N2 Training Manual

NITROGEN OPERATORS COURSE
MANUAL
TRAINING DEPARTMENT
PRO 101 Process Nitrogen Operators Manual
NITROGEN OPERATORS COURSE ....................................................................................................................1

COURSE INTRODUCTION.....................................................................................................................................7
DOCUMENT AMENDMENT PAGE .........................................................................................................................8
INTRODUCTION ......................................................................................................................................................9
What is Nitrogen? ...............................................................................................................................................9
HISTORY OF N2 IN THE OIL INDUSTRY .......................................................................................................10
BJ SERVICES NITROGEN APPLICATIONS....................................................................................................12
Nitrogen Purging ..............................................................................................................................................12
Helium Leak Detection......................................................................................................................................13
Nitrogen Foam Inerting ....................................................................................................................................13
Pipeline Pigging................................................................................................................................................14
Hot Gas Drying.................................................................................................................................................14
Vacuum Drying .................................................................................................................................................15
Pipe Freezing ....................................................................................................................................................15
Accelerated Cooldowns.....................................................................................................................................16
Clearshot Decoking...........................................................................................................................................16
Gas Lift..............................................................................................................................................................17
D.S.T. Cushion ..................................................................................................................................................18
Nitrogen Displacement .....................................................................................................................................20
Nitrified Treatment............................................................................................................................................20
Atomized Treatment ..........................................................................................................................................20
Foam Treatment................................................................................................................................................20
Foam Cleanout..................................................................................................................................................21
Nitrified Cleanout .............................................................................................................................................21
Differential Perforation ....................................................................................................................................21
Abrasijet Perforating ........................................................................................................................................21
Pressure Testing................................................................................................................................................22
Setting Hydraulic Packers ................................................................................................................................22
Foamed Cement ................................................................................................................................................22
NITROGEN PROPERTIES ....................................................................................................................................23
WHAT IS NITROGEN? ..............................................................................................................................................23
Physical properties of nitrogen.........................................................................................................................23
Critical temperature and pressure ....................................................................................................................23
CRYOGENICS?.........................................................................................................................................................23
NITROGEN SAFETY..............................................................................................................................................25
FIRE AND EXPLOSION HAZARDS ..................................................................................................................25
MATERIAL HAZARDS.......................................................................................................................................25
EFFECT OF TRAPPING LIQUID NITROGEN ..................................................................................................26
HEALTH HAZARDS............................................................................................................................................26
Asphyxia............................................................................................................................................................26
Symptoms of Oxygen Deficiency .......................................................................................................................27
Cold Burns ........................................................................................................................................................27
Frostbite ............................................................................................................................................................27
Effects of cold on lungs .....................................................................................................................................28
Hypothermia .....................................................................................................................................................28
PRECAUTIONS....................................................................................................................................................28
Liquid Nitrogen Spillage...................................................................................................................................31
NITROGEN EQUIPMENT.....................................................................................................................................32
A BJ SERVICES COMPANY
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TRAINING DEPARTMENT
MINOR ITEMS .........................................................................................................................................................32
Hoses.................................................................................................................................................................33
Treating Iron.....................................................................................................................................................34
Field Iron Colour Code Chart ..........................................................................................................................35
Plug Valve .........................................................................................................................................................37
CONNECTED N2 TREATING IRON AND EQUIPMENT................................................................................37
Typical Weco and Chiksan equipment recommended temperature ranges ......................................................39
Hot Iron Package ..............................................................................................................................................40
Relief Valves......................................................................................................................................................41
Gauges ..............................................................................................................................................................41
Chart Recorders................................................................................................................................................42
Fittings ..............................................................................................................................................................43
Fitting Do's and Don'ts .....................................................................................................................................44
Gauge Connections and Cross-Overs...............................................................................................................44
Autoclave Fittings .............................................................................................................................................44
Check valves......................................................................................................................................................45
Manifolds ..........................................................................................................................................................46
Whip checks and tie down material ..................................................................................................................47
MAJOR ITEMS..........................................................................................................................................................47
Liquid Nitrogen Storage Tanks .........................................................................................................................47
Positioning Equipment......................................................................................................................................48
Offshore Set up..................................................................................................................................................49
Land Set up .......................................................................................................................................................49
Cryogenic Hoses ...............................................................................................................................................50
System Cooldown ..............................................................................................................................................51
Preparing tanks for Decanting .........................................................................................................................54
Mobile Storage Vessels or Nitrogen Bulkers (MSV's).......................................................................................56
Ambient Vaporiser ............................................................................................................................................57
Steam Vaporiser................................................................................................................................................57
DIRECT OR INDIRECT FIRED VAPORISER .................................................................................................................58
FLAMELESS VAPORISER ..........................................................................................................................................59
Nitrogen Pump Unit ..........................................................................................................................................60
LIQUID NITROGEN CONVERTER PRINCIPLE OF OPERATION.....................................................................................61
EMERGENCY SHUTDOWN SYSTEMS FOR DIESEL POWERPACKS ................................................................................62
NITROGEN PUMP TRUCK.........................................................................................................................................64
PROCESS SERVICE NITROGEN CALULATIONS ..........................................................................................66
WORKED EXAMPLE ................................................................................................................................................67
Gas Usage.........................................................................................................................................................68
OPERATING PROCEDURES ...............................................................................................................................70
LIQUID NITROGEN STORAGE TANKS...........................................................................................................70
Introduction.......................................................................................................................................................70
Description........................................................................................................................................................70
Description Of The Components Of The Plumbing ..........................................................................................71
Valve Positions During Transit And Yard / Worksite Storage..........................................................................73
Initial Cooling ("Purge", "Cool-down" and "Fill") .........................................................................................73
Filling a "Cold" Liquid Supply Tank ................................................................................................................75
Pressure Building..............................................................................................................................................76
Liquid Level ......................................................................................................................................................77
General Storage ................................................................................................................................................77
Maintenance......................................................................................................................................................78
ELEVATIONS OF LIQUID NITROGEN TANKS ..............................................................................................80
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TRAINING DEPARTMENT
ZWICK NITROGEN UNITS OPERATING GUIDELINE ..................................................................................82
Nitrogen Cool-down and pumping....................................................................................................................83
Boost pump loss of prime ..................................................................................................................................84
SYE NITROGEN UNITS OPERATING GUIDELINE........................................................................................85
Cool-down and pumping...................................................................................................................................86
HYDRARIG 180K UNITS OPERATING GUIDELINE......................................................................................88
Nitrogen cool-down and pumping.....................................................................................................................89
PRIOR DIESEL SPLIT PIECE PUMPS (180K) OPERATING GUIDELINES ..................................................91
Nitrogen Cool-down and pumping....................................................................................................................93
FIRED UNITS ZWICK 240K (UNIT 110) OPERATING GUIDELINE.............................................................95
Nitrogen cool-down and pumping.....................................................................................................................96
Loss of boost pump prime .................................................................................................................................98
FIRED HP UNITS 90K (UNIT 101) OPERATING GUIDELINE......................................................................99
HEATER WARM-UP.......................................................................................................................................100
Engine RPM - WARNING:..............................................................................................................................100
NITROGEN COOL-DOWN AND PUMPING.................................................................................................101
Loss of boost pump prime ...............................................................................................................................103
UNIT 103 (OPEN FIRED) ..................................................................................................................................104
HEATER WARM-UP.......................................................................................................................................105
NITROGEN COOL-DOWN AND PUMPING.................................................................................................106
Loss of prime...................................................................................................................................................108
ELECTRIC UNITS (MEV II) OPERATING GUIDELINE ...............................................................................109
Prestart Checks ...............................................................................................................................................109
Power On Guidelines ......................................................................................................................................109
Preparation for nitrogen flowing ....................................................................................................................110
Nitrogen flowing guidelines ............................................................................................................................111
Stabilising flow................................................................................................................................................112
Shut down procedures.....................................................................................................................................112
AMBIENT VAPORISERS (UNIT SFV 15 & 16) OPERATING GUIDELINE ................................................113
RIG UP............................................................................................................................................................114
STEAM VAPORISERS OPERATING GUIDELINE ........................................................................................115
OPPS - MECHANICAL SHUTDOWN PANEL ................................................................................................116
EQUIPMENT DESCRIPTION........................................................................................................................116
GENERAL OPERATION OF PANEL .............................................................................................................118
OPPS Set –up procedure.................................................................................................................................119
Gauge Connections and Cross-Overs.............................................................................................................120
Operation ........................................................................................................................................................121
OPPS CALIBRATION .............................................................................................................................................122
Calibration method for settings below 150Barg .............................................................................................122
Calibration method for settings above 150Barg.............................................................................................123
Maintenance of Panel .....................................................................................................................................124
OPPS tie in point selection .............................................................................................................................124
OFFSHORE FUNCTION TEST......................................................................................................................125
EMOS - ELECTRONIC MANAGEMENT OVERPRESSURISATION SYSTEM...........................................127
DESCRIPTION OF THE COMPONENTS .....................................................................................................127
INTRODUCTION............................................................................................................................................129
TECHNICAL DESCRIPTION........................................................................................................................130
Pressure Transducer rig-up ............................................................................................................................133
Temperature Transducer.................................................................................................................................133
OPERATION...................................................................................................................................................134
PRESSURE AND TEMPERATURE ALARM DISPLAY SETTING.................................................................135
PRESSURE OR TEMPERATURE L.C.D DISPLAY .......................................................................................136
PRESSURE ALARM SETTING .......................................................................................................................137
TEMPERATURE ALARM SETTINGS ............................................................................................................138
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TRAINING DEPARTMENT
GENERAL INFORMATION............................................................................................................................138
EMOS UNIT - SIDE VIEW .............................................................................................................................144
EMOS - INSIDE UNIT....................................................................................................................................145
3GP SYSTEM .........................................................................................................................................................148
3GP PRINCIPLE OF OPERATION ...................................................................................................................148
Concept ...........................................................................................................................................................148
3GP Philosophy ..............................................................................................................................................148
GAS DETECTION ...................................................................................................................................................149
Overspeed Detector.........................................................................................................................................150
Gas Detection Principle..................................................................................................................................151
TYPICAL SINGLE ENGINE INTERCONNECTIONS .....................................................................................................152
Equipment .......................................................................................................................................................153
Gas Sensing Head (mounted in inlet tract) .....................................................................................................154
REGULATOR SETTING............................................................................................................................................155
OPERATING ..........................................................................................................................................................156
Start-up ...........................................................................................................................................................156
Stopping the Engine ........................................................................................................................................157
ENGINE TROUBLESHOOTING GUIDE ..........................................................................................................163
NITROGEN PUMPING SYSTEM TROUBLESHOOTING GUIDE ................................................................169
TANK TROUBLESHOOTING GUIDE .............................................................................................................172
EMOS - TROUBLESHOOTING ........................................................................................................................173
NITROGEN EQUIPMENT SCHEMATICS .......................................................................................................175
NITROGEN TANK - SCHEMATIC...................................................................................................................177
BULKER SCHEMATIC .....................................................................................................................................178
NITROGEN TRANSPORT SCHEMATIC LEGEND UNIT # 2724B & 2725B ................................................................179
NITROGEN UNIT - MAIN COMPONENTS ....................................................................................................180
NITROGEN UNIT - TYPICAL CONTROL PANEL.........................................................................................180
Nitrogen Pump Unit – Cryogenic Schematics ................................................................................................181
N2 PUMPER SCHEMATIC .......................................................................................................................................184
WELL SERVICE NITROGEN CALCULATIONS............................................................................................185
1 GAS LIFT DESIGN. ..................................................................................................................................186
2 D.S.T. CUSHION DESIGN. ......................................................................................................................188
3 DISPLACEMENT DESIGN........................................................................................................................195
4 NITRIFIED TREATMENT DESIGN. .........................................................................................................196
5 FOAM CLEANOUT DESIGN. ..................................................................................................................197
6 NITRIFIED CLEANOUT DESIGN. ..........................................................................................................199
EXPLANATION OF CALCULATIONS............................................................................................................201
NITROGEN EQUATIONS ..................................................................................................................................210
1 GAS EQUATIONS......................................................................................................................................210
2 COMPRESSIBILITY FACTOR (Z) FOR NITROGEN GAS .......................................................................211
3 NITROGEN VOLUME FACTORS............................................................................................................212
4 HYDROSTATIC PRESSURE OF A STATIC COLUMN OF NITROGEN GAS ........................................213
NITROGEN FLOW BACK RATIOS................................................................................................................214
BOC SITING OF MSV’S.......................................................................................................................................215
APPENDIX 1 FLANGE RATINGS......................................................................................................................219
APPENDIX 2 COLDER PRODUCTS FITTINGS INFORMATION...............................................................222
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TRAINING DEPARTMENT
APPENDIX 3 N2 PUMPER EDMONTON..........................................................................................................223
APPENDIX 4 N2 TRANSPORT EDMONTON ..................................................................................................224
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TRAINING DEPARTMENT
COURSE INTRODUCTION
The intention of this manual is to introduce the delegates to BJ PPS nitrogen

