denison P14 closed loop variable displacement pump supplies hydraulic
pressure to drive the cryogenic power end, via a gearbox and hydraulic
motor. The speed of the power end is controlled hydraulically by a pressure
relief valve which controls the angle of ‘swash’, i.e. changes the output of
the pump.
b. The Denison T6EDC triple segment pump mounted on the left hand pad
provides the following:. It consists of three sections:-
c. The Tandem Gear pump consists of one double segment which drives the
following:
d. The single vane pump provides system flushing by circulating the hydraulic
tank.
Nitrogen enters the system from a tank hose through a valve and a Y strainer into
the nitrogen centrifugal boost pump. From the centrifugal pump it is pumped
either through a low pressure vent to atmosphere or into the jacketed ends of the
cold ends where some of the liquid is forced into the pistons and some passes out
of the cold ends to tank return. The liquid that enters the piston chambers is
pressured to discharge pressure and pumped to the nitrogen vaporiser where it is
vaporised from a high pressure liquid to a high pressure gas. The gas flow
continues through a high-pressure check valve, a plug valve and on to the
customer. Instrumentation includes, centrifugal discharge pressure, centrifugal
hydraulic pressure, gas discharge pressure and gas discharge temperature. A
pressure switch stops the pump on overpressure.
The overpressure trip operates by dumping the oil from the servo supply to the
tank allowing the pump to return to zero swash.
The 3g Made Safe system works with the standard engine as a bolt on accessory
that more than meets the engine shutdown requirements of EN 1834-1:2008.
3g Made Safe holds positive advantages over alternative available systems in its
ability to interface easily as a fully functional stand alone unit, with no downside
effects on the functionality of the engine and its installation and maintenance.
Key Components:
* Gas Cooler.
* Duplex Exhaust.
* Air Inlet Flame Trap.
The engine electronic fuel system will shut down on the actuation on any one of the
following:
The following automatic shutdowns have indicators mounted in the engine control
panel:
Over temperature inputs and low lubricating oil pressure are monitored, e.g.
water and exhaust and if they go above their pre-set temperature, the engine will
be shutdown by removing the fuel supply.
The safety system is calibrated to the engine’s normal maximum speed. If this
figure is subsequently exceeded by 10%, the engine will be shutdown by closing the
air inlet valve and removing the fuel supply.
The emergency stop is activated via the red mushroom shaped button on the
Engine control panel. The system operates by closing the engine air intake flap and
Disabling the engine ignition circuit.
In the event of the system being shutdown via the emergency shutdown button or
any of the components identified in 4.5 then the system can be restarted after fault
has been identified and corrected.
100 300
150 450
200 600
250 750
300 900
350 1050
400 1200
450 1350
500 1500
550 1650
600 1800
650 1950
700 2100
750 2250
800 2400
850 2550
900 2700
950 2850
1000 3000
NOTE:
REFER TO THE OPERATIONS MANUAL IN VOLUME 2 OF THE DIESEL ENGINE FOR FULL
DETAILS ON BEFORE STARTING AND STOPPING THE CATERPILLAR 3406C DITA ENGINE ON
THIS UNIT.
5.1 Introduction
This section contains the ‘before starting engine’, ‘starting engine’ and ‘stopping engine’
guidelines. Only competent, suitably qualified personnel who have a good understanding
regarding the operation of a Nitrogen Pumping Unit should be authorised to perform such
an operation on this system.
5.2.1 Check the following fluid levels to insure levels are full or at safe working levels.
The engine and lube oil tank oils are per recommendations of suppliers in support
documents supplied with this manual. Coolant is to be 50/50 Ethylene
Glycol/water.
i. Check regulated air lubricator contains sufficient oil and is in the open position.
Isolation valve
5.2.2 Check nitrogen liquid level. Make certain tank contains sufficient liquid to cool
down the nitrogen system. Tank should be filled to the full tri-cock level.
5.2.3 Ensure that the following controls are set to the minimum adjustment.
a. Engine Throttle.
NOTE:
NOTE:
c. Triplex Control
NOTE:
NOTE:
5.2.4 Check that BOTH hydraulic suction filters are in the ‘OPEN’ position. This allows
hydraulic fluid to the pump supply.
WARNING:
NEVER OPERATE THE UNIT WITH THE SUCTION FILTERS IN
THE CLOSED POSITION.
5.4.6 Allow the system to warm up until water temperature is a minimum of 60°C (140°F).
5.4.1 Open the low pressure vent valve to allow nitrogen to cool down boost pump
1 and cold ends.
5.4.1 Turn in the pilot relief valve (boost pump control) to spin the centrifugal boost
2 pump slowly, in short bursts after it becomes frosted. DO NOT SPIN
EXCESSIVELY. This prevents pump from freezing.
NOTE
During the pumping operation it is important that the control panel gauges be
monitored to ensure that all components are functioning properly.
5.4.1 Spin the centrifugal boost pump until pump picks up prime, pressure rises to 60 –
7 80 PSI.
NOTE
If pump does not pick up prime, or loses prime, repeat procedure 5.4.11 – 19.
IMPORTANT
Close bleed valve and tempering valve to start pumping nitrogen to customer.
5.4.2 Use the load control valve to maintain a discharge temperature of 21ºC or 70ºF.
5 Increasing the load will increase the heat input into the water circuit and
consequently increase nitrogen discharge temperature. To decrease the nitrogen
temperature, decrease the load. If cooler discharge temperatures are required,
the tempering valve can be used by bypass the nitrogen vaporiser pot and allow
liquid nitrogen to enter the discharge nitrogen gas.
NOTE:
The globe metering valve is controlling the amount of liquid returning to tank.
5.5.4 Stop the centrifugal by turning out the LN2 control centrifugal valve.
5.5.5 Bring the engine back to idle and allow the engine to cool at idle for 10 to 15
minutes depending on environment.
5.5.6 Close in the nitrogen tank valves. Gently crack the vent valve to vent nitrogen.
5.5.8 After engine idle period and engine has cooled then push the engine stop button.
WARNING
DO NOT OPEN HOSE DRAIN VALVE TO DRAIN NITROGEN AFTER
PUMPING. EXPANDING VAPOUR CAN DISPLACE OXYGEN CAUSING
ASPHYXIATION AND DEATH.
