Appendix
G
Operating the Flameless
Cryomec Skid Nitrogen Unit
Note—This appendix contains material reprinted from
the Cryomec Nitrogen Unit Instruction Manual for the
Liquid Nitrogen Converter Non-Fired, Skid Mounted
Unit, Part No. 787429-2-133. This material was re-
printed with permission.
Operation
Prestart
Before running this equipment, read and understand
this manual thoroughly. Become familiar with the loca-
tion, function, and feel of the control panel, including
the indicators and valves.
Fluid Levels
Check the oil levels in the diesel engine high-pressure
pump, the gearbox, and the hydraulic reservoir. Check
the coolant level in the diesel engine. Fill all to the
proper levels with the proper fluids.
Equipment Locations and Prestart Settings
Before starting the diesel engine, set all equipment
listed below as shown. (Refer to P & I.D.–Unfired Ni-
trogen Converter Drawing No. 787427 and Panel As-
sembly Drawing No. 787668).
1. The starter accumulator isolation valve (V-17)
should be OPEN (lever parallel to the valve). This
October 1997 Page 1 of 6
valve is located on the accumulators to the right
of the engine.
2. The high-pressure pump speed-control knob
should be OFF (clockwise fully). The knob is lo-
cated on the lower right side of the control panel.
3. The tempering valve (V-11) should be CLOSED
(clockwise fully). This valve is located on the
control panel above the H.P. pump tachometer.
4. The boost pump pressure-control valve (V-10)
should be OFF. This valve is located at the lower
center of the control panel.
5. The heat-control valve (RV-3) should be OFF
(counterclockwise fully). This valve is located
above the boost pump pressure gauge.
6. The main control valve (RV-4) should be OFF
(counterclockwise fully). This valve is located
above the heat-control valve.
7. The GN2 valve (V-5, V-12) should be CLOSED.
The control for this valve is located on the lower
left side of the control panel.
8. The vent return to tank valve (V-14) should be
CLOSED (clockwise fully). This valve is located to
the far left of the skid ahead of the vent fitting on
the vent valve mounting frame.
9. The vent to atmosphere valve (V-3) should be
CLOSED (clockwise fully). This valve is located to
the far left of the skid teed off the vent line.
Appendix G

10. The boost pump priming valve (V-2) should be
CLOSED (clockwise fully). This valve is located
on the side of the vent valve mounting frame.
11. The high-pressure pump priming valve (V-4)
should be CLOSED (clockwise fully). This valve is
located on the side of the vent valve mounting
frame below the boost pump priming valve.
12. The boost pump suction valve (V-1) should be
CLOSED (clockwise fully). This valve is located to
the far left of the skid on the inlet to the boost
pump.
13. The boost pump bypass valve (V-16) should be
CLOSED (clockwise fully). This valve is located to
the far left of the skid on the inlet to the high-pres-
sure pump suction manifold.
14. The hydraulic system supply valves (V-6, V-7,
V-8) should be OPEN (counterclockwise fully).
These valves are located beneath the control con-
sole on the side of the hydraulic reservoir.
Engine Start
The start system pressure must be 1,800 psi or greater
for starting the engine (2,200 psi for cold climates). A
hand pump is provided for charging the accumulators
to the required starting pressure. The pump is located
on the skid frame to the immediate left of the control
console mounting frame. The handle for the pump is
stored in a tube on the left side of the control console
frame. If a hydraulic power supply is available, the
hand pump discharge has a convenient tee fitting which
may be used for charging the accumulators. When
using a separate hydraulic power supply for charging,
this procedure should be used:
1. Close the accumulator isolation valve (V-17).
2. Vent any pressure in the system by moving the
GN2 valve lever to the OPEN position and then
back to the CLOSED position.
3. Remove the cap from the tee fitting on top of the
hand pump.
4. Connect the hydraulic power supply hose with a
1/2-in. -37° SAE swivel nut end.
5. Open the accumulator isolation valve.
6. Charge the system to minimum psi of 1,800.
Appendix G Page 2 of 6
Nitrogen Awareness Manual
7. Close the accumulator isolation valve.
8. Remove the hydraulic power supply hose and re-
place the cap on the tee fitting.
9. Open the accumulator isolation valve.
To start the engine, open the throttle slightly (approxi-
mately three turns counterclockwise), and pull the start
handle. Release the start handle immediately after the
engine starts.
Caution—Holding the start handle too long after
the engine starts can seriously damage the starting
motor.
Set the engine speed to 1,200 to 1,400 rev/min. In-
crease the heat load by rotating the heat-control valve
knob clockwise until the charge pressure reaches 2,500
psi. Remove the heat load pressure by rotating the heat-
control knob counterclockwise fully. Allow the engine
coolant temperature to rise above 100°F before pro-
ceeding.
Pressure Gauges
The engine oil pressure should be 25 psi minimum. The
start system pressure should be 1,800 psi minimum.
The main pressure should be 0 psi. The charge pressure
should be 270 to 300 psi. The heat load pressure should
be 0 psi. The GN2 discharge pressure should be 0 psi.
The pump discharge pressure should be 0 psi. The
high-pressure pump lube oil pressure should be 0 psi.