operations.
This course is designed to give candidates a basic knowledge of the techniques and
terminology that they will encounter in the course of nitrogen operations. It is also
essential that candidates are aware of all the safety aspects and requirements
involved in these operations. This will lead to the delegate performing their
allocated task in a safe and professional manner so as ensuring that a safe and
effective operation takes place.
It has to be noted that courses such as these can only take the candidate so far.
There is no substitute for practical exposure to gaining experience.
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TRAINING DEPARTMENT
DOCUMENT AMENDMENT PAGE
NOTE Amendments to this document shall be recorded on this amendment log. Superseded
: pages will be removed, destroyed and replaced by the revised pages which shall in all
cases include this page.
REV: AM'D PAGE: DETAILS OF AMENDMENT: APP' DATE:
NO: L
BY:
One - - Initial Draft For Comments MQ Jan 97
Two One All Incorporated Comments From BJ PPS MQ Mar 97
Three Two All Well Services Applications Included MQ Mar 97
Four Three All Well Services N2 Calculations Included MQ Apr 97
Five Four All Revised document for up-date DS Jan 99
Six Five - Revised OPPS & EMOS Rig up DS Dec 00
Seven Six All Tidy up pages, amend N2 Tank Dr. etc IJ April 02
Eight seven Appendix Add BOC Information on MSV Siting IJ Jan 04
2
Nine Nine Add 3GP Information IJ Apr 05
Ten Ten Change layout of volume calculations IJ Apr 05
Eleven Eleven 76 Add Prior Diesel Split Piece Pump Detail EM Jan 06
Twelve Twelve All Convert to include PPS Canada material IJ + Jan 06
Page 8 of 224
TRAINING DEPARTMENT
INTRODUCTION
When Duke Bloom first introduced gaseous Nitrogen to the oil and gas industry in 1955, few
people realised that so many uses would develop for this common gas.
What is Nitrogen?
Nitrogen or N2 , is the chief gas in the air. It forms about 78% of the air by volume, or 75% by
weight. Almost all the rest is oxygen.
Nitrogen 78.0%
Argon 0.9%
Other Gases 0.1%
Oxygen 21.0%
Nitrogen is one of over a hundred known chemical elements. An element being "a chemically
pure substance containing molecules of only one type". Some elements are found naturally as
gases, others as solids, and only Mercury as a liquid. Nitrogen is found only as a gas under
ambient conditions. Hydrogen, oxygen and helium are other commonly known elements which
are found naturally as gases. When it was discovered, in 1772, nitrogen was one of the first
gaseous elements to be isolated. Now it is known as the most common gas on earth, and
generally inert (meaning that it does not easily combine chemically with other elements).
Methods of producing nitrogen may be grouped into two classes; separation from the
atmosphere, and decomposition of nitrogen compounds in nature. The most common industrial
method of producing nitrogen is to fractionally distil liquid air. This is carried out in a
fractionating tower using a similar process to that used for separating the different products
found in crude oil. Another method of obtaining nitrogen from air is to chemically remove all
the oxygen, carbon dioxide and water, leaving essentially only nitrogen as the residue.
Canada produces over ten million tonnes of nitrogen each year. The fertiliser industry is the
largest consumer. Large amounts of nitrogen are also used by the electronics industry, which
uses the gas as a blanketing medium during the production of such components as transistors
and diodes. Large quantities of nitrogen are used in annealing stainless steel and other steel mill
products. Nitrogen is used as a refrigerant, both for the immersion freezing of foods and during
the transportation of food products.
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TRAINING DEPARTMENT
Liquid nitrogen is used in missile work for purging components and insulating space chambers.
It is also used extensively in the oil, gas and petrochemical industries.
BJ Services uses nitrogen for purging, leak testing and pressure testing gas plants, along with a
surfactant water mixture for producing nitrogen foam, as a propellant for pigging operations, for
packing systems after drying and in liquid form for pipe freezing.
Liquid nitrogen is lighter than water. One litre of water weighs 1.0 kg whereas one litre of
liquid nitrogen (LN2) weighs only 0.809 kg.
Gaseous nitrogen is lighter than air. At 20oC, 1m3 of air weighs 1.205kg whereas 1m3 of
Nitrogen weighs 1.165 kg, to give a specific gravity (to air) of 0.967. However this only applies
to warm nitrogen gas. Cold nitrogen gas (-196oC) is nearly four times as heavy. This fact must
be taken into consideration when working alongside nitrogen pumping equipment as cold
nitrogen gas will collect in low voids when venting from storage tanks.
HISTORY OF N2 IN THE OIL INDUSTRY
In few industries have so many different persons claimed to have been the originators of new
applications or techniques as in the oil and gas industry. The uses of Nitrogen are no exception,
research of technical literature has resulted in the following list of "firsts".
1772
Gaseous nitrogen was discovered by Daniel Rutherford, a Scottish physicist, and independently
by the Swedish chemist, Karl Wilhelm Scheele. Scientists were subsequently unable to liquify
this new gas for over a 100 years.
1883
Nitrogen was liquified by Wroblewski and Olszewski by the application of combined
compression and refrigeration to temperatures below -147oC.
1955 March
Nitrogen was introduced to the oil industry by Duke Bloom of Bloom Aircushion Corporation
of Bakersfield, California. A "tube transport" , which was a truck carrying tiers of high pressure
nitrogen cylinders, was used to supply gaseous nitrogen to cushion a drill stem test in the Arvin
Field, California. A new industry was born.
1957 June-November
A liquid nitrogen pump and vaporiser system was developed in a Cambridge, Massachusetts
laboratory to operate at 10,000psi. Design considerations for larger pumps were proven
technically feasible.
September 7, 1959
John F. (Spi) Langston of Denton Spencer Company introduced the first use of nitrogen to the
Canadian oilfield industry, using tube trailers to supply nitrogen in conjunction with a 500
gallon acid job for United Canso in Hoosier, Saskatchewan.
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TRAINING DEPARTMENT
1959
Paul Duron, an engineer from California, built the first high volume liquid nitrogen pump. This
pump was subsequently manufactured by Airco Cryogenics. Although larger pumps are now
available, the basic design remains essentially unchanged today.
1960 July
Bloom introduced the first liquid nitrogen unit, using an insulated liquid tank, a cryogenic pump
and a vaporiser. This same type of equipment had been in use since 1946 for liquid oxygen
("Cascade System" for hospital bottle refill), but had not been used for nitrogen.
1970 Approximate
World's first foam frac using a process developed by Roland Blauer, then a student at the
Colorado School of Mines. Blauer claims that the first job was performed in the Rocky
Mountains area of Colorado, USA using Dowell pumping equipment and Air Products to supply
the nitrogen. BJ Services claims that the first job was performed for East Ohio Gas with
Halliburton pumping and BJ Services on the nitrogen. In either case it is apparent from this
writers observations that the process was originally conceived and documented by Blauer.
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TRAINING DEPARTMENT
BJ SERVICES NITROGEN APPLICATIONS

Gaseous or liquid nitrogen plays a major part in most of the services carried out by BJ Services
and hence is a very important part of our operations. For new employees, Nitrogen Pumping is
probably the first skill that anyone will obtain and knowledge of this is important throughout the
whole of BJ Services 's operations.
The following PROCESS services all utilise nitrogen:-

Nitrogen Purging
Nitrogen, being inert, can be used to displace an atmosphere of unwanted composition (eg
potentially explosive), replacing it with an atmosphere of desired composition, an unreactive
nitrogen blanket.
Nitrogen purging can be used in various industrial process systems but within the oil, gas and
petrochemical industry it is normally used to commission or decommission process systems.
Commissioning involves the removal of air (oxygen) from a process system prior to the
introduction of hydrocarbons in order to avoid a potentially explosive mixture at the
hydrocarbon air interface. Decommissioning is the removal of hydrocarbons prior to opening
up systems to atmospheric air, again avoiding the formation of an explosive mixture.
Various types of purge can be carried out on a process system and these are governed by a
number of variables - composition of the unwanted atmosphere, pressure rating of the system,
system configuration and nitrogen usage.
Vacuum Cycle Purging

The unwanted atmosphere is removed with the use of a vacuum pump and the system is back
filled with nitrogen to atmospheric pressure, or slightly above. Vacuum cycle purging uses the
lowest volume of nitrogen however the system has to be able to be evacuated and the
atmosphere cannot be highly reactive.
Displacement Purging
Nitrogen is pumped through the system slowly to avoid mixing and is vented continuously from
a discharge point as far as possible from the point of gas injection. The system is maintained at
atmospheric pressure or very slightly above throughout the operation. Displacement purging is
good for simple systems such as pipelines where interface between purge gas and the unwanted
atmosphere is small (relatively little mixing occurs). It is not suitable for complex systems.
Dilution (Pressure Cycle Purging)

Nitrogen is pumped at a high flow rate into a closed system producing maximum mixing.
System pressure is increased to a predetermined level, left to stabilise and
then vented off. This is then repeated until the required atmosphere is obtained. Pressure cycle
purging is ideal for complex process systems.
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TRAINING DEPARTMENT
Helium Leak Detection
Helium at a concentration of approximately 1% is mixed with the injection stream of nitrogen

and used to pressurise process systems to 90-95% of their design pressure.
All potentially leaking joints are taped with coloured adhesive tape to avoid leaking test gas
from being blown away from the leaking joint and to aid system identification. A remote probe
is then used to sample the gas beneath the tape.
The sample probe is attached to a helium mass spectrometer which is used to quantify the
concentration of helium beneath the tape and establish the leak rate from that joint.
The nitrogen and helium mix is used as it closely simulates the hydrocarbon gas that will be
present in the system once it is commissioned.
Nitrogen Foam Inerting
Nitrogen gas is blown through a wire gauze, onto which a mixture of water and surfactant has
been sprayed. This produces a stream of nitrogen foam. The nitrogen foam can be used for
filling systems with a visible form of nitrogen gas creating inert conditions. This enables hot
cutting to be carried out on pipework or vessels which have previously contained flammable
hydrocarbon liquids or gases.
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TRAINING DEPARTMENT
Pipeline Pigging
Nitrogen can be used as a propellant for running individual pigs or pig trains used for cleaning,
gauging, commissioning or dewatering. Nitrogen is pumped into the system behind the pig
producing the differential pressure required in order to move the pig or train along the line.
Nitrogen can also be used in the form of a slug between two pigs as an integral part of a drying
or commissioning train.
Hot Gas Drying
Liquid nitrogen as supplied has a certified dewpoint of approximately -70oC (very dry) hence
nitrogen can be used as a drying agent. For hot gas drying nitrogen is pumped through the
system at a high flow rate and an elevated temperature (temperatures in excess of 100oC are
attainable using a steam vaporiser or pump truck). Water evaporates from within the system and
is transported by the flow of gas and expelled from the system at the vent point.
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TRAINING DEPARTMENT
Vacuum Drying
On completion of vacuum drying operations when the required dew-point has been attained, gas
pipelines or process systems are usually packed with a dry inert nitrogen blanket. Nitrogen is
pumped into the system to obtain a slightly positive pressure or alternatively it is used to
pressurise the line to a pressure close to its working pressure prior to the introduction of
hydrocarbons.
Pipe Freezing
Various forms of pipe freezing are carried out but most in the oil, gas and petrochemical
industry utilise liquid nitrogen in one form or another. The most basic form of pipe freeze is the
direct contact method where liquid nitrogen is poured directly over the pipework. Using this
method the pipework sees temperatures of -196oC so it is only applicable for low temperature
stainless steel lines.
The second method utilises an aluminium jacket or freezing coil which is placed around the
pipe, liquid nitrogen is then passed through the coil or jacket. This method is still relatively
uncontrollable with the inlet side of the system seeing temperatures close to -196oC and the
outlet relatively higher temperatures. The controllability of this system can be improved by
utilising cold gaseous nitrogen rather than liquid.
The third method utilises a secondary refrigerant which is cooled by liquid nitrogen using a heat
exchanger and then the secondary refrigerant is pumped through the freeze jacket. This method
is very suitable for subsea freezing.
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TRAINING DEPARTMENT
Accelerated Cooldowns
There are several different types of accelerated cool-downs that are conducted on various
different vessels in plants. The most common type of accelerated cool-downs are conducted
using nitrogen gas as the cooling medium. This type of cool-down is done by pumping the
nitrogen gas through the customers system at a specified rate and temperature until the vessel
reached the required conditions.
Accelerated cool-downs are one of the few nitrogen application in which the nitrogen gas
temperature will be pumped below 0oC. The nitrogen injection rates and temperatures for these
applications are specified by the engineer designing the job. The rates and temperature used will
vary throughout the course of the pumping operation.
Other types of accelerated cool-downs that require the use of nitrogen include; Hybrid ACD’s
using a mixture of CO2(Liq) and N2(Gas) or Liquid N2 cool-downs which are conducted by
injecting liquid nitrogen into a gas stream.
Clearshot Decoking
This service is used to remove deposits form the inside of piping systems by using high velocity
nitrogen to suspend abrasive particle in the flow. The abrasive and N2 mix is then injected
through the system to be de-coked and caught in a vessel at the outlet of the system. This service
will be engineered prior to start to estimate what the required Nitrogen injection rates and
abrasive loading in the nitrogen flow will be. The following illustration shows the typical layout
for a Clearshot operation:
Tailpipe Water line
Injector head
Effluent
Customer’s bin
system Clearshot skid
Abrasive line
Nitrogen line
Nitrogen Bulker
Liquid nitrogen Purge hose
transfer hose
Treating Iron
Nitrogen Pumper
Hard pipe
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TRAINING DEPARTMENT
The following WELL services all utilise nitrogen:-
Gas Lift
This term is used to describe the displacement of fluid from a well by circulating gas.
This process is also known as a "Kick-Off" or "Fluid Lift".
Gas lifts are carried out in one or two manners, either down the tubing and up the annulus or down
the annulus and up the tubing.
Gas lifts down the tubing are generally out using a temporary inner string - Coiled Tubing or small
diameter work-over string - which is run through the production tubing.
Gas lifts down the annulus are normally carried out through circulating sleeves in the production
tubing in a similar way to permanent Gas Lift through Gas Lift mandrels. With wells that are
producing at a low FWHP, if they are closed in they quite often will not flow when opened up
again. In this situation it is quite economically desirable to fit
circulating valves or sleeves to production tubing.
For our purposes the most common form of gas lift we are likely to encounter is through coiled
tubing.
Coiled tubing gas lifts are carried out by running the coiled tubing string to around 70% of the well
depth while pumping nitrogen at a low rate, usually 250 scfm. On reaching the depth the N2 rate is
increased to around 800-1500scfm.
Pumping while running in the hole serves several purposes. Coiled tubing is prevented from
collapsing, pressure at circulating depth is reduced, returns are more consistent and excessive
slugging is reduced. Pumping at higher rates whilst running in the hole is avoided to prevent
nitrogen wastage rather than for any technical reason.
When on depth N2 efficiency is increased so rate is increased to speed up the lift process. There is a
maximum rate which is most efficient, this is difficult to determine without excessive calculation. It
is usually sufficient to estimate a suitable rate from experience. For a guide you can double the
diameter and add two 0's i.e. 2.375" tubing - 500scfm, 4.5" tubing - 900scfm and 7" tubing -
1400scfm.
It is important to note that pumping at too high a rate may cause so much friction that no lifting is
accomplished.
One further problem may be encountered while carrying out gas lifts in large diameter deviated
holes is when the fluid is bypassed by the gas passing up the hole, this is known as slippage.
Normally in a gas lift the fluid is displaced up the tubing in a piston like manner and little by pass
occurs. However large diameter tubing lying nearer the horizontal, the fluid tends to lie on the low
side allowing the gas to pass unhindered up the tubing. The is best remedied by using a larger inner
string, or by using foam or gel slugs to change the rheology of the fluid being lifted.
Page 17 of 224
TRAINING DEPARTMENT
PRODUCTION
GAS
GAS LIFT COILED
TUBING
COMPLETION GAS LIFT
THROUGH
NITROGEN GAS COILED

