OPERATIONS AND MAINTENANCE MANUAL

OP502

Issue 3

04/02

TITLE CRYOGENIC COLD END – PART No. 645-00011

1.625″ AND 1.375″ DIA. HYDRA RIG

SALES & SERVICE HYDRA RIG UK

Telephone: 01493 651801 Boundary Road,
Facsimile: 01493 651805 Harfreys Industrial Estate,
Great Yarmouth,
Email – sales@hydrarig.co.uk Norfolk, England, NR31 0LW
service@hydrarig.co.uk
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1.0 INTRODUCTION

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

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

CAUTION

Do not allow the pump to operate without liquid supply. Damage to the pump
may result.

1.1 Cryogenic Pumping - NPSH Requirements

The performance of the high pressure positive displacement cryogenic pump is

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

CAUTION

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

1.2 Preventing Vapour Lock

The most common method used to remove this condition is to provide enough head
(NPSH) on the pump suction so that the pressure at the inlet of the pump is always
greater than the vapour pressure of the liquid. The term “available NPSH” is the head
pressure available at the required point due either to pressurisation or elevation of the
liquid holder or sub-cooling the liquid. (Sub-cooling meaning cooling liquid below
its normal boiling point at atmospheric pressure). The actual vapour pressure of a
liquid cannot be changed without increasing or decreasing the temperature of the

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liquid. The tendency in a cryogenic system is to continually increase the temperature
of the liquid, thereby increasing the vapour pressure of the liquid. This condition
places further demands on the artificially applied suction pressure (NPSH). The
remaining liquid may have its temperature reduced by allowing the liquid storage tank
to be vented to atmosphere thereby reducing tank pressure.

1.3 Volumetric Efficiency and NPSH

The volumetric efficiency of the positive displacement pump is the percentage of

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

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

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

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

Vapour Pressure Determination

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

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

b. Sub-cooling of the liquid.

c. Pressure increase in the tank.

d. Better insulation of the piping.

e. Reduction of pressure loss in piping.

1.4 Priming

The priming of a positive displacement pump for cryogenic service will vary with
respect to the specific system suction characteristics. It is necessary for an operator to
become familiar with the characteristics of the pump itself and also the system in
order to understand its operation. The cryogenic pump must be chilled down until the
temperature of the metal is the same temperature as the incoming liquid or does not
exceed the temperature of the liquid at its established NPSH. When the pump is
started, the operator should pay very close attention to the discharge pressure rise
which could indicate pump prime. If there is no immediate indication of pumping
action, the pump must be stopped and further chilling should take place. If a small
volume of liquid can be returned to the tank or to the atmosphere in order to
determine pump prime, the starting procedure is much simpler.

1.5 System Variations

The operator should become familiar with the particular system characteristics. A re-
circulation line back to the storage tank may be used, so that the liquid being
circulated does not enter the tank in the suction areas which could cause unnecessary
turbulence and allow gas to be carried into the suction system. During the operation
of a high pressure pump, occasional heat build-up in either pump cylinder or in the
suction line itself may occur. This heat will flow into the pumping liquid, and will
raise the vapour pressure, causing cavitation of the pump, thereby reducing or
stopping performance.

1.6 Precautions

1.6.1 WARNING

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

1.6.2 CAUTION

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

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

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

adequate oil pressure.

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

WARNING

This is a positive displacement pump. If the discharge system is closed off,

extreme pressure may result, therefore, a safety valve should always be included
in the discharge system.

2.0 ROTATION, STARTING AND OPERATION

2.1 Rotation

Pump rotation must be as indicated by rotational arrow. If there is any doubt, remove

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the balance weight cover on the NP 200 and observe the pump connecting rod to
determine the correct rotation. Reverse rotation will not allow proper drive assembly
lubrication and may result in major damage.

CAUTION

The rotation must be as indicated by rotational arrow on the pump crankcase,

otherwise serious damage may occur.

2.2 Pump Start-Up

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

a. Check oil level of the pump.