5.7.3 Ensure that valves on nitrogen inlets are closed and the caps are replaced.
NOTE
If water gets in, it will accumulate in the Y strainer and be blown through into the nitrogen
centrifugal on the next job. This will almost certainly freeze the centrifugal seal and it will
tear when the centrifugal is spun.
NOTE: REFER TO THE OPERATIONS MANUAL OF THE DIESEL ENGINE FOR ALL MAINTENANCE
AND TROUBLESHOOTING ON THIS UNIT.
6.1 Introduction
This section contains Inspection, Maintenance, Cleaning, and Troubleshooting. Only qualified
Personnel shall be authorised to perform maintenance on this system.
6.2 Inspection
a. CLEANLINESS. Inspect all nitrogen components for cleanliness. Remove all forms of
foreign material and contaminants from equipment. Special attention should be given to
couplings to ensure that no contamination or foreign materials can enter the nitrogen
system.
b. CORROSION. Inspect entire nitrogen system for any forms of corrosion. Clean and
inspect corrosion area. Repair as required. Take preventative measures to inhibit future
corrosion.
c. WELDMENTS. Inspect all welded parts for evidence of cracked or broken welds.
Determine cause and take measures to prevent future failures. Repair as required.
d. GLASS. Inspect all glass components for cracks or breaks. Rework and repair as required.
e. VALVES. Check all valves for general condition, missing parts, and signs of leakage.
Operations of the system, inspect valves for ease of operation and positive seating. Note
problem areas and make repairs as soon as conditions permit.
f. LEAKAGE. Inspect all fittings and tubing for looseness and signs of leakage. Repair as
required
g. HOSES. Inspect hoses for excessive wear. Inspect fitting for wear or physical damage.
Remove and repair as required
h. ATTACHING HARDWARE. Inspect entire system for loose or missing hardware (E.g. nuts,
bolts, etc.) Repair and re-torque as required.
The following schedules are guidelines only. The frequency of any particular maintenance or
service is dependant on the operational conditions, environment, and age or condition of the
system.
c. Check that all hydraulic suction valves on the hydraulic tank are open.
b. Check all critical bolted connections for tightness. Include but do not limit
to the following:
c. Check air intake connections for tightness. Check rubber seals and ducts for
deterioration which could cause leaks.
b. Drain hydraulic and lubrication tanks and clean thoroughly with a suitable
solvent. Replace fluids with new clean fluid.
b. Drain hydraulic and lubrication tanks and clean thoroughly with a suitable
solvent. Replace fluids with new clean fluids.
e. Check all hose and clamps on hydraulic, lubricating and coolant circuits.
Replace, repair or tighten as required.
f. Drain coolant fluids in vaporiser coolant circuit and flush with clean water.
Replace coolant fluids with 50 per cent ethylene glycol mixture and 50 per
cent clean fresh water.
Cleaning precautions related to cleaning the system and its components shall be followed.
Specific precautions which accompany cleaning solutions or solvents shall be followed. The
following precautions are standard to the system and should be observed at all times when
cleaning is required.
a. Wear appropriate safety equipment, when using cleaning solutions, solvents, and
compressed air.
d. When using solvents, always keep these items away from a source of flame, sparks
or heat. Do not leave any containers open. These substances can ignite or form
harmful gases when heated.
The following schedules are guidelines only. The frequency of any particular maintenance or
service is dependant on the operational conditions, environment, and age or condition of the
system. For detailed information on the compressor fitted, please refer to the component
manufacturer data contained in Volume 2.
The following schedules are guidelines only. The frequency of any particular maintenance or
service is dependant on the operational conditions, environment, and age or condition of the
system.
Belt Inspection
NOTE.
Belt tension should be checked initially within the first 20 / 40 hours of engine
operation. Check the following fluid levels:
WARNING
Use of standard belts on this engine may cause an explosion which may result in
personal injury or death. Only non-static belts should be used on this engine.
c. Ensure the belt is not too loose. Refer to operators’ manual for correct
tension.
d. Ensure the belt is not too tight. Refer to operators’ manual for correct
tension.
The following schedules are guidelines only. The frequency of any particular maintenance or
service is dependant on the operational conditions, environment, and age or condition of the
system. For detailed information on the starter motor fitted, please refer to the component
manufacturer data contained in Volume 2.
The following schedules are guidelines only. The frequency of any particular maintenance or
service is dependant on the operational conditions, environment, and age or condition of the
system.
Visual Inspection
c. Ensure wire rope sling is free from corrosion (protect with non-acidic
lubricants)
f. Check wire rope sling fittings are not damage i.e. ferrules, thimbles etc;.
g. Check the wire rope slings wires are not cut or broken.
h. Check the wire rope sling for signs of heat damage or discolouration.
6.8.2 Annually
Proof Load / Certify wire rope slings. Refer to Volume 3 – Certification Databook
for recommended recertification date as detailed by the supplier.
Shackles
Visual Inspection
c. Ensure the shackle is free from corrosion (protect with non-acidic lubricants)
f. Check the shackle pin is the correct one for the shackle and it is not bent or
damaged and the thread form is complete.
6.8.3 Annually
NOTE
This equipment requires periodic safety and maintenance inspections.
Subject
Monthly
Weekly
Yearly
Daily
Subject
After first Interval
After first
replacement, according to
100 hours of
every 500 contamination
operation
hours indicator
Subject
If required
Half
Daily Yearly (according to
Yearly
experience)
NOTE
This equipment requires periodic safety and maintenance inspections.
· Inspect unit frame for any signs of deformation, damage and leakage Inspect
attaching hardware for security and/or missing items. Particular attention
should be paid to areas of potentially high material stress.
· Inspect electric components (cables, glands) for security, wear and tightness.
NOTE
Use the maintenance schedule to determine action points.