CIRCULATED
TUBING
GAS LIFT
THROUGH
VALVES COILED TUBING
FLUID LEVEL
JETTING NOZZLE
PACKER
FORMATION FORMATION
FORMATION FORMATION
D.S.T. Cushion
Drill Stem Cushions are run to provide a controllable reduction of pressure at the formation for the
temporary completion. The test used to be run using only a water cushion above the test valve
which determined the drawdown pressure on the formation when the valve was opened. This
pressure is seen at the formation as soon as the valve is opened causing potential formation damage
and a very unstable uncontrollable situation.
By placing a small cushion of water above the valve we can fill the air space above the water
cushion with nitrogen gas at pressure.
N2 pressure can then be bled off at surface after the test valve is opened allowing the drawdown on
the formation to build up gradually.
Calculation of the volume of the N2 required is generally the only item required by the client.
Page 18 of 224
TRAINING DEPARTMENT
TO N2 CONVERTER
9 5/8" CASING TEST STRING
D.S.T. STRING
SEA WATER
PRIOR TO
MUD
MUD
N2 CUSHION
CIRCULATING
VALVE CLOSED
TEST VALVE
CLOSED RETRIEVABLE
PACKER
T.C.P. GUNS
FORMATION FORMATION
MUD
MUD
TO N2 CONVERTER
PRESSURIZED TO N2 CONVERTER
N2 GAS BLED DOWN SLOWLY

MUD
MUD
COMMENCEMENT
MUD
MUD
EFFECT
OF OF
PRESSURIZED N2 GAS
D.S.T. STRING D.S.T. STRING

N2 CUSHION N2 CUSHION
SEA WATER
SEA WATER
SEA WATER
SEA WATER
OIL
CIRCULATING CIRCULATING
VALVE OPEN VALVE CLOSED
TEST VALVE TEST VALVE

MUD
MUD
MUD
MUD
CLOSED RETRIEVABLE OPEN RETRIEVABLE

PACKER PACKER
OIL
T.C.P. GUNS PERFORATED JOINT

T.C.P. GUNS ACTIVATED
FORMATION FORMATION FORMATION FORMATION

MUD
MUD
Page 19 of 224
TRAINING DEPARTMENT
Nitrogen Displacement
Displacement of treatment fluids by nitrogen is carried out to help with rapid flowback and cleanup
or to prevent other fluids from entering the formation.
Acid treatments are commonly displaced in this fashion for both the above reasons as over
displacement can be accomplished without pumping damaging fluid into the formation and on
completion of displacement the fluid will flow back rapidly as soon as the well is opened at surface.
Calculations for displacements are usually required by the client from the operator.
Nitrified Treatment
Nitrified treatments are performed by injecting N2 into the well at the same time as the treatment
fluid.
Nitrified acid is the most common form of this treatment and is generally carried out at 400 - 1000
scf/bbl of acid.
The greatest advantage of Nitrified treatment is in the accelerated flow back, and when used in
conjunction with a nitrified displacement or nitrogen displacement, removes the need for
bringing back wells by swabbing or gas lift.
Other benefits are greater treatment penetration, acid retardation, reduced leak off into the formation
of treatment fluid and greater treatment efficiency.
Friction and WHP - BHP calculations will be requested by the client.
Atomized Treatment
Atomized Treatments are performed to allow small quantities of concentrated treatment fluid to be
forced deep into the formation. The advantage to this is the reduction of damaging water being
pumped into the formation.
Acid and Corrosion Inhibitor treatments are the most commonly performed. In both cases an
atomizer is used to finely divide the fluid into very small drops similar to an aerosol spray.
Nitrogen to fluid ratio is calculated at downhole pressure and is generally from 2:1 up to 5:1.
Foam Treatment
Acid is the most common form of foam treatment and is generally pumped into the formation at a
Gas - Fluid Ratio of 7 : 3. This is normally expressed as a percentage, in this case 70% foam
quality, means 70% N2 to 30% Fluid.
The advantage of using foam treatments are similar to those for nitrified acid. In particular the acid
is able to penetrate deep into the formation as the small bubbles act to retard the acid, preventing it
from spending too fast. In addition it has good fluid loss properties and has good flowback
characteristics. Special foaming agents are required to foam the acid, the details of which can be
found in the stimulation manual.
Page 20 of 224
TRAINING DEPARTMENT
Calculations are required to determine the N2 : Acid ratio to obtain 70% F.Q. at Bottom Hole
Temperature and Pressure. In addition it is also possible to calculate the hydrostatic gradient of a
column of foam.
Foam Cleanout
Foam Cleanout are the process used to clean out well bores in gas wells with relatively low BHFP's.
Coiled Tubing is run to fill depth and the well circulated to foam with a choke on the annulus to
control the circulating pressure in the well.
Foam Qualities of 60 - 70% are generally used. Because Foam contains N2 which is compressible,
the hydrostatic pressure gradient profile is quite complex. Friction pressure is an important factor as
the foam starts to expand on its return journey to surface.
Nitrified Cleanout
The nitrified cleanout is a variation on the foam cleanout, ie. there is reduced hydrostatic circulation.
Foam cleanouts are only used in Gas Wells, due to foam breakdown by hydrocarbons in oil wells,
while nitrified cleanouts may be used in both types of well.
Nitrified cleanouts can either take the form of N2 and gel slugs alternately. The advantage of
pumping gel and N2 slugs is that the efficiency of the gel cleanout is combined with the reduced
hydrostatic of introduced N2 slugs. This option is popular in low pressure oil and gas wells where a
full column of water cannot be supported by the formation.
Differential Perforation
Differential Perforation of the formation is performed to reduce the hydrostatic head of fluid that
will exert pressure on the formation once it is perforated.
This is similar to D.S.T. cushions. In both cases it is beneficial top be able to control the pressure
exerted on the formation.
The procedure is to circulate out the fluid from the production tubing either with C.T. or a
circulating sleeve. Then adjust the N2 pressure until 500 - 1000psi. drawwdown is
achieved at the formation.
When the perforating guns are fired the perforating debris is ejected by the well fluid thus
preventing completion fluid from entering the formation and causing damage.
Calculation is required to determine the amount of N2 required to exert a given pressure at the
producing interval, as in the N2 calculations.
Abrasijet Perforating
Abrasijet perforating is carried using sand laden fluid discharged from a nozzle under pressure. The
result is to cut a hole in the casing cement and into the formation.
The addition of 200scf of N2 per barrel of fluid will improve penetration by 100%. Higher N2 levels
only increase friction and thus will serve no purpose.
Page 21 of 224
TRAINING DEPARTMENT
Pressure Testing
Nitrogen can be used to pressure test completions and other tubular goods.
Pressure testing of tubulars usually takes place in conjunction with D.S.T. cushions or differential
perforating cushions.
Calculations in these cases are the same as those required for cushions using N2 gradient tables and
scf/bbl.
Setting Hydraulic Packers
Setting hydraulic packers usually takes place in conjunction with running completions and
perforating underbalanced. A water cushion is usually left in the tubing and a ball dropped to set
the packer. Then pressure up on the ball to set the packer. N2 pressure can then be adjusted for
perforating underbalanced.
Foamed Cement
The purpose of foamed cementing of primary casing is to reduce the hydrostatic of the cement
column to prevent lost circulation while at the same time providing a strong support for the casing.
It is possible to more than halve the weight slurry with a reduction in strength approximately
proportional to the weight reduction. Other weight reduced systems do not provide the quality and
strength for a given weight that can be obtained using foamed cement systems.
Calculations for a foamed cement job are quite complex and are performed by taking the casing
hole annulus and dividing it into many stages eg. 250 ft. N2 compression and thus relative N2 to
slurry rate can be calculated on this premise.
Page 22 of 224
TRAINING DEPARTMENT
NITROGEN PROPERTIES
WHAT IS NITROGEN?
In its normal state (at 20oC and 1013 mbA), it is a gas.
• colourless
• odourless
• non toxic or irritating
• pure
• dry
• inert
- does not burn or support combustion
- does not support life functions
• poor conductor of heat
Physical properties of nitrogen
(at atmospheric pressure)
Boiling point -196oC

Specific Gravity (relative to water) 0.81
Gas density at 20oC (relative to air) 0.97
Gas density at -196oC (relative to air) 3.8
Expansion ratio (liquid to gas) 696 to 1
Critical temperature and pressure
• Critical temperature
• The temperature above which a gas cannot be liquefied by pressure alone
• (Nitrogen = -147oC)
• Critical pressure
• The pressure required to liquefy gas at its critical temperature
• (Nitrogen = 34.5 barg)
CRYOGENICS?
The field of science that deals with processes and technology of extremely cold materials is
called "Cryogenics". The upper limit of temperature usually accepted in cryogenics is -100oC
which, by comparison, is considered colder than dry ice (solid carbon dioxide) at -78oC.
All liquids that have a boiling point below -100oC, are known as cryogenic liquids. Liquid
nitrogen at -196oC, is one of these. Due to the extremely cold temperature of liquid nitrogen,
only certain materials' molecular structures can withstand them.
Page 23 of 224
TRAINING DEPARTMENT
Normal carbon steel will embrittle at only -40oC. Liquid nitrogen if exposed to it, will shrink it
so fast that it separates. This being comparable to the way that glass "explodes" when engulfed
in fire. The outside of the glass expands more rapidly than the inside which causes the material
to separate. When this occurs, any sudden shock could cause the material to break like glass.
The rocket industry is largely credited for the development of the portable cryogenic equipment
required for nitrogen service as we know it today. It was in this industry that new techniques for
storing and handling ultra cold liquids on a large scale were devised. In 1960, the use of the
high pressure cryogenic pump, in connection with liquid nitrogen, opened the door to new areas
of service in the petroleum industry.
Most of the components of nitrogen pumping units (e.g. engine block and crash frame) are
constructed of materials which cannot withstand cryogenic temperatures. Do not expose these
components to extreme cold. Most construction materials are adversely affected by extreme low
temperatures. It is imperative that the components engineered for use in cryogenic service be
chosen from suitably approved materials.
NON-CRYOGENIC MATERIALS NON-CRYOGENIC COMPONENTS
1. Carbon Steels 1. High Press, Treating Iron

2. Low Alloy Steels 2. Cryogenic Tank Casing
3. Most Rubbers 3. Hydraulic & HP Treating Hoses
4. Most Plastics 4. Structural Components
CRYOGENIC MATERIALS CRYOGENIC COMPONENTS
1. Stainless Steel 1. Inner Vessel of N2(Liquid)Tank