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

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

2.3 Priming the Pump

Fully open the suction, discharge, by-pass and vent to top of tank valves. The liquid
will flow into the pump through the suction line, and gas will return to the tank
through the vent line. Cooling of the pump will act as a pressure building coil. For
rapid priming of the pump, close the vent to top of tank valve and open the vent to
atmosphere valve.

When frost appears over the pump head and approximately two-thirds of the length of
the cold cylinder, (after cooling time of approximately fifteen minutes of venting to
tank or five minutes when venting to atmosphere) the pump will be cooled down
sufficiently to begin pumping. The suction, discharge, by-pass and vent to top of tank
vales should be open and vent to atmosphere valve should be closed. Start the pump,
liquid will flow through the by-pass valve and back to the tank. The indications that
the pump has primed are as follows:

a. The discharge by-pass line to the tank will begin to frost.

b. A light clicking sound will be heard, indicating that the valves are being operated
by the flow of liquid.
c. A pressure increase will register on the discharge pressure gauge.

Gradually close the by-pass valve, if this becomes completely closed without a
pressure increase, the pump is not primed; in this case re-open the by-pass valve, stop
the pump, and repeat as above. If prime cannot be attained, or if prime is lost while
pumping, it may be an indication of too low a suction pressure. Raise the supply tank

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pressure another 5-10 psi. The pump requires a minimum of 25 psi pressure above
the vapour pressure of the liquid itself.

Once the pump has primed, the head valve positions are:

Suction valve – open

Discharge valve – open
Vent to top of tank valve – open
Vent to atmosphere valve - closed

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

WARNING

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

3.0 HIGH PRESSURE PUMP MAINTENANCE – Refer to Drawing CR187

3.1 Removal of the Cold End

3.1.1 Disconnect suction, vent and discharge lines.

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

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

3.1.4 Using a strap wrench if necessary, unscrew the cold end from the installation.

3.2 Disassembly of Cold End

3.2.1 Unscrew assembled packing nut consisting of retaining ring, scraper adapter,
and scraper, from cylinder and disassemble. (Items 11, 18 and 27).

3.2.2 Relieve jamming pressure of setscrews; then, remove head jam ring (item 19)
from cylinder. Remove setscrews (item 26) from head jam ring.

3.2.3 Remove the discharge fitting (item 20), gasket (item 7), discharge spring (item
1) and poppet (item 15).

3.2.4 Remove pump head (item 25), gasket (item 12), head gasket (item 8), suction
plate (item 22), suction spring (item 3), and (only if required) cylinder sleeve
(item 13) from cylinder.

NOTE The cylinder sleeve is a shrink fit in the body and required rapid heating of the
body to release the sleeve.

3.2.5 Push the piston (item 24) out from the bottom.

3.2.6 Remove the seal ring, hat seals, hat seals spacers and Belleville washer (items
10, 16, 17 and 2)

3.3 Assembly of Cold End

3.3.1 Inspect the disassembled parts thoroughly. Replace all soft goods (seals,
gaskets, rings, hat seals, etc.) and re-assemble in the reverse order as it was
disassembled. Pay particular attention to the torque requirements noted on the
drawing. Special tools are required.

3.3.2 During assembly of the cold end, care should be taken to keep all parts free of
moisture, lubricants and foreign materials.
3.3.3 For satisfactory service, valve seats, piston rings and seals must be free of
nicks or scratches or any foreign material when reassembled.

3.3.4 Assemble piston, with rider rings, piston ring expanders, and piston rings.
The gap in the forward piston ring must be in line with the gap in its
respective piston ring expander. The gap in the aft piston ring, to be 180°
from gap in its respective forward piston ring, and the groups should be
rotated 120° from each other. (Detail C on Drawing CR187).

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3.3.5 Assemble piston with rings and rider rings into ring compressor tool. Press
piston through the chamfered end of tool, until all rings are compressed and
then turn chamber so that the high-pressure end is up. Insert piston and tool
into chamber and press in piston until all rings are through the tool and the
tool located in the top of the cylinder.