The boost pump hydraulic power supply pump should
have 1,000 psi discharge pressure (the gauge is located
on the discharge of the pump mounted on the diesel
engine on the left camshaft drive behind the control
console). The boost pump discharge pressure should be
0 psi.
Pump Cooldown
Suction Line
The line between the liquid nitrogen supply tank and
the boost pump suction fitting should be as short as
possible and of as small a diameter as practicable to
minimize heat leak into the nitrogen supply. Too large
a line will cause sufficiently low velocities in the line
to allow heat leak into the nitrogen/wall boundaries, al-
lowing vapor to form in the flow stream. This vapor
October 1997
Nitrogen Awareness Manual
will cause the boost pump and the high-pressure pump
to lose prime.
The recommended line size is a 1-in. ID (a 1.5-in. ID is
acceptable; however, at low flow rates on warm days,
there may be a problem maintaining prime).
Vent Line
Connect a line between the vent return valve on the
liquid nitrogen supply tank and the vent connection on
the skid. The vent connection is located to the far left
on the vent valve mounting frame. The line should be
as straight as possible and arranged such that gas
pockets cannot form in the line (no loops, severe bends
rising above the vent connection, etc.).
Pump Cooldown
1. Vent the liquid nitrogen supply tank to 0 psi;
close the tank vent valve.
2. Open the tank supply and vent return valves.
3. Open the tank pressure building coil valve.
4. Open the boost pump suction valve (V-1).
5. Open the boost pump priming valve (V-2).
6. Open the vent return to tank valve (V-14).
Note—For faster cooldown or to prevent saturating the
supply tank liquid on warm days, the vent to atmo-
sphere valve (V-3) may be opened instead of the vent
return to tank valve.
7. Open the high-pressure pump priming valve (V-
4).
8. After the boost pump has a heavy layer of frost,
rotate the boost pump pressure-control valve le-
ver (V-10) to INCREASE.
9. Open the atmospheric vent valve. Close the atmo-
spheric vent valve and the boost pump priming
valve when the liquid begins to flow through the
vent line.
10. Observe the boost pump discharge pressure
gauge. The pressure should be 20 to 40 psi above
tank pressure. If not, close the boost pump pres-
sure-control valve and continue the cooldown of
the boost pump.
October 1997 Page 3 of 6
High-Pressure Pump Start
1. During the cooldown of the boost pump, the high-
pressure pump should have been cooling down al-
so. When a heavy layer of frost is formed on the
cold ends, start the high-pressure pump by turn-
ing the pump speed control knob counterclock-
wise. Set the pump speed to approximately 400
rev/min.
2. Open the GN2 discharge valve.
3. Close the high-pressure pump priming valve (V-
4). Observe the pump discharge and main system
pressure gauges. There should be a rise in pres-
sure. If not, open the high-pressure pump priming
valve and continue the cooldown of the pump.
Stop the high-pressure pump and close the GN2
discharge valve.
Running
1. Set the engine speed to the minimum rev/min re-
quired for the desired flow rate. A chart on the
control panel shows the required engine speed
versus the flow rate.
2. Open the GN2 valve.
3. Start the high-pressure pump as outlined in the
“High-Pressure Pump Start” section, Page 3.
4. Increase the heat load pressure until the GN2 tem-
perature indicator begins to rise.
5. Slowly adjust the high-pressure pump speed to
the rev/min required for the flow rate. A chart on
the control panel shows the pump speed versus
the flow rate.
Caution—Too rapid an increase in pump speed
without a corresponding increase in heat load pres-
sure may cause the water vaporizer to form an ice
block inside. This will severely restrict the ability of
this system to vaporize the nitrogen. When icing oc-
curs, it is necessary to terminate the nitrogen flow
and maintain the heat load on the engine until the
engine temperature reaches 185 to 195°F.
6. When the required pump speed is reached, main-
tain the gas temperature by increasing or decreas-
ing the heat load pressure.
Appendix G

7. If the nitrogen temperature continues dropping
when the heat load pressure reaches 2,500 psi, it
will be necessary to increase the main system
pressure by turning the main control knob clock-
wise. Maintain the GN2 temperature by increas-
ing or decreasing the main pressure.
8. If the gas temperature is too high when the heat
load control and main control knobs are turned
fully counterclockwise, the temperature may be
controlled with the tempering valve. Rotate the
valve counterclockwise very slowly until the gas
temperature is regulated.
Note–The gas temperature should never be maintained
below 0°F. The recommended temperature range is
50°F to 90°F.
9. If the high-pressure pump vibrates at very high
flow rates, the vent return to tank valve must be
throttled down to minimize bypass flow. This will
increase the boost pump discharge pressure
enough to eliminate cavitation in the high-pres-
sure pump.
10. If the boost pump fails to operate, a bypass valve
is provided for supplying nitrogen to the high-
pressure pump directly from the supply tank.
Close the boost pump suction valve (V-1). Open
the boost pump bypass valve. Raise the tank pres-
sure to 40 psi and maintain this pressure. Start the
high-pressure pump as outlined in the “High-
Pressure Pump Start” section, Page 3.