2. Stainless Steel 2. N2(L) High & Low Pressure Piping
3. Aluminium 3. Ambient Vaporiser Fins
4. High Nickel Steels 4. HP Piping to Vaporiser
Page 24 of 224
TRAINING DEPARTMENT
NITROGEN SAFETY
FIRE AND EXPLOSION HAZARDS
Neither gaseous nor liquid nitrogen are flammable and do not in themselves constitute a fire or
explosion risk. However, both gaseous and liquid nitrogen are normally stored under pressure
and the storage vessels, whether gas containers or liquid tanks, should not be located in areas
where there is a high risk of fire or where they may normally be exposed to excessive heat.
Containers containing compressed gaseous nitrogen may rupture violently if overheated as a
result of exposure to fire.
At constant pressure the boiling point of liquid nitrogen is lower than that of liquid air therefore
air will condense on the external surfaces of vessels or pipework containing liquid nitrogen.
The liquid air produced can result in oxygen enrichment of the atmosphere local to the
equipment. Special precautions must therefore be taken with regard to the insulation of the
vessel before any maintenance or repair work is started, particularly where the use of open
flames or other potential sources of ignition is intended.
MATERIAL HAZARDS
Certain steels such as carbon steel and some other materials are unsuitable for service at sub-
zero temperatures because they lose impact strength and become extremely brittle. Carbon steel
cannot be used safely at temperatures below -30oC and is obviously unsuitable for service with
liquid nitrogen. Materials normally suitable for service at low temperatures are the austenitic
stainless steels, aluminium and copper and its alloys. In an area where liquid nitrogen spillage
can occur, care should be taken to ensure that liquid nitrogen and cold nitrogen vapour are not
trapped in a closed system without any form of automatic pressure relief. Otherwise pressures
well in excess of the equipment working pressure will be generated as the system warms up,
thus creating a possible rupture hazard.
Liquid Nitrogen Gaseous Nitrogen
One Volume = 696 Volumes

8,000 Litres = 5440 m3
(196,000 Scf)
Page 25 of 224
TRAINING DEPARTMENT
EFFECT OF TRAPPING LIQUID NITROGEN
1 Cubic 1 Cubic
Foot Foot
LIQUID NITROGEN AT THE SAME GASEOUS NITROGEN AT

o o
-196 C and 0 psig 20 C and 10,200 psig
TRAPPED LIQUID NITROGEN WILL EXERT A PRESSURE IN EXCESS

OF 4.6 TONNES PER SQUARE INCH ON ITS CONTAINER IF IT IS
o
VAPORISED AND ALLOWED TO WARM UP TO 20 C
HEALTH HAZARDS
Asphyxia
Nitrogen, although non toxic, can constitute an asphyxiation hazard through the displacement of
the oxygen in the atmosphere. The potential for this type of hazard is significant because of BJ
SERVICES 's widespread use of nitrogen in oil, gas and petrochemical operations and because
neither nitrogen gas nor oxygen depletion are detectable by the normal human senses. 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.
Oxygen is necessary to support life and its volume concentration in the atmosphere is normally
21%. At normal atmospheric pressure (1013 mbA) persons may be exposed to oxygen
concentrations of 18% by volume (equivalent to a partial pressure of 180 mbA), or even less,
without adverse effects; however, the response of individuals to oxygen deprivation varies
appreciably. The minimum oxygen content of breathing atmosphere should be 18% by volume
(at normal atmospheric pressure) but to ensure a wider margin of operational safety it is
recommended that persons are not exposed to atmospheres in which the oxygen concentration
is, or may become, less than 20% by volume. Symptoms of oxygen deprivation, such as
increased pulse and rate of breathing, fatigue, and abnormal perceptions or responses, may be
apparent at an oxygen concentration of 16%.
Page 26 of 224
TRAINING DEPARTMENT
Permanent brain damage or death may arise from breathing atmospheres containing less than
10% oxygen. Initial symptoms will include nausea, vomiting and gasping respiration. Persons
exposed to such atmospheres 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.
Symptoms of Oxygen Deficiency
% Oxygen at Ambient Pressure Signs and Symptoms of Oxygen

Deficiency, at rest
12 -14 Respiration deeper, pulse faster,
co-ordination poor
10 - 12 Giddiness, poor judgement, lips blue
8 - 10 Nausea, vomiting, unconsciousness, ashen
face
6-8 8 minutes:- No recovery possible
6 minutes:- 50% chance of recovery
4-5 minutes:- Recovery with treatment
4 Coma in 40 seconds, convulsions,
respiration ceases, death follows
Cold Burns
Liquid nitrogen and cold nitrogen vapours or gases can produce effects on the skin similar to a
burn. Naked parts of the body coming into contact with uninsulated parts of equipment may
also stick fast (because all available moisture is frozen) and the flesh may be torn on separation.
NOTE: Liquid nitrogen will cause IMMEDIATE DAMAGE if in contact with the eye.
This will usually mean IRREPARABLE DAMAGE. The severe nature of eye
injuries with liquid nitrogen emphasises the extreme importance of wearing eye
protection.
Frostbite
Severe or prolonged exposure to cold nitrogen vapour / gas can cause frostbite. Local pain
usually gives warning of freezing but sometimes no pain is experienced. Frozen tissues are
painless and appear waxy with a discolouration. Thawing of the frozen tissues can cause intense
pain. Shock may also occur if the burns are at all extensive.
Page 27 of 224
TRAINING DEPARTMENT
Effects of cold on lungs
Prolonged breathing of extremely cold atmospheres may damage the lungs.
Hypothermia
Low environmental temperatures can cause hypothermia and all persons at risk should wear
warm clothing. Hypothermia is possible in any environmental temperature below 10oC but
susceptibility depends on time, temperature and the individual. Older persons are more likely to
be effected. Individuals suffering from hypothermia may find that their physical and mental
reactions are adversely affected.
PRECAUTIONS
Operations and maintenance

It is essential that operations involving the use of gaseous or liquid nitrogen, particularly where
large quantities are used, are conducted in well ventilated areas to prevent the formation of
oxygen deficient atmospheres.
Ideally, nitrogen should be vented into the open air well away from areas frequented by
personnel. Nitrogen should NEVER be released or vented in enclosed areas or buildings where
the ventilation is inadequate.
Before entering areas, vessels or other equipment for maintenance or other purposes in which
the atmosphere is, or may become, deficient in oxygen action should be taken to make the
equipment safe. Preparatory work will include equipment isolation from hazardous processes,
purging and continued ventilation with air as appropriate. Equipment in service with flammable
gases should be purged with nitrogen prior to purging with air to avoid the formation of
flammable mixtures. NEVER USE OXYGEN AS A SUBSTITUTE FOR AIR AS A PURGING
MEDIUM.
Prior to entry, the atmospheres should be tested with a portable oxygen analyser (calibrated
before use) to ensure that the oxygen content lies between 20% and 22% by volume. The use of
a safety work permit system is strongly recommended.
It should be recognised that although nitrogen is slightly lighter than air at equal temperatures,
liquid nitrogen and cold nitrogen vapour are denser than air and can accumulate in low lying
areas such as pits and trenches. Where large spills of liquid nitrogen occur, a fog is formed in
the vicinity of the spill caused by the condensation of water vapour in the surrounding air. The
fog, in addition to severely reducing visibility, may contain oxygen concentrations appreciably
lower than that of air thus presenting a local asphyxiation hazard.
Page 28 of 224
TRAINING DEPARTMENT
IF IT IS NECESSARY FOR A PERSON TO ENTER AN OXYGEN DEFICIENT

ATMOSPHERE FOR MAINTENANCE OR OTHER PURPOSES IT IS ESSENTIAL THAT
HE WEAR, AND BE TRAINED IN THE USE OF, SELF CONTAINED BREATHING
APPARATUS.
Persons entering an oxygen deficient area are recommended to wear a safety belt with a manned
safety line attached. Standby personnel should have ready access to self-contained breathing
apparatus in case emergency assistance is required.
Personal Protection
Persons handling equipment in service with liquid nitrogen should wear hard hats, steel toe
capped boots, safety glasses or protective face shields, loose fitting, dry leather or insulated
gauntlets, and coveralls outside boots.
EMERGENCIES
In the event of accident or emergency the instructions below should be implemented
without delay.
Asphyxiation
Persons showing symptoms of oxygen deprivation should be moved immediately to a normal
atmosphere. Persons who are unconscious or not breathing must receive immediate first aid.
Medical assistance should be summoned without delay and first aid measures including
inspection of the victim's airway for obstruction, artificial respiration and simultaneous
administration of oxygen should be completed immediately. The victim should be kept warm
and resting.
It is important to note that personnel carrying out rescue operations must minimise the risk to
themselves.
A RESCUER SHOULD NOT ENTER AN OXYGEN DEFICIENT ATMOSPHERE
WITHOUT USING SUITABLE SELF CONTAINED BREATHING APPARATUS
OTHERWISE HE MAY HIMSELF BE OVERCOME. Many double fatalities have occurred in
industry as a result of personnel who, with the best intentions but without proper breathing
apparatus and equipment, have entered an oxygen deficient atmosphere in an attempt to rescue a
colleague.
Page 29 of 224
TRAINING DEPARTMENT
Treatment of cold burns and frostbite

Cold burns should receive medical attention as quickly as possible. However, such injuries are
not an everyday occurrence and doctors, hospital staff or works first aid personnel may not be
aware of the basic methods of treatment. The following notes describe the first aid treatment
and recommended advice for further treatment to be given by a medical practitioner or a
hospital.
1. First Aid
In severe cases summon medical attention at once. Flush affected areas of skin with
copious quantities of tepid water to reduce freezing of tissue. Loosen any clothing that
may restrict blood circulation. Move the victim to a warm place but not to a hot
environment and do not apply direct heat to the affected parts. Every effort should be
made to protect the frozen parts from infection and further injury. Dry, sterile bulky
dressings may be used but should not be applied so tightly that blood circulation is
restricted.
2. Treatment by medical practitioner or hospital
a) Remove any clothing that may constrict the circulation to the frozen area. Remove
patient to sick bay or hospital.
b) Immediately place the part of the body exposed to the cryogenic material in a water
bath which has a temperature of not less than 40oC but not more than 45oC. (See
below for exceptions to this recommendation.) NEVER USE DRY HEAT OR
HOT WATER. Temperatures in excess of 45oC will superimpose a burn upon the
frozen tissue.
c) If there has been massive exposure to the super-cooled material so that the general
body temperature is depressed, the patient must be re-warmed gradually. Shock
may occur during re-warming, especially if this is rapid.
d) Frozen tissues are painless and appear waxy with a discolouration. They become
painful, swollen and very prone to infection when thawed. Therefore do not re-
warm rapidly if the accident occurs in the field and the patient cannot be
transported to hospital immediately. Thawing may take from 15 to 60 minutes and
should be continued until the blue, pale colour of the skin turns to pink or red.
Morphine or some potent analgesic is required to control the pain during thawing
and should be administered under professional medical supervision.
e) If the frozen part of the body has thawed by the time medical attention has been
obtained, do not re-warm. Under these circumstances cover the area with dry
sterile dressings with a large bulky protective covering.
f) Administer a tetanus booster after hospitalisation.
Page 30 of 224
TRAINING DEPARTMENT
Hypothermia
Persons suspected to be suffering from hypothermia should be wrapped in blankets and moved
to a warm place. Slow restoration of temperature is necessary and forms of locally applied heat
should not be used. Summon medical attention.
Fire fighting
Nitrogen is not flammable and no special fire fighting precautions or equipment are needed. If
an outbreak of fire occurs in the vicinity of nitrogen storage equipment the fire crew or local fire
brigade should be summoned at once. Unless containers containing liquid or compressed
gaseous nitrogen can be removed safely to an unaffected area, every effort should be made to
keep them cool by spraying them with large quantities of water.
Liquid Nitrogen Spillage
If large spills of liquid nitrogen occur, large quantities of water should be used to increase the
rate of liquid vaporisation.
Vehicles involved in a heavy liquid spillage should not be moved as the tyres may be frozen to
the ground and the rubber will be brittle.
- Safe storage and handling of liquid nitrogen
- Suitable, dry gloves should always be worn
- Eye protection should always be worn
- Coveralls should be worn outside boots
- Personnel should be trained in handling cryogenic liquids
- Nitrogen pumps and bulk nitrogen storage tanks should be positioned in a well
ventilated area
- Nitrogen storage tanks should be positioned well away from potential fire hazards
- All valves should be kept closed and all outlets should be plugged.
- Dangers of compressed gas

- When we compress a material we input energy into that material
- The more compressible a substance is, the more energy can be stored within it
- Problems occur if this energy is released uncontrollably.
Page 31 of 224
TRAINING DEPARTMENT
NITROGEN EQUIPMENT
MINOR ITEMS
- Hoses
- Treating Iron
- Relief Valves
- Gauges
- Chart Recorders
- Fittings
- Check Valves
- Whip Checks and Tie Down Material
Although the above equipment has been designated as minor, it is crucial for the successful
completion of the operation.
Page 32 of 224
TRAINING DEPARTMENT
Hoses
- 1" R12 (rubber) Maximum working pressure 4,000 psig

1/4" R13R (rubber) Maximum working pressure 10,000 psig
- 1/2" R9R (rubber) Maximum working pressure 6,000 psig
- 3/4" R9R (rubber) Maximum working pressure 6,000 psig
- 1/2" POLYFLEX Maximum working pressure 20,000 psig
- Stainless steel cryogenic hoses Maximum working pressure 6 barg
1” R12 is the most used hose in Western Canada, being used in purge jobs. East Coast use ½”
and ¼” hoses.
Page 33 of 224
TRAINING DEPARTMENT
Treating Iron
One piece construction to eliminate Wing union nut

all welds & threads detaches for field removal
Green Band
H2S Service Circlip
Segments
Uninterrupted bore
Available in lengths up to 10 ft
INTEGRAL JOINTS
Type of Cold Working End Bore Size Wall Weight
Size (ins.) Service Pressure (PSI) Connect (Ins.) Thickness (Ins) per Foot (Lbs)
2 Standard 15000 Fig. 1502 1.75 0.375 8.5
2 Sour Gas 10000 Fig. 1502 1.75 0.375 8.5
Page 34 of 224
TRAINING DEPARTMENT
Field Iron Colour Code Chart
FIELD IRON
COLOR CODE CHART
HIGH PRESSURE STANDARD TREATING LINE SYSTEMS
Yellow Silver Dark Green
PN 135199 PN 135202 PN 135198