Codes Used
Item
3 Monthly
6 Monthly
Monthly
1200hr
Yearly
300hr
600hr
Daily
10hr
Electric cables/earthing/glands/mct 1 4 18
Electric junction boxes 4 20
Tags/decalls/placards 1&2
Complete electrical system 1
For a full troubleshooting guide please refer to Volume 2 where you will find the CAT 3406
Manual.
The following troubleshooting tables are simply checks that field maintenance can make. Any
detailed engine problems should be performed by an authorised engine repair facility. Field
maintenance personnel should be trained by qualified personnel. Field maintenance personnel
should possess a good understanding and working knowledge of the properties and dangers of
power pack equipment before attempting to troubleshoot this unit.
Refer to pump
Determine
manufacturer’s
hydraulic tank
viscosity effect on
temperature
pump power levels
- Confirm type
of start, air,
- Initiate motor start hydraulic or
sequence electric
- Confirm
engine controls
location
Bring hydraulic
reservoir Hydra Rig UK
temperature to at Service Dept.
least 110°F
Yes
- Confirm suction
valves are open
- Confirm tank
Close.Loop temperature
Charge pressure at
230 psi or above? - Confirm oil
column at sight
No
level gauge
Yes
Hydra Rig UK
Service Dept.
- Proceed with
required operations
6.16.1 Daily
* Exhaust gas flame traps. (If fitted)
Shut the engine down and remove each element, (do not fit dummy units to
run, if an immediate run is required fit spare flame trap elements).
Solvent soak the dirty elements and brush clean, power-hose or ultra-sound
cleaning methods are very effective. (Never poke with mechanical objects)
blow dry with compressed air. Do a mechanical integrity check of the
element and its local surrounding fitting location, if all is well refit.
* Be alert and observe the suitable operation of the Air Shutdown valve on
general start and stop. Don’t forget the air valve is slaved by the run
solenoid so proves the suitability of both components.
6.16.2 Weekly
* Visual check
Visual checks are the first line of defence, at all times during normal
operation of the equipment correct any defective component that is
observed as dangerous or potentially dangerous.
6.16.3 Monthly
* Component soundness
Undertake a physical check on all the areas mentioned in the weekly visual
check. In this instance, physically check fixing security, cable glanding,
jointing etc.
Components in contact with the exhaust gas such as the Spark Arrestor will
be fitted with a soot/drain box, in the first instance run for six months and
observe the content of the soot box. Adjust this inspection in line with your
observations.
If the battery is to give a long and useful service it requires attention. The
degree of attention depends on the level of operation of the equipment and
the conditions of the local environment.
Check electrolyte level and specific gravity more regularly if cold no active
situations are evident. Always recharge in a safe area with the lid removed,
make your connection at the bus-bar.
Never charge the Battery on location and/or still fitted into the equipment.
Always remove the battery with its enclosure from the equipment and place
the whole assembly in a safe area before charging is attempted, also
reference the manufacturers (care for your Battery) instructions.
Always remove the battery enclosure lid before and during the charge
procedure.
Some users run all year round with anti-freeze, this is acceptable if the
cooling system is designed to accommodate the difference in performance,
in any event check the concentration in the winter months.
Type Oil Type Manufacturers Filter NOV Hydra Rig Quantity of Services
Number Filter Part Filters on Unit Interval Filters
Number and Oil
Engine Oil Filter
15/40 1R-1808 2VEF00021 1 250 HOURS
895
29 26 29 12 14 4 11 12 3 23 2 27
CONFIDENTIAL-PROPRIETARY
ITM QTY UOM PART NUMBER DESCRIPTION
N/A
THIS DRAWING IS THE PROPERTY OF
N/A HYDRA RIG, INC. AND IS SUBJECT TO LIST OF MATERIALS
RETURN UPON REQUEST. THE DRAWING
INCLUDES CONFIDENTIAL AND PROPRIETARY TOLERANCES SCALE DRAWN
N/A INFORMATION OF HYDRA RIG, INC. AND IS (UNLESS NOTED OTHERWISE) Z HOPKINS
1:5
N/A
LOANED IN CONFIDENCE WITH THE UNDER-
STANDING THAT IT IS NOT TO BE COPIED
OR REPRODUCED WITHOUT EXPRESS WRITTEN
.X ± .040
.XX ± .020
.XXX ± .005
FRACTIONAL
ANGULAR
± 1/16
± 1/2°
125
DATE HydraR g CHECKED
ENGINEER
D McLAUGHLIN
C-017 Rupture Disc 2" Type SCRD-UT Burst Pressure 14Bar ST/ST 316 19 Vaporiser Circuit Safety Valve 2HXR00001
C-018 Thermowell 0.75"NPT Male ST/ST 21 Temperature Gauge Capiliary Socket 2ITS00001 N/A
Job Number HALLIBURTON 180K NITROGEN UNIT Schematic No.
J15177001 2NE090245
NO. ON
ITEM No. ITEM POSITION / FUNCTION PART No. IHRA No.