Shutdown
Normal Shutdown
1. Close the pump vernier speed-control knob by ro-
tating it fully clockwise to stop the high-pressure
pump.
2. Turn the heat load control valve and the main sys-
tem pressure-control valve counterclockwise ful-
ly.
3. Reduce the engine speed to idle.
4. Close the pump feed valve (V-1) or (V-16).
5. Vent any high-pressure gas from the discharge
line.
Appendix G Page 4 of 6
Nitrogen Awareness Manual
6. Open the vent valve on the tank. Vent the tank to
0 psi.
7. After the cold ends have warmed up, close the
vent control valve (V-14) or (V-3).
8. Disconnect the gas discharge line from the skid.
9. Disconnect the line between the skid and the sup-
ply tank. Replace the caps on the fittings.
10. Close the GN2 discharge valve.
11. Check the starter pressure by opening the accu-
mulator isolation valve (if closed). If the pressure
is less than 2,500 psi, increase the engine speed to
1,400 rev/min and increase the heat load pressure
to 2,500 psi. Close the accumulator isolation
valve. Reduce the heat load pressure to 0 psi. Re-
duce the engine to idle.
12. Stop the engine by pulling the STOP knob.
Emergency Shutdown
Pull the large round knob on the panel for an emergen-
cy shutdown. The air door trip lever must be reset after
using the emergency shutdown.
Controls and Indicators
Converter System Controls
• Pump Speed Control—strokes the main hydrau-
lic pump to provide a variable hydraulic flow rate
to the high-pressure pump drive motor.
• Tempering Valve (V-11)—allows the liquid ni-
trogen to bypass the heat exchangers to provide for
the cooling of over-temperature discharge gas.
• Boost Pump Pressure-Control Valve (V-10)—
provides a variable hydraulic flow rate to boost the
pump drive motor.
• Heat-Control Valve (RV-3)—varies the dis-
charge pressure of the heat load hydraulic pump.
• Main Control Valve (RV-4)—varies the dis-
charge pressure of the main transmission pump by
varying the backpressure on the drive motor.
• GN2 Valve Selector Valve (V-12)—opens and
closes the GN2 discharge valve.
• Emergency Kill Knob—closes the engine intake
air door.
October 1997
Nitrogen Awareness Manual
• Engine Stop Knob—closes the engine fuel stop
lever.
• Engine Start Knob—releases the stored fluid in
the accumulators to the engine starter motor for
starting the engine.
• Engine Throttle—controls the diesel engine
speed.
• Boost Pump Suction Valve (V-1)—supplies the
liquid nitrogen to the boost pump.
• Boost Pump Bypass Valve (V-16)—supplies the
liquid nitrogen to the high-pressure pump, bypass-
ing the boost pump.
• High-Pressure Pump Priming Valve (V-4)—by-
passes the high-pressure pump discharge to the
vent system.
• Boost Pump Priming Valve (V-2)—bypasses the
boost pump discharge to the vent system.
• Vent Return to Tank Valve (V-14)—controls the
rate of flow of vapors bypassing the high-pressure
pump cold ends to the vapor phase of the supply
tank.
• Vent to Atmosphere Valve (V-3)—vents vapors
in the system to the atmosphere. The vent line
sprays vapor on the exhaust heat exchanger outer
shell to flash any dangerous liquid drops that may
be in the vapor.
• Accumulator Isolation Valve (V-17)—isolates
the accumulator from the hydraulic system to elim-
inate a loss of charge pressure.
• Hand Pump—allows the accumulators to be
charged manually.
Converter System Indicators
• Lube Oil Pressure Gauge (PI-4)—indicates the
high-pressure pump drive end lubricating oil pres-
sure.
October 1997 Page 5 of 6
• Pump Speed Tachometer—indicates the high-
pressure pump speed.
• GN2 Temperature Gauge (TI-1)—indicates the
discharge gas temperature.
• Pump Discharge Pressure Gauge (PI-10)—indi-
cates the discharge pressure of a high-pressure
pump.
• GN2 Discharge Pressure Gauge (PI-3)—indi-
cates the discharge gas pressure at the discharge
valve.
• Boost Pump Discharge Pressure Gauge (PI-1)—
indicates the boost pump discharge pressure (the
high-pressure pump suction pressure).
• Heat Load Pressure Gauge (PI-9)—indicates the
heat load hydraulic pump discharge pressure.
• Charge Pressure Gauge (PI-2)—indicates the
hydrostatic transmission pump charge pressure
(the return loop pressure).
• Main Pressure Gauge (PI-5)—indicates the hy-
drostatic transmission pump discharge pressure.
• Start System Pressure Gauge (PI-8)—indicates
the start system pressure (the hydraulic pressure
charge in the accumulators).
• Oil Pressure Gauge (PI-6)—indicates the diesel
engine oil pressure.
• Water Temperature Gauge—indicates the diesel
engine coolant temperature.
• Auxiliary Pump Pressure Gauge (PI-7)—indi-
cates the boost pump hydraulic power system pres-
sure.
Appendix G
 Nitrogen Awareness Manual

Appendix G Page 6 of 6 October 1997