20,000 psi 15,000 psi 10,000 psi
Working Pressure Working Pressure Working Pressure
White Blue Orange
PN 135196 PN 135195 PN 136756

6,000 psi 4,000 psi 2,000 psi
Working Pressure Working Pressure Working Pressure
SPECIALIZED TREATING LINE SYSTEMS

Flourescent Green Black Red
PN 135200 PN 135201 PN 135197

H2S Sour Gas N2 Nitrogen Service* CO2 Carbon Dioxide
Service* Service*
* Sour Gas (H2S), Nitrogen (N2), and Carbon Dioxide (CO2) treating line
equipment are to be identified as specialized treating line systems and
must be kept isolated from standard treating line systems.
See reverse side for Note and Caution
Page 35 of 224
TRAINING DEPARTMENT
FIELD IRON
COLOR CODE CHART
NOTE
It is the responsibility of District Personnel to confirm that all field iron is

identified by the proper color coding per this chart.
On Nitrogen, Carbon Dioxide, H2S sour gas service, and 15,000 psi working
pressure iron, the color shall be applied to the whole piece of iron including
the end connections. All other field iron (excepting cementing plug container
systems) shall have the union ends appropriately color coded and the remainder
painted silver.
All cementing plug containers, manifolds and related connections shall be

painted blue, PN 135195.
All high pressure field iron that does not meet specifications shall immediately be
taken out of service and painted fluorescent orange at both union ends and at any
portion or segment that has been identified as having a deficiency.
CAUTION
On components with multiple pressure rated ends - Example: 2 inch Fig. 2002
male union end by 2 inch Fig. 1502 female union end - the lowest rating of the
ends is the dictating pressure rating. In this case, all ends are to be painted
with the lower pressure rating.
Note : Source Field iron maintenance data base in standard practices
Page 36 of 224
TRAINING DEPARTMENT
Plug Valve
2" INTEGRAL PLUG VALVE

FEMALE MALE
UNION UNION
SEGMENTS
CONNECTED N2 TREATING IRON AND EQUIPMENT

1. On N2 jobs the rigging-in of iron is always performed from the wellhead back to the pump
unit. Treating iron wing-halves shall be pointing from the pump unit to the wellhead.
2. If treating iron is laid on uneven terrain, install two-way and three-way swivel joints or
doglegs as necessary to eliminate undue strain on the treating line.
3. If the injection point is “Teed” into a frac, acid or cement treating line, the junction manifold
must consist of at least one three-way chiksan located on the N2 pumper side of the connection.
This helps prevent line failure from horizontal and vertical movement in the treating iron caused
by the fluid pumps jacking.
4. When injection rates are in excess of 600 m3/minute , use:
¾ Two separate 2 inch lines with two separate 2 inch injection points
¾ Two separate 2 inch lines with a single 3 inch injection point
¾ A single 3 inch treating line with a 3 inch injection point
5. All discharge piping connections shall be made with integral unions.
6. All connections shall be clean and properly lubricated during rig-up.
7. The end of each N2 discharge line at a junction with another line (or at the wellhead) shall be
equipped with a 2 X 2 Hamer valve (N2 control valve). This valve will isolate N2 from the fluid
pumping units. Next to the N2 control valve and toward the N2 pumper, install a ground bleed
system and then a check valve.
8. Wherever possible, the line should be secured to solid structures every 3 to 4 meters. Should a
line failure occur, this arrangement would reduce the unrestrained movement of lengths of
treating iron.
Page 37 of 224
TRAINING DEPARTMENT
Single Pump Unit Rig-In

The following illustration shows a typical single unit rig-in from the wellhead or Coiled Tubing
Unit to the pumper.
The order for installing the equipment from the wellhead or other treating line to a single pump
unit, using either a “Tee” or a flange, is listed below. Starting at the wellhead, install:
1. integral swage, “Tee” or flange - with thread-half connection
2. 2" plug valve (Hamer valve)
3. 2" 2-way swivel joint
4. pup or long joint as required
6. pup or long joint as required
8. recorder “Tee”
9. bleed-off “Tee” - “Tee” with 2” x 1” plug valve (Hamer valve)
10. 2" check valve
11. treating line as necessary to reach pump unit
12. 2" 2-way swivel
13. treating line to connect to pumper
Page 38 of 224
TRAINING DEPARTMENT
Typical Weco and Chiksan equipment recommended temperature ranges
Page 39 of 224
TRAINING DEPARTMENT
Hot Iron Package
1” Schedule 80 316L Stainless steel

Railroad type unions
Pressure rating in the range of 4200 psi @ 100 oF down to 2500 psi at 750 oF
Used in hot gas jobs (212 oF plus) and accelerated cooldowns (including LN2)
Ensure every part of rig up is suitably pressure and temperature rated
Page 40 of 224
TRAINING DEPARTMENT
Relief Valves
- System relief valves should be on line at all times during pressurisation and testing in
order to avoid the possibility of system over pressurisation.
- If systems are not protected by their own relief valves a suitably calibrated temporary
relief valve, or as an absolute minimum, BJ Services 's EMOS or OPPS overpressure
protection system should be connected to the system prior to any pressurisation.
Gauges
-A minimum of 2 calibrated pressure gauges of the correct range should be installed on the
system for monitoring pressure.
System gauges are adequate as long as they are in calibration, however test gauges may be
requested by the client.
Page 41 of 224
TRAINING DEPARTMENT
Chart Recorders
-In addition to pressure gauges, a pressure chart recorder may be desirable. Chart recorders
provide both advantages and disadvantages:-
Positive aspects include having a hard copy of the pressurisation and depressurisation profile
which can be used as evidence and proof that systems were not over pressurised and were
depressurised prior to repairs being carried out.
Negative aspects include problems with requiring frequent re-pressurisation of a badly leaking
system in order to keep the system pressure at a level acceptable to the client.
Correct use of chart recorders
i) Ensure that the chart recorder covers a suitable time period. (Do not use a 24 hour
chart recorder for a 10 minute test or a 3 hour recorder for a 24 hour test.)
ii) Ensure that the chart recorder covers an adequate pressure range. (Test pressure
should be approximately 2/3 of the full scale deflection of the chart.)
iii) Ensure that the correct chart is used. (Do not manually adjust the charts pressure
scale or use a temperature chart.)
iv) Ensure that the chart recorder is operational prior to commencing the test.
(Recorder is fully wound up and the pen is marking the paper.)
v) Always sign charts on and off and insert start and finish times.
Page 42 of 224
TRAINING DEPARTMENT
Fittings
P arallel thread w ith internal cone seat. U sed

for joining and connecting hoses. N o thread
BS P sealant should be used w ith these fittings.
Tapered thread, with thread and sealant

form ing the seal. U sed for connecting injection
NPT m anifolds instrum ents etc. to process
system s.
P arallel thread with external cone seat. U sed
for joining and connecting hoses. N o thread
sealant should be used with these fittings.
JIC Hydraulic hoses on the nitrogen pum p units
are predom inantly JIC. JIC fittings are not
norm ally used on H .P. injection hoses
however they are som etim es used on H askel
P um p C onnections.
NPT BSP
60O Thread angle. 55O Thread angle.

Pitch = 0.7143 (measured in inches) Pitch = 0.7142 (measured in inches)
Truncation of root and crest are flat Truncation of root and crest are round
Taper angle 1 4O 7' Taper angle 1 4O 7'
NOTE THAT NPT AND BSP THREADS ARE SIMILAR AND CAN BE
FORCED TO MATE RESULTING IN A FAULTY CONNECTION.
Page 43 of 224
TRAINING DEPARTMENT
Fitting Do's and Don'ts
- Never mix fittings of different types eg. parallel and tapered

- Use standard wrenches or crescent wrenches to make up fittings, not pipe wrenches
- Use correctly sized shifters to avoid over-torquing
- Ensure fitting threads and sealing faces are clean before making up joints
- Ensure that fittings of a suitable pressure rating are used: pressure rating should be
marked on fittings (3,000 psi, 6,000 psi, 10,000 psi WP).
Gauge Connections and Cross-Overs
Please refer to OPPS section for this information.
Please refer to the Colder products pipe thread information at the end of the manual for more
details on fitting
Autoclave Fittings
Left hand thread on collet

1.5 threads should be showing on top of collet
Tell Tail may indicate that fitting not seated correctly or collet in wrong position
Page 44 of 224
TRAINING DEPARTMENT
Check valves
A high pressure check valve should be included in all injection manifolds as a means of
preventing the back flow of nitrogen from a pressurised process system in the event of the high
pressure injection hoses failing.
If the manifold is made up as the following sketch, hoses can be depressurised and removed
from the system leaving a double block and bleed at the injection point.
Typical High Pressure Check Valve
Page 45 of 224
TRAINING DEPARTMENT
Manifolds
Injection Manifold Set Up
High Pressure,
Nitrogen Gas Injection
Page 46 of 224
TRAINING DEPARTMENT
Whip checks and tie down material
Whip checks should be used to link the ends of two hoses across a join and to attach the end of
the hose to the system injection point or the nitrogen pump discharge manifold.
Rope of adequate breaking strain should be used to secure hoses to fixed anchorage points along
the hose length at regular intervals (every 5 to 10 metres).
MAJOR ITEMS
• Liquid nitrogen storage tanks

• Bulkers
• Ambient vaporisers
• Steam vaporisers
• Nitrogen pump units
• Nitrogen pump trucks
• Overpressure System (OPPS or Isoplex System)
Liquid Nitrogen Storage Tanks
All of our work requires the safe transportation and storage of the raw product, liquid nitrogen.
The difficulties associated with this stem from the extraordinary cold nature of the liquid.
Liquid nitrogen at -196oC boils at atmospheric pressure and would vaporise if it were exposed to
ambient temperatures, therefore we transport and store it in vessels mechanically similar to a
thermos flask.
Our cryogenic vessels consist of a tank within a tank. The inner tank is stainless steel which, as
explained in the earlier section, can withstand cryogenic temperatures. This tank is suspended at
each end by fusible supports which will not conduct heat from the outside tank to the inner. The
outer tank is constructed of carbon steel, designed for ambient temperatures. The space between
the two tanks is filled with an insulating material (typically perlite) and is evacuated down to 0.1
mbar. The combination of the insulating material and the vacuum reduce the heat ingress to the
liquid, thus slowing down the boiling process.
If the vacuum is lost due to an internal rupture of the inner or outer vessel, the emergency vent
(burst disk), which is held in place by the vacuum will release itself from the tank. This will
now give the inner vessel surface contact with the outside ambient temperature, thus a rapid boil
off of the liquid will take place.
Page 47 of 224
TRAINING DEPARTMENT
Although the tanks are insulated there is an unavoidable heat transfer into the liquid nitrogen.
This results, under normal conditions, to an approximate 1% loss of liquid per day due to
vaporisation. This loss will initially be seen as a pressure build up within the tank, eventually
resulting in the release of pressure. This is achieved either manually via the vent valve or
automatically by one of the safety relief valves, set at 3 barg. This pressure is the maximum
working pressure of most of BJ Services 's tanks and is monitored by a gauge.
However we do have some HP tanks with a maximum working pressure of 6 barg and tanks are
available with working pressures in excess of 10 barg. The other gauge seen on a nitrogen tank
is there to monitor the contents. This is achieved by sensing differential pressure between the
top and the bottom of the tank. A bypass valve connects the two ports allowing the facility to
zero the gauge.
Positioning Equipment
When positioning the nitrogen converter, enough room must be available to locate at least two
nitrogen tanks at the suction side of the converter. The first tank, or work tank as it is more
commonly called, should be set directly in front of converter leaving approximately four foot of
gap. This is to allow a close proximity of tank valves and converter controls.
The second tank should be parallel with the first and as close together as possible. Alternatively
pumps and tanks can be placed side by side but should be positioned in such a way as to
minimise the length of cryogenic hose required to link pump to tank.
NOTE: When positioning the two tanks, care must be taken not to have the vent line
directly inline with the opposite tank's frame as excessive venting will frost the steel and
possibly crack it.
If there is a need for more tanks during the job, then the outside tank is lifted out when empty
and a new one put in it's place. In certain instances, additional tanks may have to be stacked on
top of each other (two high maximum).
It is important however, when doing this, to either remove the slings from the bottom tank or
support the top tank on wooden planks if slings are not protected in a void. The following
picture illustrates a typical site layout plan with all the required equipment in place:
Page 48 of 224
TRAINING DEPARTMENT
Offshore Set up
Land Set up
Page 49 of 224
TRAINING DEPARTMENT
Cryogenic Hoses
The Nitrogen converter will come complete with three nitrogen hoses, two 7 foot hoses and one
15 foot. These will be either stainless steel braided or cloth fibre. Before attempting to couple
the hoses, each hose in turn must be hooked up to the tank discharge.
A small quantity of gas can now be blown through the hoses in turn to remove any moisture that
may have settled during transport.
NOTE: Prior to hooking any hoses up, the teflon (or copper union) seal on all tank
connections must be checked for damage or over use.
CAUTION: Do not prolong the purge of the hoses as the gas may turn to liquid and spill
onto the deck.
Once purged, the first of the 7 foot hoses can be connected to the N2 converter boost pump
suction. The other 7 foot hose can be connected to the tank return line and the re-circulation
line from the converter. Longer hoses may be required if tanks and pump are placed side by
side.
NOTE: All cryogenic hoses must not come in contact with steel decks, as over exposure to
extreme low pressure may result in the deck cracking. It is good working practice to place
wooden boards underneath hoses even if the area is completely boarded.
Liquid Nitrogen Temperature Conservation
Care must be taken in all stages of storage, transfer and transport to conserve the low
temperature of the liquid nitrogen.
The atmospheric environment is an infinite source of heat with a temperature difference as large
as 200oC or more relative to the boiling point of liquid nitrogen (-196oC).
Liquid nitrogen has a relatively small latent heat of vaporization and a small amount of energy
input results in considerable evaporation of the liquid.
For efficient storage (1 volume of liquid nitrogen becomes 696 volumes of gas at STP) handling
and pumping, it is required that the maximum quantity of nitrogen is maintained in the liquid
state up to the point of final application. This means that in all stages of storage, transport and
use detailed attention must be given to carrying out the correct procedures.
The following guide-lines are based on established methods of cryogenic operations and
principles of energy conservation.
Page 50 of 224
TRAINING DEPARTMENT
Heat In-leak
Efficient insulation is required for liquid nitrogen storage tanks in continuous or long period
operations.
The generally accepted transport tanks for offshore use are super insulated. This means that the
inner tank in wrapped with insulation material and reflective foil. The gap between the tanks is
then pulled to a very low vacuum. The effectiveness of these tanks is very dependent on
maintaining the low vacuum.
Icing on the tank outer surface indicates faulty insulation (except for localized cold spots which
occur during liquid transfer). Remedial action should be taken as early as possible to repair the
insulation and to maintain the vacuum. Further deterioration of the vacuum will greatly increase
cost and down time because of contamination to the vacuum from atmospheric water vapour.
System Cooldown
Before liquid circulation can be established, the complete mass of vessel piping, valves etc,
must be cooled down to liquid nitrogen temperatures.
This is termed "heat mass" and is a function of the specific heat and density of materials (for
example 2 litres of N(Liquid) are required to cool down 3.5 kg of copper or 1/2" valve).
It can be seen from the following diagram that there is a large amount of piping, valves, pumps,
hoses etc. that must be cooled down, giving a large "heat mass"
It follows that systems should incorporate the least heat mass as possible, i.e. shortest hose
length as practical, fewest valves, simplest circuit.
When liquid nitrogen is introduced into the "hot" sections, it will "flash" to "cold" gas and the
aim should be to use as much of the heat in the gas to cool down the system. The gas, however,
has a poorer heat transfer coefficient than the liquid and can also entrain the liquid reducing its
cooling down effect.
It is therefore important to start the cool down very slowly by "cracking" the liquid feed valve
and gradually opening it as the "frost line" progresses down the system.
The rate of cool down must be judged to be fast enough to overcome the rate of heat in-leak fro
the atmosphere.
The saying "more haste less speed" definitely applies to the cooling down process as the
higher the gas velocity the greater the resistance to flow.
In systems with high "heat mass" it is often justified to cool down in sections by venting at
strategic points.
Whenever possible, and so long as it does not penalize the cooling down process, the vent gas
should be used to pressurise tanks etc.
The "heat mass" of the circuit can be used to vaporise nitrogen and build pressure in the tanks .
Page 51 of 224
TRAINING DEPARTMENT
BASIC HP LN2 PUMP/VAPORISER SYSTEM
Wasteful Energy Input