SCHEMATIC
P-001 Start/Stop Valve Black Button 1 Start Valve W-20VD-0001 092
P-002 Start/Stop Valve Black Button 1 Stop Valve W-20VD-0001 092
P-003 Start/Stop Valve Black Button 1 Permissive Start Valve W-20VD-0001 092
P-004 Start/Stop Valve Black Button 1 GN2 Discharge Valve Interlock W-20VD-0001 092
P-005 Valve 3/2 Palm Button Latching Emergency Stop 2 Engine Emergency Stop Valve 2AVD00014 093
P-006 Restrictor Air 4 Control Circuit Air Restrictor W-20REA-0001 094
P-007 Restrictor Air 4 Emergency Stop Circuit Air Restrictor W-20REA-0001 094
P-008 Restrictor Air 4 OPP Point Air Restrictor W-20REA-0001 094
P-009 Solenoid Starter Air 5 Engine Starter Motor Solenoid W-25ASM-0002 101
P-010 Starter Air 150BMP 6 Engine Air Starter Motor 2VEX00217 304
P-011 Lubricator Assembly 1.25 7 Air Starter Lubricator W-20LA-0003 098
P-012 Valve Fuel Shut Off 8 Engine Fuel Stop Valve W-20VFS-0001 085
P-013 Air Receiver Horizontal 200Ltr 9 Air Receiver 2NC060008 013
P-014 Valve Overspeed 10 Engine Overspeed Valve W-20VO-0001 086
P-015 Relay Indicator Pneumatic 11 Low Engine Oil Pressure Indicator W-20IR-0002 091
P-016 Relay Indicator Pneumatic 11 High Exhaust Temperature Indicator W-20IR-0002 091
P-017 Relay Indicator Pneumatic 11 High Engine Coolant Temperature Indicator W-20IR-0002 091
P-018 Manifold Brass 12 Control Air Manifold W-20MA-0001 N/A
P-019 Valve Ball 0.25NPT 14 Rig Air Supply Bleed Down Valve W-23VB-0001 047
P-020 Valve Ball 0.25NPT 14 Air Receiver Drain W-23VB-0001 047
P-021 Relief Valve 0.50" Set @ 150 PSI 15 Air System Safety Relief Valve W-20VR-0001 070
P-022 Gauge Pressure 2.50 0.25NPT 0-160PSI 16 Panel Mounted System Air Pressure Gauge W-24GP-0031 021
P-023 Temperature Valve High Water (96ºC Rising) 17 High Engine Water Temp Shutdown Valve W-20VT-0001 156
P-024 Pressure Valve Low Oil (10psi Falling) 18 Low Engine Oil Pressure Shutdown Valve W-20VP-0001 155
P-025 Valve Ball 1.00 NPT Brass 19 Air Receiver/Rig Supply Isolation Valve W-23VB-0005 047
P-026 Temperature Valve High Exhaust (200ºC Rising) 21 High Exhaust Temperature Shutdown Valve W-20VT-0002 154
P-027 Bendix Governer 22 Compressor Unloader Valve W-20RA-0002 081
P-028 Valve Check 0.50NPT Brass 24 Compressor Protection Check Valve W-20VC-0003 082
P-029 Compressor Engine Driven 25 Engine Mounted Main Air Compressor N/A 014
Job Number HALLIBURTON 180K NITROGEN UNIT Schematic No.
J15177001 2NE090245
NO. ON
ITEM No. ITEM POSITION / FUNCTION PART No. IHRA No.
SCHEMATIC
P-030 Regulator Filter Air 26 0.50" Externally Mounted System Filter Regulator W-20RA-0001 099
P-031 Valve 3/2 Pilot/Spring 1/4" 27 Engine Stop/Emergency W-20VPD-0010 096
P-032 Cylinder Single Acting 28 Engine Stop Cylinder 2AXC00004 153
P-033 Directional Valve 4/2 32 P14 Pump Servo Pressure Vent W-23VD-0044 166
P-034 Directional Valve 4/2 32 GN2 Discharge Valve Oil Supply W-23VD-0044 166
P-035 Shutdown Switch 0-10,000 PSI 34 GN2 Over Pressure Shutdown Valve 6901 121
P-036 Red/Green (Frog Eye) Indicator 1/8"BSP 35 Panel Mounted Nitrogen Indicator W-20IR-0003 118
P-037 Red/Green (Frog Eye) Indicator 1/8"BSP 35 Panel Mounted Position Indicator W-20IR-0003 118
P-038 Pressure Gauge 0-100 PSI 2.50 36 Engine Oil Pressure Gauge W-24GP-0030 021
P-039 Diecrtional Valve 3/2 Pilot/Pilot G1/4 38 GN2 Discharge Valve indicator Relay 2AVD00009
P-040 Valve 3/2 Roller Spring G1/4 39 GN2 Discharge Valve Open Valve 2AVD00004
P-041 Valve 3/2 Roller Spring G1/4 39 GN2 Discharge Valve Close Valve 2AVD00004
P-042 Air Dryer Bendix AD9 40 Compressor Air Dryer W-20FHA-0005 097
Job Number HALLIBURTON 180K NITROGEN UNIT Schematic No.
J15177001 2NE090348
NO. ON
ITEM No. ITEM POSITION / FUNCTION HR PART NO. IHRA REF
SCHEMATIC
N-001 Valve Relief 1/4"NPT x 1/2"BSP SET @ 200 PSI 1 VR1 W-21VR-0007 049
N-002 Valve Relief 1/4"NPT x 1/2"BSP SET @ 200 PSI 1 VR2 W-21VR-0007 049
N-003 Valve Relief 1/4"NPT x 1/2"BSP SET @ 200 PSI 1 VR3 W-21VR-0007 049
N-004 Valve Relief 1/4"NPT x 1/2"BSP SET @ 200 PSI 1 VR4 W-21VR-0007 049
N-005 Valve Relief 1/4"NPT x 1/2"BSP SET @ 200 PSI 1 VR5 W-21VR-0007 049
N-006 Valve Relief 1/4"NPT x 1/2"BSP SET @ 200 PSI 1 VR6 W-21VR-0007 049
N-007 Valve Relief 1/4"NPT x 1/2"BSP SET @ 200 PSI 1 VR7 W-21VR-0007 049
N-008 Valve Relief 1/4"NPT x 1/2"BSP SET @ 200 PSI 1 VR8 W-21VR-0007 049
N-009 Valve Relief 9/16"HP 2 GN2 Relief Valve Connected to High Pressure Manifold 2CVR00011 050
N-010 Valve Ball 2.00 Cryo S/Weld 3 Inlet Isolation Valve No.1 W-21VB-0007 047
N-011 Valve Ball 2.00 Cryo S/Weld 3 Inlet Isolation Valve No. 2 W-21VB-0007 047
N-012 Valve Ball 2.00 Cryo S/Weld 3 Boost Pump Bypass W-21VB-0007 047
N-013 Valve Ball 2.00 Cryo S/Weld 3 Boost Pump Inlet Crossover W-21VB-0007 047
N-014 Valve Ball 1.50 Cryo S/Weld 4 Rapid Cooldown Valve W-21VB-0006 047
N-015 Valve Ball 1.50 Cryo S/Weld 4 Return Isolation W-21VB-0006 047
N-016 Valve Ball 1.50 Cryo S/Weld 4 Boost Pump Isolation W-21VB-0006 047
N-017 Valve Ball 0.75 Cryo S/Weld 5 Boost Pump Prime Vent Valve W-21VB-0009 047
N-018 Valve Needle 2-Way 9/16" 6 LN2 Tempering Valve 2CVH00004 150
N-019 Valve Needle 2-Way 9/16" 6 GN2 Vent Valve 2CVH00004 150
N-020 Valve Plug 2" x 1" c/w BRC012 Danfoss Actuator 7 GN2 Discharge Valve Hydraulic Actuator W-21VP-0010 183
N-021 Valve Globe 1.00" St/St S/Weld 8 Back Pressure Globe Valve 2CVG00008 173
N-022 Gauge 0-12000PSI 6" Panel Mount 9 GN2 Discharge Pressure Gauge W-24GP-0063 188
N-023 Valve Check 1.00" St/St S/Weld 10 Between 1" Globe Valve & Return Manifold 2CVC00005 112
N-024 Valve Check 1.00 High Pressure 11 GN2 Check Valve 2CVC00007 051
N-025 Pump Centrifugal 1½ x 2½ x 6 12 LN2 Charge Pump 2LE100002 042
N-026 Strainer 2.00" St/St S/Weld 13 Boost Pump Inlet Filter 2CLS00001 123
N-027 Strainer 2.00" St/St S/Weld 13 Boost Pump Bypass Inlet Filter 2CLS00001 123
N-028 Totalizer Flowrate MC-11 ATEX 14 Pump GN2 Flow Rate/Totalizer 2ITE00020 N/A
N-029 Suction Cryogenic Manifold for Standard 180K Unit 15 LN2 Inlet to Cold Ends 2ND070042 124
Job Number HALLIBURTON 180K NITROGEN UNIT Schematic No.