NOTE It may be necessary to adjust the fit of the rider rings, before assembling the
piston, as follows – fit one rider ring to the piston and check the fit in the
cylinder sleeve to ensure it is snug. If the fit is too tight remove a small
amount of material from the inside surface of the rider ring with a scraper or
emery cloth and then re-check the fit. Repeat this procedure with both rider
rings until a good snug fit is achieved. A good fit is essential to prevent
contact between the piston and cylinder sleeve.

3.3.6 Remove the tool from the piston. Be careful not to mar the finish on the
piston.

3.3.7 Install suction spring (item 3) and plate valve (item 22) into cylinder sleeve.

3.3.8 Install head gasket (item 8) onto the pump head (item 23) and carefully lower
head into cylinder. Do NOT disturb plate valve or head gasket.

3.3.9 Install poppet (item 15), spring (item 1), wedge seal (item 12) and discharge
gasket (item7).

3.3.10 Carefully lower in discharge fitting (item 20) into cylinder housing. Install
setscrews (item 26) into jam ring (item 19).

NOTE Coat threads with anti-seize compound.

3.3.11 Screw jam ring down until it tightens onto the discharge fitting. Tighten
setscrews to specified torque, tighten evenly in sequence by torquing
diagonally opposite screws.

3.3.12 Release torque on setscrews, retighten jam ring and re-torque setscrews as
above.

3.3.13 Low Pressure Packing End

a. Install Belleville springs, with inside edges together, allowing the outer
diameter to have deflection.

b. Install seal spacers with chamfer outward, in sequence with hat seals,
with lip down as shown on drawing. (Detail B on Drawing CR187).

c. Install seal ring and o-ring.

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3.3.14 Reassemble the packing nut together with its related parts. Install it, and
torque it to 16-18 ft. lbs. (Detail A on Drawing CR187).

3.4 Installation of Cold End Assembly

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

3.5 Head Clearance Adjustment

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

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

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

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

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

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

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

f. Tighten the lock nut.

4.0 LUBRICATION

Ambient Temperature Non-Oxygen Service

-40°F to +45°F SAE 10W

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

The lubrication system is a self-contained design, and is trouble-free if the proper

grade of oil is used. Oil levels should be checked at least once a week to safeguard

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against damage to the drive end. It is recommended that the oil be changed after the
first twenty (20) hours of service. Thereafter the oil should be changed every 500
hours, or once every six (6) months whichever comes first.

5.0 HIGH PRESSURE PUMP TROUBLE SHOOTING

This section contains a brief troubleshooting guide to be used to locate probable

malfunctions.

Trouble Probable Cause Remedy

Failure to prime, loss of prime
while pumping or low flow.
Insufficient suction head.
Verify proper operation of boost
pump and the two related solenoid
valves. If pump and valves operate
satisfactorily, review the section on
NPSP to verify the condition of the
liquid supply.

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Leaking low pressure seals.
Leaking crosshead oil seal.
Excessive drive noise or high drive
temperature.
Excessive drive noise or high
temperature.
Low Discharge Pressure
Vent line closed.
Foreign material in cold end.
Loss of suction pressure.
Dirty filter.
One cylinder not primed.
Worn packing.
Worn seal.
Loss of Oil.
Worn parts.
Overloaded.
Worn or damaged parts.
Insufficient NPSH.
Worn piston rings.
Damaged suction valve.
Damaged discharge poppet.
Insufficient NPSH.
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Open vent valve to tank.
Warm to 150° to 225°F and purge
with dry gas.
Increase pump suction to minimum
of 25 psi over vapour pressure.
Clean suction filter.
Repeat priming procedure. Check
NPSH.
Replace low pressure seals.
Replace oil seal in intermediate.
Drain and replenish oil. Rotate
pump by hand and check for noise
or abnormality of operation.
Reduce discharge pressure.
Discharge system restricted.
Repair drive assembly.
Verify proper operation of boost
pump and check liquid flow by
opening boost pump prime valve
slightly until flow is verified.
Replace piston rings.
Repair valve; relap valve.
Replace poppet.
Verify proper operation of boost
pump system, and check liquid
condition in supply tank.
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