For BJ Service's operations liquid nitrogen requires to be below it's boiling point. It is therefore
most advantageous to maintain the liquid as cold as possible up to the point where it is to be
vaporised.
The graph below shows the boiling point of nitrogen in comparison to pressure.
Page 52 of 224
TRAINING DEPARTMENT
When pumping from and returning to the same tank, the body temperature of the liquid will rise
above - 196oC with resulting pumping problems due to loss of prime as gas breaks out of the
liquid phase.
It is important that since the liquid is at a higher boiling point, additional pressure is still
required, either by hydrostatic head or by imposed pressurisation, to prevent flash gas
generation. This will be a problem in the line supplying the liquid to the centrifugal pump.
If flash gas generation occurs here then the centrifugal pump will lose prime. The Net Pressure
Suction Head (NPSH) must therefore be enough that it will overcome the pressure losses in the
hose which could bring the pressure to below boiling point. This is described visually in the
diagram below.
This is particularly important when maintaining pump prime. Imposed pressure, either by
pressure raising coil or feed back of pump cool down gas, does not add to the body temperature
of the liquid because of the "stratified layer" while the tank is stationary, but as soon as the tank
is moved or refilled under closed vent, the enclosed gas will add its heat content to the liquid.
Maintaining pump prime is an operational "must". It is also important to avoid considerable

liquid losses associated with the re-priming operation.
Page 53 of 224
TRAINING DEPARTMENT
Preparing tanks for Decanting
Tanks which have been in transit or standing with the vent closed for a period of time will build
up pressure due to liquid agitation and heat transfer from the outside ambient temperature to the
liquid inside the tank. As the temperature rises in the liquid, the pressure within the vessel
increases because the liquid is boiling off and has nowhere to go. Therefore a tank which has
been standing with 100 kPag will contain "hot" liquid, around -181oC.
At this time the liquid in the tank is acting similar to that of water in a pressure cooker, that is to
say, the increase in pressure has raised the liquid's boiling point 7oC. If the liquid was to stay in
the tank then it would slowly boil away, gradually increasing it's temperature and pressure until
the tank limit of 300 kPag, whereupon the tank relief valve would vent the excess pressure to
atmosphere.
NOTE: It must be noted that over full tanks of nitrogen may spray liquid nitrogen from
the vent line at relief valve pressure, therefore, nitrogen tanks should never be over filled
and if the tanks are stored away from the worksite unsupervised, it may be necessary to
bleed the pressure down to prevent the relief valve from lifting and releasing liquid
nitrogen.
The liquid, however, has to be transferred from the tank to the converter and pumped as a cold
gas-free liquid before being converted to a gas at 25oC. If the liquid is already warm before
leaving the tank it will most certainly boil off due to the extra heat absorbed along the lines. In
this situation the liquid will become unpumpable.
To overcome this problem we have to return the liquid nitrogen to it's original temperature (-
196oC) and cool it again sufficiently to allow for the additional heat transfer. We do this by
"supercooling" the liquid nitrogen.
To explain this principle we need to look at the diagram below. In example 1 the liquid nitrogen
tank has had it's temperature raised to -189oC. This has boiled of liquid and produced 1 barg of
pressure inside the tank. If we were to transfer the liquid in this state it would start boiling
immediately due to the additional heat absorbed.
A liquid will boil when it's saturated vapour pressure is equal to or above atmospheric
pressure.
Liquid nitrogen will boil at -196oC at atmospheric pressure, 1 barA or 0 barg. The tank
conditions in example 1 are also at boiling point so any further heat induction will accelerate the
boiling process. In both situations (example 1 and 3) we are at boiling point with no
temperature tolerance to work in as both saturation pressures equal their "atmospheric"
pressures.
To rectify the problem we first have to reduce the temperature of the liquid by venting off the
tank pressure to zero, thus returning the liquid to -196oC.
Page 54 of 224
TRAINING DEPARTMENT
AMBIENT HEAT TRANSFER

TO LIQUID
1 1
VENT CLOSED
0 0
Barg Barg
1 Barg Venting to 0 Barg VENT PRESSURE

TO ATMOSPHERE
1 Barg BOILING LIQUID NITROGEN
SATURATED LIQUID NITROGEN
o o
-189 C -189 C
HOT LIQUID HOT LIQUID
1. TANK IN EQUILIBRIUM 2. TANK RETURNING TO EQUILIBRIUM

BY BOILING OFF HEAT
1 1
0 0 VENT CLOSED
Barg Barg
VENT OPEN
0 Barg 1 Barg PRESSURE GENERATED
0 Barg (Vap. Press.) 0 Barg (Vap. Press.) ARTIFICIALLY
VAPORISER
BY
SATURATED LIQUID NITROGEN COLD LIQUID NITROGEN
o o
-196 C
COLD LIQUID
-196 C
COLD LIQUID
3. TANK IN EQUILIBRIUM 4. TANK READY TO DECANT
We now artificially increase the pressure of the inner vessel by bleeding off some liquid
nitrogen from the bottom of the tank, feed it through a vaporiser and return it to the top of the
tank as a cold gas.
What we have created is an "unnatural" situation of an "atmospheric pressure" of 1 barg and a

liquid saturated vapour pressure of 0 barg.
If we now look at the table (see over page) and at the theory of boiling liquid, the temperature in
the liquid nitrogen will have to raise 7oC before it will start to boil. To increase the temperature
that much will take a considerable amount of time.
Although this is only one small part of the entire nitrogen pumping operation, you will find that
the success of the operation will depend on the operator balancing the tank pressure and the
liquid saturation pressure.
Page 55 of 224
TRAINING DEPARTMENT
SATURATED VAPOUR PRESSURE OF NITROGEN
Saturated Temperature
o
Pressure (psig) C
0 -196
5 -193
10 -191
15 -189
20 -188
25 -186
30 -185
35 -184
40 -183
45 -182
50 -181
Mobile Storage Vessels or Nitrogen Bulkers (MSV's)
Where static large volume reservoirs of liquid nitrogen are required a mobile storage vessel or
nitrogen storage tanker can be utilised.
The design of the MSV is very similar to that of a liquid nitrogen storage tank however nitrogen
storage tankers have a capacity of 23,000 litres of liquid nitrogen, the equivalent of 3½ liquid
nitrogen storage tanks.
They are equipped with an onboard auxiliary engine and liquid nitrogen discharge pump capable
of pumping at a rate of 380 litres per minute at a pressure of 17 barg.
Liquid Nitrogen to Gas Conversion

In order to convert liquid nitrogen into gas we need to apply heat. Heat can be provided in a
number of ways and is the basis of all the converters used by BJ Services .
Page 56 of 224
TRAINING DEPARTMENT
Ambient Vaporiser
The most simple method for converting liquid nitrogen to gas is to utilise ambient heat. Liquid
is passed through an aluminium finned vaporiser which absorbs heat from the surrounding air
and uses this to convert liquid nitrogen into gas. Flow rate and pressures attainable are
dependent on the maximum pressure obtainable from the liquid storage system and ambient
conditions.
Steam Vaporiser
Where plant steam is available on site (refineries, chemical plants and some platforms) this can
be used to convert liquid nitrogen into gas again. Flow rate and discharge pressure are
determined by the maximum working pressure of the liquid storage vessel, however the
temperature of the discharge gas can be elevated to well in excess of 100oC if pressurised steam
is utilised.
Page 57 of 224
TRAINING DEPARTMENT
DIRECT OR INDIRECT FIRED VAPORISER
The Zwick Cryogenic Direct Fired Vaporizer is a direct fired burner heat exchanger unit
designed to vaporize liquid N2 to approximately 30° C (+ /- 10°C) at rates up to 170 m3/min
(model 6000 - DFA - 10) or 280 m3/min (model 10K - DFA - 10) and at pressures up to 70,000
kPa (10,000 psi).
¾ The unit consists of a blower, fuel pump, burner chamber, heat exchanger, and
¾ control system
¾ A hydraulically driven high speed blower provides combustion air to the burner
¾ A belt driven fuel pump supplies fuel
¾ Burner exhaust flows over a tube heat exchanger in which liquid N2 is vaporized
¾ The burner controls are mounted in two watertight enclosures
¾ A junction box, mounted on the exchanger skid, houses the electrical and
thermocouple connections, a propane solenoid valve and the ignition system
¾ Remote equipment housed in a control box includes switches, warning and
¾ indicator lights, pyrometer, safety shutdown device, fuel solenoid valves, and a
low pressure switch
¾ The fuel flow on the unit is controlled manually
The following is an illustration of a Zwick Direct fired Vaporiser:
Page 58 of 224
TRAINING DEPARTMENT
FLAMELESS VAPORISER
Flameless
BJ Canada has several units which do not depend on the burning of diesel fuel to generate heat
for the vaporizer. Typically, these units consists of:
¾ Cryogenic pump
¾ vaporizer (hydraulic back-pressure or water-brake technology)
¾ Hydraulics to drive the triplex and other pumps
¾ Liquid-storage tank with pressure-control devices
Nitrogen vaporizing and heating to final discharge is achieved by transferring heat from the
engine and hydraulics through specially designed heat exchangers, rather than by direct
combustion of diesel fuel. The high-pressure cryogenic pump and heating circuit are
hydraulically run directly from the transmission, providing simple, straightforward control and
reduced maintenance. The rate of flow and temperature of the gaseous nitrogen can be
controlled over a wide range of operating conditions. The following schematic shows on of the
common flameless vaporiser schematics:
Page 59 of 224
TRAINING DEPARTMENT
Nitrogen Pump Unit
The nitrogen pump unit's basic concept is to pump nitrogen as a cold liquid then transfer it to a
gas at 20oC for line use.
The main components of the unit are:
1. Cryogenic Boost Pump: This supplies the main nitrogen triplex pump (cold ends) with
a positive head of liquid.
2. Cryogenic Triplex Pump: This is a very high pressure pumping unit (10,000 psi working
pressure) for liquid nitrogen. These units come in different
sizes and pressure ratings.
BJ Services have two sizes of converter: 150m3/min (5300scfm) and 250m3/min (8800scfm),
both of which have 10,000 psi working pressures. It is these abbreviations, SP6000 and
SP10000, that the converters are usually identified by.
3. N2(Liquid) Vaporiser: This part of the unit converts the liquid nitrogen to a gas.
It does this by channelling all the waste heat from the engine
and hydraulic systems and artificially induced heat from the
hydraulic heat system or the water dyno system into the
cooling system.
The cooling water acts as a hot water jacket for the very cold
high pressure coils inside the vaporiser pot, thus changing the
state of the liquid nitrogen to gaseous nitrogen as it passes
through.
Although all converters, primarily work under the same principle of operation, the designs of the
heat recovery have changed from model to model. The criteria of converter design, is for it to
operate at it's extreme range ie 150 m3/min at 10,000 psi and therefore the cooling and hydraulic
transmission systems have to be able to convert liquid nitrogen from -196oC to 20oC at this high
rate and pressure. As you can see, a considerable amount of heat is required.
However it is very rare that we will ever operate the unit in this range. This now gives the
operator infinitely more variables on how the converter is set up and performs during operations
of low pressure and rate. There are no tables on hydraulic pressures and
temperature ranges for any given rate, only experience in various job types will allow the
operator to become fully acquainted with the system.
On no account must the operating parameters of any unit type be exceeded.
Page 60 of 224
TRAINING DEPARTMENT
LIQUID NITROGEN CONVERTER PRINCIPLE OF OPERATION
During normal operation, liquid nitrogen is fed from the supply tank into a cryogenic centrifugal
pump. The centrifugal pump boosts the liquid nitrogen to around 50 psi, prior to entering the
high pressure triplex pump. This pressure boost is required to assure a positive pressure on the
suction side of the triplex pump.
The triplex pump is a positive displacement pump which increases the liquid nitrogen pressure
to a maximum of 10,000 psi. From the triplex pump high pressure liquid nitrogen flows through
the nitrogen vaporiser pot, or vaporiser ducting system. The vaporiser provides sufficient heat
which is absorbed by the system.
The heat raises the temperature of the nitrogen to that of 20oC at the maximum flow rate of the
converter.
If the maximum rate is not used then the temperature of the nitrogen can be raised much higher.
Therefore the operator must control the discharge temperature. He does this by the tempering
valve. This valve allows cold fluid to by pass the vaporiser system and enter the line, co-
mingling with the hot gas, thus reducing the temperature. Obviously it must be noted that too
much tempering may reduce the temperature of the gas sufficiently to frost the line (white
lining).
THIS MUST NEVER HAPPEN!
Page 61 of 224
TRAINING DEPARTMENT
EMERGENCY SHUTDOWN SYSTEMS FOR DIESEL POWERPACKS
Reasons for Fitting