J15177001 2NE090348
NO. ON
ITEM No. ITEM POSITION / FUNCTION HR PART NO. IHRA REF
SCHEMATIC
N-030 Manifold Discharge High Pressure 16 Triplex Discharge Manifold 2ND070037 039
N-031 Gauge 0-12000PSI 6" Panel Mount 17 GN2 Pressure Gauge W-24GP-0060 188
N-032 Pressure Gauge 0-200 PSI 4.00 Panel Mount 19 Panel Mounted Boost Pump Pressure W-24GP-0052 021
N-033 Temperature Gauge 4" 0-120C/248F 20 GN2 Temperature W-24GT-0016 036
N-034 Valve Ball ½" Cryo S/Weld 21 Inlet No. 1 Vent W-21VB-0008 047
N-035 Valve Ball ½" Cryo S/Weld 21 Inlet No. 2 Vent W-21VB-0008 047
N-036 Shutdown High Pressure 0-10,000 PSI 22 GN2 Over Pressure Shutdown Valve 6901 121
N-037 Vaporiser Pot Assembly 180K 29 LN2 Evaporator 2LD400002 038
N-038 Assembly Cold End 1.625 31 Cold End 1 2LD000014 041
N-039 Assembly Cold End 1.625 31 Cold End 2 2LD000014 041
N-040 Assembly Cold End 1.625 31 Cold End 3 2LD000014 041
N-041 Valve Check 1.5" ST/ST S/Weld 33 Second Inlet Isolating Valve 2CVC00004 179
N-042 Valve Ball Excess Flow 1/4" 39 GN2 Pressure Gauge Damper 2CVB00004 051
N-043 Valve Ball Excess Flow 1/4" 39 LN2 Pressure Gauge Damper 2CVB00004 051
N-044 Valve 2-Way 0.25 Angle 40 GN2 Vent Valve 2CVH00003 190
OPEN 180K NITROGEN UNIT
LENGTH
ITEM HOSE TYPE/ SIZE HOSE ENDS QTY (inches) HOSE ROUTING DESCRIPTION FROM -TO
P/H 1 ½" 3K ST 90 1 12.5 FROM BRASS RETURN HYDRAULIC MANIFOLD TO PANEL BULKHEAD RETURN
P/H 2 ½" 3K ST 90 1 61.5 RETURN OUT OF HYDRAULIC LOAD CONTROL VALVE TO BRASS RETURN MANIFOLD
P/H 3 ½" 3K ST 90 1 31 HYDRAULIC LOAD PRESSURE FROM BULKHEAD IN PANEL TO HYD LOAD CONTROL VALVE
P/H 4 ½" 3K ST ST 1 37 REGULATED AIR IN FROM PANEL BULKHEAD TO AIR MANIFOLD
P/H 5 ⅜" 3K ST 90 1 44.5 RETURN OUT OF BOOST PUMP CONTROL VALVE TO BRASS RETURN MANIFOLD
P/H 6 ⅜" 3K ST 90 1 40 RETURN OUT OF DISCHARGE CONTROL "OPEN/CLOSE" VALVE TO BRASS RETURN MANIFOLD
P/H 7 ⅜" 3K ST 90 1 19 RETURN OF BOOST PUMP SUN CONTROL VALVE TO PANEL BULKHEAD RETURN
P/H 8 ¼" 3K ST 90 1 20.5 BOOST PUMP HYD PRESSURE FROM PANEL BULKHEAD TO BOOST PUMP CONTROL VALVE
P/H 9 ¼" 3K ST 90 1 26.5 PRESSURE FROM PANEL BULKHEAD TO TRIPLEX CONTROL VALVE "PRESSURE IN" PORT 2
P/H 10 ¼" 3K ST 90 1 20 CONTROLED PRESSURE OUT OF TRIPLEX CONTROL VALVE PORT 1 TO PANEL BULKHEAD
P/H 11 ¼" 3K ST 45 1 26 DISCHARGE CONTROL VALVE "OPEN/CLOSE" PRESSURE FROM PANEL BULKHEAD TO DISCHARGE
- - - - - - CONTROL VALVE PRESSURE IN
P/H 12 ¼" 3K ST ST 1 29 PRESSURE OUT OF DISCHARGE CONTROL VALVE "PORT 1 OPEN" POSITION TO PANEL BULKHEAD
P/H 13 ¼" 3K ST ST 1 27.5 PRESSURE OUT OF DISCHARGE CONTROL VALVE "PORT 2 CLOSED" POSITION TO PANEL BULKHEAD
P/H 14 Microbore ST ST 1 16 PRESSURE OUT OF HYDRAULIC LOAD VALVE TO HYDRAULIC LOAD PRESSURE GAUGE IN PANEL
P/H 15 Microbore ST ST 1 20 PRESSURE OUT OF HYDRAULIC BOOST PUMP CONTROL VALVE TO BOOST PUMP PRESSURE GAUGE IN PANEL
P/H 16 Microbore ST ST 1 25.5 MAIN AIR PRESSURE FROM PANEL BULKHEAD TO AIR PRESSURE GAUGE IN CONTROL PANEL
P/H 17 Microbore ST ST 1 29 MAIN ENGINE OIL PRESSURE FROM PANEL BULKHEAD TO ENGINE OIL PRESSURE IN GAUGE IN PANEL
P/H 18 Microbore ST ST 1 33.5 TRIPLEX LUBE OIL PRESSURE FROM PANEL BULKHEAD TO TRIPLEX LUBE OIL PRESSURE GAUGE IN PANEL
P/H 19 Microbore ST ST 1 30 SYSTEM HYDRAULIC PRESSURE FROM PANEL BULKHEAD TO SYSTEM HYDRAULIC PRESSURE GAUGE IN PANEL
P/H 20 Microbore ST ST 1 31 CHARGE PRESSURE FROM PANEL BULKHEAD TO CHARGE PRESSURE GAUGE IN PANEL
Job Number HALLIBURTON OPEN SKID 180K NITROGEN UNIT WF 168 Iss 3
J15177001 HOSE REGISTER
LENGTH
ITEM HOSE TYPE/ SIZE HOSE ENDS QTY (inches) HOSE ROUTING DESCRIPTION FROM -TO
1 ½" 3K ST ST 1 36 INLET MAN TO COMP IN PORT
2 ⅜" 3K ST ST 1 56 SEC FUEL FILTER OUT PORT TO AMOT FUEL VALVE PORT B
3 ⅜" 3K ST 90 1 37½ LIFT PUMP TO SEC FUEL FILTER IN PORT
4 ⅜" 3K 90 90 1 36 AMOT VALVE (T) TO FUEL PUMP OUT PORT
5 ⅜" 3K ST 90 1 39 AMOT VALVE PORT (A) TO FUEL PUMP IN PORT
6 2" 32G1H ST 90 1 26 HEAT EXCHANGER TO T67 MANIFOLD
7 2" 32G1H 90 ST 1 75 HEAT EXCHANGER TO VAPORISER POT WATER OUT
8 2" 32G1H 90 45 1 60 WATER PUMP TO VAPORISER POT WATER IN
9 1¼" 20G1H 90 ST 1 31 V12 VALVE TO V10 LINK HOSE
10 1¼" 20G1H ST 90 1 41 BOTTOM HYDRAULIC TANK TO RETURN FILTER OUT PORT
11 1¼" 20G1H ST 90 1 66 RETURN FILTER OUT PORT TO HEAT EXCHANGER MANIFOLD
12 1¼" 20G1H ST ST 1 61 TOP OF T ON V10 VALVE TO MANIFOLD ON HEAT EXCHANGER
13 1¼" 20G1H 90 ST 1 70 BOTTOM OF P14 TO SUCTION FILTER MANIFOLD
14 1¼" 20G1H ST 90 1 67 RETURN FILTER IN PORT TO FLOW DIVIDER ON T67
15 1¼" 20G1H 90 ST 1 14½ RETURN FILTER IN PORT TO CHECK VALVE ON MANIFOLD T67
16 1¼" 20G1H 90 ST 1 18 STARTING MOTOR TO STARTING SOLENOID
17 1¼" 20G1H ST 90 1 63 TRIPLEX N.R.V. TO LUBE PUMP
18 1¼" 20G1H ST 45 1 73 AIR RECEIVER TO STARTER LUBRICATOR
19 1" 3K ST ST 1 44½ SUCTION FILTER MANIFOLD TO TANDEM GEAR PUMP
20 1" 3K ST ST 1 64 TOP OF HYDRAULIC TANK TO P14 CASEDRAIN/RETURN
21 1" 3K ST 90 1 29 MANICOOLER TO BOTTOM OF DUPLEX
22 1" 3K ST 90 1 30 MANICOOLER PIPEWORK TO MANICOOLER
23 1" 3K ST 90 1 82 AIR RECEIVER TO RIG AIR
24 ¾" 3K ST ST 1 52½ BOTTOM OF TRIPLEX TO FULFLO OUT PORT
Job Number HALLIBURTON OPEN SKID 180K NITROGEN UNIT WF 168 Iss 3
J15177001 HOSE REGISTER
LENGTH
ITEM HOSE TYPE/ SIZE HOSE ENDS QTY (inches) HOSE ROUTING DESCRIPTION FROM -TO
25 ¾" 3K ST 90 1 90 LUBE PUMP TO LUBE FILTER 'IN' PORT
26 ¾" 3K ST 90 1 71 HIGH PRESSURE FILTER OUT PORT TO P14 K PORT (UPPER)
27 ¾" 3K ST 90 1 63½ HIGH PRESSURE FILTER IN PORT TO P14 J PORT (LOWER)
28 1¼" 20GIH ST ST 1 50 SUCTION FILTER MANIFOLD TO SINGLE VANE PUMP
29 ¾" 3K 90 ST 1 145 HEAT EXCHANGER PIPEWORK TO HEADER TANK
30 ¾" 3K ST 90 1 39 BOOST PUMP RV RETURN TO T ON SINGLE VANE PUMP
31 ¾" 3K ST 45 1 105 WATER PUMP MOTOR IN PORT TO T67 WATER PUMP (RV) PORT B
32 ¾" 3K ST 90 1 80 WATER PUMP MOTOR OUT PORT TO RETURN MANIFOLD PORT A
33 ¾" 3K ST 90 1 65 WATER PUMP RV RETURN TO RETURN MANIFOLD
34 ¾" 3K ST 90 1 75 TOP OF DUPLEX TO ENGINE WATER JACKET
35 ¾" 3K ST 90 1 29½ LUBE OIL FILTER OUT TO TRIPLEX LUBE MANIFOLD
36 ¾" 3K ST ST 1 24 TRIPLEX LUBE MANIFOLD TO TRIPLEX SWIVEL
37 ¾" 3K ST ST 1 54 TOP OF TRIPLEX MOTOR TO TOP OF HYDRAULIC TANK
38 NOT USED
39 ½" 3K ST 45 1 86 AIR DRYER IN PORT TO COMPRESSOR CHECK VALVE
40 ½" 3K ST ST 1 178 AIR DRYER OUT PORT TO AIR RECEIVER
41 ½" 3K ST ST 1 265 AIR RECEIVER TO AIR REG IN PORT
42 ½" 3K ST 90 1 22 HEAT LOAD RV LINK HOSE
43 ½" 3K ST 90 1 78½ PANEL B/H TO HEAT LOAD RV
44 ½" 3K ST ST 1 93½ TOP OF HYDRAULIC TANK TO PANEL B/H (RETURN)
45 ½" 3K 90 ST 1 32 PANEL B/H TO AIR REG OUT PORT
46 ½" 3K 45 90 1 45 BOOST PUMP RV TO BOOST PUMP IN PORT
47 ½" 3K 45 ST 1 50½ BOOST PUMP OUT PORT TO T ON SINGLE VANE PUMP
48 ½" 3K ST ST 1 136 FUEL FILTER IN PORT TO FUEL TANK OUT PORT
Job Number HALLIBURTON OPEN SKID 180K NITROGEN UNIT WF 168 Iss 3
J15177001 HOSE REGISTER
LENGTH
ITEM HOSE TYPE/ SIZE HOSE ENDS QTY (inches) HOSE ROUTING DESCRIPTION FROM -TO
49 ½" 3K 90 ST 1 136 AMOT FUEL VALVE TO FUEL TANK IN PORT
50 ⅜" 3K ST 90 1 67 TRIPLEX MOTOR TOP PORT TO HYD TANK
51 NOT USED
52 ⅜" 3K ST ST 1 136 WATER PUMP MOTOR TO TOP OF HYDRAULIC TANK
53 ⅜" 3K ST ST 1 29 4D01 LINK HOSE 45 TO TOP OF TEE
54 ⅜" 3K ST 90 1 76 TOP OF HYDRAULIC TANK TO 4D01 VALVE
55 ⅜" 3K ST ST 1 94 TOP OF HYDRAULIC TANK TO PANEL B/H (SUN RETURN)
56 ⅜" 3K ST ST 1 115 TOP OF HYDRAULIC TANK TO BOOST PUMP CASE DRAIN
57 ¼" 3K ST 90 1 246 PANEL B/H (DIS CLOSE) TO DISCHARGE VALVE CLOSE SHUTTLE HYDRAULIC
58 ¼" 3K ST 90 1 239 PANEL B/H (DIS OPEN) TO DISCHARGE VALVE OPEN SHUTTLE HYDRAULIC
59 ¼" 3K ST 90 1 225 AIR REGULATOR TEE TO DISCHARGE VALVE OPEN SHUTTLE TEE
60 ¼" 3K ST 90 1 16 DISCHARGE VALVE OPEN SHUTTLE TEE TO DISCHARGE VALVE CLOSE SHUTTLE
61 ¼" 3K ST ST 1 239 DISCHARGE VALVE PORT B TO PANEL B/H (DIS OPEN) INDICATOR
62 ¼" 3K ST ST 1 238 DISCHARGE VALVE PORT A TO PANEL B/H (DIS CLOSE) INDICATOR
63 ¼" 3K ST 90 1 52 WATER PUMP RV TO DISCHARGE 4D01 PORT P
64 ¼" 3K ST ST 1 120 PANEL B/H (DIS PILOT) TO DISCHARGE 4D01 PILOT
65 ¼" 3K ST 90 1 127 PANEL B/H (DIS PRESS) TO DISCHARGE 4D01 PORT B
66 ¼" 3K ST 90 1 131 IDEAL VALVE TEE TO SPEED 4D01 PILOT
67 ¼" 3K ST 90 1 109 PANEL B/H (SUN OUT) TO SPEED 4D01 PORT P
68 ¼" 3K ST ST 1 18 SPEED 4D01 PORT B TO P14 PORT P2
69 ¼" 3K ST ST 1 92½ P14 PORT P1 TO TOP OF HYDRAULIC TANK
70 ¼" 3K ST ST 1 92 PANEL B/H (CHARGE) TO P14 PORT KG
71 ¼" 3K ST ST 1 89 PANEL B/H (SUN IN) TO P14 PORT G
72 ¼" 3K ST 90 1 107 PANEL B/H (BOOST) TO BOOST PUMP RV
Job Number HALLIBURTON OPEN SKID 180K NITROGEN UNIT WF 168 Iss 3
J15177001 HOSE REGISTER
LENGTH
ITEM HOSE TYPE/ SIZE HOSE ENDS QTY (inches) HOSE ROUTING DESCRIPTION FROM -TO
73 ¼" 3K ST ST 1 155 PANEL B/H (LUBE) TO LUBE FILTER
74 ¼" 3K ST ST 1 33 PANEL B/H (REG AIR) TO IDEAL VALVE 90
75 ¼" 3K ST 90 1 30 PANEL B/H (N2 O/PRESS) TO IDEAL VALVE TEE
76 ¼" 6K ST ST 1 91 PANEL B/H (SYSTEM) TO P14 PORT BG
77 ¼" 3K ST 90 1 207 ENGINE BLOCK TO OIL AMOT TOP OF TEE
78 ¼" 3K ST ST 1 172 ENGINE WATER TEMP AMOT TO PANEL B/H (HIGH WATER)
79 ¼" 3K ST ST 1 147 EXHAUST TEMP AMOT TO PANEL B/H (HIGH EXHAUST)
80 ¼" 3K 90 45 1 78 ENGINE AIR FLAP TO OVERSPEED
81 ¼" 3K 90 ST 1 140 FUEL AMOT 5.2 VALVE PORT 1 TO PANEL B/H (STOP)
82 ¼" 3K 90 ST 1 136 ENGINE STARTER LH PORT TO PANEL B/H (START)
83 ¼" 3K ST ST 1 274 AIR RECEIVER TO PANEL B/H (AIR PRESSURE)
84 ¼" 3K ST ST 1 87 FUEL AMOT TO ENGINE AIR FLAP
85 ¼" 3K 90 ST 1 70 ENGINE STARTER MOTOR RH PORT TO START SOLENOID
86 ¼" 3K 90 ST 1 36 ENGINE OVERSPEED TO PANEL B/H (EM STOP)
87 ¼" 3K 90 ST 1 34 ENGINE STOP RAM TO FUEL AMOT 5.2 VALVE PORT 2
88 ¼" 3K ST 90 1 152 AIR RECEIVER TO COMPRESSOR GOVENOR R/H PORT
89 ¼" 3K ST 90 1 125 AIR DRYER TO COMPRESSOR GOVENOR L/H PORT
90 ¼" 3K ST ST 1 103 TOP OF DUPLEX TO TOP OF RADIATOR
91 ¼" 3K ST 90 1 18 LUBE MANIFOLD TO COLD END LUBE
92 ¼" 3K ST 90 1 27½ LUBE MANIFOLD TO COLD END LUBE
93 ¼" 3K ST 90 1 36 TRIPLEX LUBE MANIFOLD TO COLD END LUBE
94 ¼" 3K ST ST 1 134 HEADER TANK TO VAPORISER POT
95 1½ R13R 90 90 1 50 TRIPLEX MOTOR TO P14
96 1½ 20G1 ST ST 1 58½ TRIPLEX MOTOR TO P14
Job Number HALLIBURTON OPEN SKID 180K NITROGEN UNIT WF 168 Iss 3
J15177001 HOSE REGISTER
LENGTH
ITEM HOSE TYPE/ SIZE HOSE ENDS QTY (inches) HOSE ROUTING DESCRIPTION FROM -TO
97 ¼" 3K ST ST 1 44 OIL AMOT TEE TO PANEL B/H OIL PRESSURE
98 ¼" 3K 90 ST 1 52 OIL AMOT TO PANEL B/H LOW OIL
99 1 ¼ FC300 ST ST 1 78 ENGINE OIL IN PORT TO OIL FILTER HOUSING OUT
100 1 ¼ FC300 ST ST 1 78 ENGINE OIL OUT PORT TO OIL FILTER HOUSING IN
101 ¼" 3K ST ST 1 31 PANEL B/H N2 O/PRS TO OPP ON MOUNTING FRAME
102 ½" 3K ST NPT 90 1 78 GEARBOX DRAIN
103 ¾" 3K ST NPT 90 1 78 ENGINE DRAIN
104 ¾" 3K ST ST 1 19 ENGINE WATER JACKET TO TURBO LOWER PORT
OPEN 180K NITROGEN UNIT
10.1 Loler/Puwer
A. LOLER
The skid and framework of the unit was proof loaded as part of the manufacturing
process with welds MPI tested pre and post test.
B. PUWER
The checklist is designed so that the ideal outcome is "Yes" to each question.
c) Overturning? YES
d) Collapse? YES
e) Overheating or fire? YES
f) Disintegration? YES
g) Explosion? YES
15. Is the equipment made stable where appropriate by bolting, clamping or tying? YES
16. Is there sufficient general and (where necessary) local lighting? YES
17. Is there protection against contact with hot or very cold temperature, so far as is appropriate? YES
18. In the case of pressurised equipment, is there a written scheme of examination?
19. If gas, fume or dust is released when the equipment is used, is there:
a) A local exhaust ventilation, tested annually? YES
or b) A COSHH assessment YES
Dangerous Parts of Machinery
20. Are all dangerous parts of machinery guarded? YES
21. Are all guards sound and in good working order? YES
22. Do they permit an adequate view of the operation where this is necessary? YES
23. Is it difficult to bypass or disable them? YES
24. Can the machinery only be started when a specific labelled start device is used: (NB. the normal cycle of automated machinery is exempt from this YES
requirement?)
25. Is it impossible to start the machine just by resetting a safety device? YES
26. Is there a readily accessible stop device which stops the machinery in a safe way? YES
27. Where appropriate (i.e. where in a foreseeable emergency it could help) is there a prominent easily accessible emergency stop device? YES
28. Can controls be operated safely and easily? YES
29. Is there a system of work which ensures that nobody is in a dangerous position when machinery is about to be started? YES
30. Does the start device need to be activated to restart the machine if:
a) The power fails? YES
b) A control or safety device fails or trips out? YES
31. If the power is isolated does the machinery come to rest safely without the possibility of access to dangerous parts? YES
32. Can the equipment be securely isolated from power to prevent inadvertent reconnection
a) By removing a plug from a socket which is easily visible to the person at risk? YES
b) By locking it off? YES
Summary
The equipment operates with adjacent components at opposite ends of the temperature
spectrum. The cryogenic system having a lower limit of -196°C, the temperature of liquid
nitrogen, whilst the maximum will be 200°C, the temperature at which the high exhaust
temperature shutdown will operate. Coupled with the temperature extremes pressures of
up to 9000 psi may be seen.
As described in the previous sections the unit is fitted with a range of measures designed
to minimise risk to both the operator and the environment
ITEM COMPONENT
A check list for essential health and safety requirements relating to the design and
construction of machinery has been constructed to establish compliance with Schedule 3
of Statutory Instruments No. 3073 1992 and its 1994 Amendment SI 2063.
This check list has been applied to the NOV Hydra Rig UK Nitrogen Pumping System Serial
Number J15177001 manufactured for Halliburton.
Definitions
1 "Danger zone" means any area within and/or around machinery in which an
exposed person is subject to a risk to his health or safety;
3 "Operator" means the person or persons given the task of installing, operating,
adjusting, maintaining, cleaning, repairing or transporting machinery.