Emergency shut down systems are fitted to nitrogen pump units to ensure that any high
temperature or naked flames/sparks cannot accidentally ignite any hydrocarbons that may be
present in the environment.
The ignition of any hydrocarbons could lead to severe equipment damage or, more importantly,
personal injury and even loss of life.
Each offshore location is divided into zoned areas. These consist of:
Zone 0 In which an explosive gas/air mixture is continuously present for long periods.
Zone 1 In which an explosive gas/air mixture is likely to occur in normal operation.
Zone 2 In which an explosive gas/air mixture is not likely to occur in normal operation and
if it occurs, it will only exist for a short time.
Summary of System Operation

An engine requires fuel and air to run, therefore to stop the engine we require to eliminate the
fuel supply or air supply.
Cutting off the fuel supply allows the engine to run down and stop slowly, therefore this method
is preferred as the "Normal Kill".
Cutting off the air supply will stop the engine immediately. This method is used for
emergencies only, as it can have catastrophic effects on the engine if activated whilst
running at high rpm. On diesel driven power packs the fuel and air supplies have actuators
inline which are held open, or run position, by pneumatic cylinders.
The low pressure air supply to them can only be sustained if the shutdown system has
commissioned all of it's functions.
The shut down system monitors the engine temperatures and pressures and can stop the engine
automatically if the following conditions exist:
1. High exhaust temperature

2. Low oil pressure
3. High water temperature
4. Low coolant level
5. Engine overspeed
6. High discharge pressure
Page 62 of 224
TRAINING DEPARTMENT
If any of the above conditions exist, the actuators controlling the condition will shift position
and allow the low pressure air in the line to vent. This depressurisation then in turn allows the
indicator on the control panel to change to red. At the same time this shift in position allows the
fuel and air inlet cylinders to vent, thus shutting down the unit.
On the newer units the Engine over-speed is linked directly to the air inlet cylinder. Thus if this
condition existed, the engine would stop immediately. The engine over-speed is in place to
prevent the engine destroying itself in the event of gas entering the air inlet.
Important note:
As has already been stated, the shut down system is fitted for very important reasons. If the
system is defective or overridden, the consequences could be catastrophic. It is therefore
essential that the system is properly maintained and correctly used at all times.
Another consequence of incorrect use of the shutdown is to render the certification of that unit
null and void. This means that not only are the rules of the customer and BJ Services being
broken but also the rules of the Department of Energy. It is also in contravention of the Health
and Safety at Work Act.
To abuse or misuse the emergency shut down system is immoral, illegal and downright
foolish. You are putting your own life at risk, as well as others by doing so.
Page 63 of 224
TRAINING DEPARTMENT
NITROGEN PUMP TRUCK
The basic equipment used in N2 operations is the nitrogen pump unit. It can be mounted either
on a trailer, or on a single-chassis truck. The unit incorporates three main components:
¾ Tank or storage vessel- an insulated and vacuum sealed vessel that contains the
liquid nitrogen
¾ Cryogenic pumping system
¾ Vaporizing unit to convert liquid nitrogen to nitrogen gas
BJ Services 's nitrogen pump trucks are totally mobile with their own onboard nitrogen storage
tank making them self contained pumping units. Pump trucks utilise a diesel fired burner
system to provide the heat for liquid nitrogen vaporisation and are capable of gaseous nitrogen
flow rates and discharge pressures of 250 m3/min at 6000 psig
The following schematic illustrates the general layout of a Nitrogen pump:
Page 64 of 224
TRAINING DEPARTMENT
ISOPLEX / EMOS
BJ Services 's Electronic Management Overpressure System and Isoplex is used for monitoring
nitrogen discharge temperature and system pressure during nitrogen pumping operations. The
system is set up to shut down the liquid nitrogen pump if minimum temperature or maximum
pressure exceed the desired parameters.
OPPS’s
BJ Services 's Mechanical Overpressure Systems ( Brisco & Metnor ) are used for monitoring
nitrogen system pressure during nitrogen pumping operations. The system is set up to shut
down the liquid nitrogen pump if maximum pressure exceeds the desired parameters.
Page 65 of 224
TRAINING DEPARTMENT
PROCESS SERVICE NITROGEN CALULATIONS

In order to be able to estimate the quantity of gas that is required in order to complete a nitrogen
operation we first need to be able to calculate system volumes.
Once the volume of a system is known we multiply this by the system test pressure to give the
total requirements.
When calculating system volumes we can assume that all vessels and pipework are simple
cylinders, and hence we need to use the following equations.
TT
ID
2 2
V= D /4 x L o r V = R L
W h e re V = Vo lu m e o f th e C ylin d e r
D = ID (in te rn a l d ia m e te r)
R = 1 /2 ID (in te rn a l r a d iu s )
L = T T (ta n g e n t to ta n g e n t le n g th )
o r L e n g th o f th e P ip e
= 3 .1 4 2
NOTE: It is important that units of volume, length etc. are taken into consideration as
vessel dimensions are often metric whereas pipework dimensions are generally imperial.
The following conversion factors may be useful :
1m = 3.28ft
1ft = 0.305m
1m = 1000mm
1mm = 0.001m
1ft = 12in
1in = 0.083ft
1m3 = 35.31ft3
1ft3 = 0.028m3
Page 66 of 224
TRAINING DEPARTMENT
WORKED EXAMPLE
π
SET @ 75 BAR
4" 2"
16"
12"
4"
3"
ID=2750mm
V =πD2 / 4xL or V =πR2L
TT=4800mm
Vessel
ID = 2750mm TT = 4800mm
ID = 2.75m (length)TT = 4.8m
Using: V = πD2 / 4 x L
V = π x 2.752 / 4 x 4.8
= 28.51m3
To Convert to Using ft3: 1m3 = 35.31ft3
= 28.51 x 35.31
= 1007ft3
Pipework
Since most volume calculations are based on information from P&ID’s alone, it is not possible
to determine the length of pipework in a test system. Therefore a ‘piping’ factor, commonly 1.5,
is included in the total volume requirements in order to account for this unknown volume.
Therefore: V = Vessel volume x 1.5
V = 1007 x 1.5 (28.51 x 1.5)
= 1510.5ft3 (42.765 m3)
Page 67 of 224
TRAINING DEPARTMENT
Gas Usage
Gas usage requirements are calculated by multiplying the calculated system volume by the
system test pressure in Barg.
eg If three 4 bar pressure cycle purges are carried out on the above system, total nitrogen
requirement will be:
3 x 4 x 1510.5 scf (3 x 58psi x 42.765 m3)
= 18126 scf (2480m3)
Nitrogen used during cool-downs must also be taken into account. Assume 10,000scf per cool-
down, and 1 cool-down in total for a purging operation.
Total = 18126 + 10000 (2480 + 300)
= 28126 scf (2780m3)
NOTE : SCF or "standard cubic feet" is a measurement of a volume of gas at standard

conditions (1013mb and 20oC). It should not be confused with ft3 or "cubic
feet" which should be used when describing the volume of a system, vessel or
pipework.
eg For a leak test at 95% of the system PRV setting, with contingency for a second test:
0.95 x 75 x 1510.5 (0.95 x (1088 + 14.7)/14.7) x 42.765m3)
= 107623 scf per test (3047m3)
Total = 107623 x 2 Tests (+ 2 cool-downs)
= 215246 + 20000 (3047m3 + 2 x 300 m3)
= 235246 scf (6694m3)
Page 68 of 224
TRAINING DEPARTMENT
Assumptions
In this example, a nitrogen spread will be required to remain onboard a platform for the duration
of a shutdown (i.e. purge and leak testing). 8000ltr N2(liq) tanks will be supplied, with a
pumpable volume of 150,000scf (4247m3)per tank. Therefore:
Purge = 28126 scf (796m3)
Leak test = 235246 scf (6661m3)
Total = 263372 scf (7457m3)
2 tanks would be required (300,000 scf, 8500m3) as a minimum. If possible it would still be
better to have at least 3 tanks on board to cover the unforeseen such as passing valves, additional
purges, excessive use of nitrogen during the purge or a long delay between purging and retesting
the system.
Page 69 of 224
TRAINING DEPARTMENT
OPERATING PROCEDURES
LIQUID NITROGEN STORAGE TANKS
Introduction
This instruction is based on Air Liquide's RBP 8000 HLR reservoir. RBP 8000 HLR is used
to designate an 8000 litre Horizontal Reservoir or "Nitrogen tank" for the transportation and
utilisation of liquid Nitrogen at a pressure of 3.0 barg (43psig). However there are tanks used
that are designed to be operated in excess of this pressure which are virtually identical to this
type. Although most liquid Nitrogen tanks are similar in design and operation, there will be
some differences on tanks when the operator must be vigilant. Differences may include
cryogenic plumbing, a higher pressure rating (up to 6 bar(g) 87psig or higher) or the volumetric
capacity of the reservoir. Generally, there are 3 types of tanks in use 2.5 bar(g) (36psig), 3.0
bar(g) (43psig) and 6 bar(g) (87psig) tanks manufactured by one of the following suppliers
"Hydra Rig", "Cryolor" and "Air Liquide".
The tanks are designed to store liquid Nitrogen under controlled conditions for use in both on &
offshore operations where conversion to Nitrogen gas may then be carried out.
Description
The Nitrogen tank is a vacuum sealed, super insulated cryogenic reservoir encased within a
crash frame.
The vacuum sealed, super insulation allows the tank to have a low rate of evaporation in the
region of less than 1% [liquid Nitrogen] volume per day [dependant upon ambient temperatures
and other mechanical factors].
The tank is made up of a stainless steel inner chamber, firmly fastened to an outer chamber
made of carbon steel.
The tank has a rapid pressurisation system to increase and maintain pressure for the extraction
of liquid contained. The pressurising "heater" vaporises the liquid and sends it back to the
gaseous section of the reservoir.
(There is no need for a pump or for any electrical equipment to pressurise the liquid and operate
the transfer.)
Operational controls and gauges are situated at the front of the unit which are protected by an
external crash frame.
The reservoir is delivered within an independent certified crash / lifting frame which can be
handled by a lift truck or by the lifting lugs located on the upper part and inside the frame.
Important: While positioning the reservoir, be sure that the surface on which it is to be set is
firm and free from all objects which could damage the reservoir. In addition special attention
should be given to its positioning upon a Plastic / P.V.C covered wooden latted area if being
placed upon a steel deck.
Page 70 of 224
TRAINING DEPARTMENT
DIMENSIONS
HEIGHT (M) WIDTH (M) LENGTH (M)

2.560 2.438 4.770
DESIGN SPECIFICATION
GROSS CAPACITY 8100 LITRES

NET CAPACITY 7690 LITRES
EQUIVALENT CAPACITY NITROGEN GAS 5330 M3 (188 K SCF)
MAXIMUM OPERATING PRESSURE 3 BAR (43psig)
TARE WEIGHT [EMPTY] 5290 Kg
GROSS WEIGHT [FULL] 11300 Kg
NORMAL EVAPORATION RATE LESS THAN 1% N2/DAY
Description Of The Components Of The Plumbing
1 - LIQUID LEVEL GAUGE:

Indicates the quantity of liquid in the reservoir, which is usually in inches of water.
2 - PRESSURE GAUGE:
Indicates the pressure of the inner chamber of the reservoir (usually measured in kPa or PSI).
3 - FILL VALVE [95%]:

Is used to determine when the reservoir is full during filling operations. The liquid will run out
by this valve once the reservoir is full - normally closed.
4 - RELIEF VALVES:
Automatically opens and evacuates the pressure of the inner chamber, should the pressure
exceed a pre-set limit.
5 - TRANSPORT VALVE:
Valve used when nitrogen tanks are being shipped. Must be opened to place the pressure relief
valve on line
Page 71 of 224
TRAINING DEPARTMENT
6 - VENT VALVE:
Is used to let off the pressure of the head of gas in the inner chamber - normally closed.
7 - CHECK VALVE:
Used to prevent return of the reservoir's gas to the pump.
8 - OUTBOARD DISCHARGE VALVE:

Used to draw the liquid towards the high pressure pump.
9 - PUMP RETURN VALVE:

Used to recover the gas / liquid during "cool-down" and operation of the pump.
10 - INBOARD DISCHARGE VALVE:

Used to isolate the reservoir from the withdrawal valve [8].
11 - PRESSURE BUILDING VALVE:

Used to regulate the flow of liquid within the pressurising system. Normally partially or fully
open during the emptying of the reservoir.
12 - PRESSURE BUILDING COIL:
Used to convert the liquid into vapour and to re-inject it into the gaseous section of the reservoir.
13 - VACUUM SYSTEM:
This fitting must only be handled by skilled personnel as this is used to create the vacuum
between the chambers.
14 - FILL VALVE AT 85%:

Is used to determine when the tank is full at 85% of its gross capacity - normally closed.
15 - BURSTING DISC:
Outer capacity safety device in case of inner capacity rupture or inner piping breaking.
16 - IN-FILL NOZZLE:
Liquid in-feeding and return gas connection point.
17 - DISCHARGE NOZZLE :
Liquid Nitrogen discharge point.
18 - BACKFILL NOZZLE :
Liquid Nitrogen discharge or suction to from rear of tank.
19 - GAS WITHDRAWL VALVE:

Valve used when nitrogen gas is needed.
Page 72 of 224
TRAINING DEPARTMENT
SAFETY VALVES @ 3 BAR 19 CHECK VALVE 9

VENT VALVE 7 RETURN VALVE
6
OVERFILL VALVE
3 +14 16
BURST 5
TANK
DISC
PRESSURE
15 2
TANK
LEVEL
VACUUM 1
POINT
13 SAFETY VALVES @ 10 BAR
PRESSURE COIL 11
12 8 17
10
BACK FILL LINE
AMBIENT HEAT
Valve Positions During Transit And Yard / Worksite Storage
All valves must be in a closed position except during venting or maintenance / repair work.
The only exception to this rule shall be during transit on board a ship where due to the sea's
natural swell the tank's relief valve may vent off. This would be caused by liquid Nitrogen
forcing any trapped gas pockets to compress and hence generate pressure to lift the relief
valve. Therefore in some circumstances the vent valve [point 6] may be left partially or fully
open with all appropriate personnel made aware of this fact. None of BJ Services tanks have a
transit valve which may be left open all the time during transportation however the vent valve
[point 6] will suffice for this limited purpose.
Initial Cooling ("Purge", "Cool-down" and "Fill")
If the reservoir has not contained liquid Nitrogen for a considerable period or if valve [point 6]
and / or the draw-valves [point 8 & 10] have been open for a long period of time, it is
necessary to purge the inner chamber with nitrogen gas to eliminate all traces of humidity and
possible dust contamination within the chamber, before filling up.
(The reason for this is to ensure that all traces of water and / or contaminants are
removed. Water will freeze which may cause damage to moving cryogenic equipment
during pump operations).
Page 73 of 224
TRAINING DEPARTMENT
To flush out the inner vessel, use evaporated nitrogen from a supply tank / tanker or
alternatively connect a bottle of nitrogen gas to the filling line [point 16].
Important: Remember to purge through all feed lines before use with small amount of
Nitrogen as moisture or dust contamination may have accumulated within the lines.
Open valves [point 6, 3, 8, 9, 10, 14 & 11]. Turn the "On / Off" valve on the gas bottle to open.
Purge the container for a period of approx 12 hrs, then close the valves [point 6, 3, 8, 9, 10, 14
& 11] and the bottle of gas.
Allow 1 hour for stabilisation, then get a sample of nitrogen gas contained from within. The
tank will be considered free from humidity if the Dew point is at least equal to -50OC.
If not carry on purging until the Dew point is acceptable then close valves [point 6, 3, 8, 9, 10,
14 & 11] and disconnect the supply of Nitrogen gas.
Connect a filling line from an external reservoir supply to the feed reservoir [point 16]. Open
valves [point 6, 9, 3 & 14] and the external feed tank valve to allow a small volume of liquid to
enter the reservoir chamber and vaporise off for approximately half an hour.
The reason for this operation is to gradually decrease the inner chamber's temperature ie
"Cool Down" sufficiently to allow Liquid Nitrogen to be filled without creating a sudden
temperature drop within and thus avoiding any possible shock fatigue or cold damage to
the inner chamber wall.
Once the inner chamber has been cooled down sufficiently the tank will then be ready to be
filled.
NOTE: If the tank is not to be filled immediately all valves must be closed and the tank
pressurised to 0.5 bar with dry Nitrogen gas. This is to prevent moisture ingress. The "Cool
Down" operation will have to be carried out again prior to filling.
To fill, fully open the external supply feed valve the liquid will now flow into the reservoir.
Continue filling until liquid is seen flowing out of the 85% fill valve [point 14] whereupon it
must then be closed. Continue filling until liquid flows from the 95% fill valve [point 3] then
close both the 95% fill valve [point 3] and the external supply valve. Purge the supply feed line
and ensure valve [point 9] is closed.
Since there is a Non-Return Valve [point 7] in line with the pump return valve [point 9], no
liquid Nitrogen can flow back in to the feed line, however the internals of the NRV may have
been inadvertently removed so therefore the pump return valve [point 9] must always be closed
after filling and pumping operations.
Check the internal gas pressure to ensure the pressure is at or below 0.5 bar (7 psig) then close
vent valve [point 6].
If the pressure is higher keep the vent valve open until the pressure drops to below 0.5 bar (7
psig) then close the vent valve [point 6].
Page 74 of 224
TRAINING DEPARTMENT
NOTE: Although there are liquid level gauges on all tanks these must be used as a guide only.
The fill valves [85% & 95%] are more accurate and must be used on all filling operations.
Disconnect the feed line and ensure that the protective cap is placed on to the filling point end
for the prevention of moisture and contamination ingress and ensure all valves are closed.
Filling a "Cold" Liquid Supply Tank
After the reservoir tank has been in service, it will be returned to the liquid supply source and
usually there will be a small quantity of liquid Nitrogen remaining in it.
This liquid will keep the inner vessel in a "cold" ideal condition for replenishment. This will
also minimise losses during refill. If however there is no liquid Nitrogen in the tank refer to the
previous section "Purge", "Cool-down" and "Fill".
To fill the reservoir open valve [point 3, 14 & 6], ensure valves [point 11 (pressure building
valve), 8 & 10] are fully closed. Connect a filling line from an external reservoir supply to the
feed reservoir [point 16], open the pump return valve on the reservoir [point 9]. Open the
external feed tank slowly and check for leaks.
If leaks are detected along the filling line close the external feed valve, remedy the problem and
continue filling.
Important: Do not under any circumstances close vent valve [point 6] or open pressure
building valve [point 11] during filling operations as high pressure will be created within the
chamber which will result in the relief valves lifting.
Do not leave unattended any filling operations.
NOTE: When filling into a "hot" reservoir noise and seemingly large volumes of visible gas
will be generated, a rise in pressure will also be seen - both these occurrences are perfectly
normal.
When liquid is seen to flow through 85% fill valve [point 14], close this valve. When liquid is
seen flowing from 95% fill valve close this valve and close the external feed valve on the
supply source and purge the line of liquid after which the pump return valve [point 9] may then
be closed.
Disconnect the feed line, ensure that the gas pressure within is 0.5 bar(g) or below then close
vent valve [point 6].
NOTE: On this type of tank there are two fill valves [point 3 & 14] on some tanks there may
only be one. It is worth remembering that if there are two such valves one will be to indicate a
level of approx 85% full and the other is full at 95%. If there is only one such valve then this is
the full at 95% valve.
Remember a liquid Nitrogen tank is never 100% full.
Page 75 of 224
TRAINING DEPARTMENT
Finally, double check to ensure that all valves are in a closed position and that the internal gas
pressure is 0.5 bar(g) (7 psig)or below.
As a guide and prior to transportation ensure that the gas pressure is below 0.5 bar(g) (7 psig).
The reason for this is that during transportation, adverse warm weather conditions and also due
to the normal day to day liquid evaporation the internal gas pressure will increase resulting in
the relief valve lifting. This may prove alarming to the uninitiated public.
Receiving Tank Supply Tank
14 3
9
10
6 8
11
Liquid
Numbered valves open all other valves

Pressure raise valve on the Supply tank should initially only be
Pressure Building
To evacuate liquid Nitrogen from the reservoir it is necessary to build a pressure within to
"push" the liquid out.
Connect a feed line from the reservoir to be pressurised to the fill point on the receiving unit.
The receiving unit may be an alternative reservoir or a Nitrogen converter.
To pressurise the reservoir, ensure all valves are fully closed and open valve [point 11]. Liquid
Nitrogen will now start to flow into the reservoir's own ambient vaporiser or "pressurising
heater".
The temperature of the surrounding air will be drawn in to the liquid Nitrogen through the
vaporiser walls and hence change the liquid to a gaseous state.The gas obtained is then piped
back to the gaseous section of the inner chamber thus building the inner pressure up.
When the pressure gauge [point 2] indicates a pressure of between 1 and 3 bar(g) 14 and 43
psig) (the pressure is dependant upon whether De-canting or Pumping is carried out), start the
liquid extraction by opening valves [point 8 & 10] and immediately close pressure building
valve [point 11].
To reduce the pressure open valve [point 6].

Refer to simplified schematic.
Page 76 of 224
TRAINING DEPARTMENT
Liquid Level
The liquid level is measured by a differential pressure gauge [point 1]. This indicator should be
used only as a guide especially during filling operations or when the tank is under pressure. The
85% fill valve [point 14] gives an indication when the reservoir is 85% full. The 95% fill valve
[point 3] gives an indication when the reservoir is 95% full. Usually the gauge is calibrated in
inches of water and a conversion chart may be displayed on some tanks.
General Storage
In order to avoid pollution of the inner reservoir by the introduction of moisture or other
contamination, the tank must be stored by applying the following instructions:-
The tank is "cold" (liquid Nitrogen present within)

Ensure all valves are closed, all protective caps are fitted to the inlet and outlet connection
points.
Allow the inner liquid to vaporise off and increase pressure. The pressure may be controlled by
the relief valve or by manual control via the vent valve [point 6]. The pressure must be
maintained above 500 kPa(g).
The tank is "heated" (no liquid Nitrogen within)

Ensure all valves are closed, all protective caps are fitted to the inlet and outlet connection
points. A minimum pressure of 500 kPa(g) (7 psig) dry Nitrogen gas must be maintained
within.
The tank must not be left with any valves open unless it is in the course of maintenance or
repair work or in accordance with section 4.0 Valve positions during transit & yard / worksite
storage.
Page 77 of 224
TRAINING DEPARTMENT
Maintenance
Periodical Check-Ups
To ensure that the apparatus operates properly, periodical examination must be made.
These check ups are as follows:
Parts to be examined Frequency
Check all valves and related equipment Every time the equipment is used.
to detect possible leaks.
Check, adjust and calibrate relief valves. Every year.
Check the liquid level & Pressure gauge. Every year.
Check vacuum pressure and fitments. Every year.
Other statutory requirements. as required.
Cleaning
All parts that are soiled with oil or grease must be cleaned off with a solvent.
Maintenance
It is preferable to replace used parts rather than repair them.
When a part has to be replaced, empty the reservoir of its cryogenic liquid and let the reservoir
depressurise completely.
All parts that have been dismantled and/or replaced must be protected from climatic conditions,
either with a plastic tape or by a well fastened plastic film.
Maintenance must be carried out in accordance with the company's Quality Management
System requirements under Inspection and Testing procedures.
Damage to the reservoir's vacuum

The reservoir is not equipped with a thermocouple gauge to measure the vacuum. Being a super-
insulated reservoir, damage to or a loss of vacuum will be detected by cold spots, frosts or
premature condensation on the outer chamber. Moreover, the gas pressure within will build up
abnormally quickly.
If none of these signs are noticed, the vacuum level is satisfactory. Should one of these signs
appear, contact the Company Engineer in order to obtain information on the procedure then to be
followed.
Page 78 of 224
TRAINING DEPARTMENT
Checking of the evaporation rate
After filling a reservoir, let it stabilise in an ambient temperature of 20oC (for 72 hours if the tank
is cold at the beginning - for 168 hours if the tank is warm at the beginning), under atmospheric
conditions i.e vent valve open [point 6].
The filling level shall be such that after stabilisation there must be 50% of liquid left within.
Check evaporation losses by means of a volumetric gaseous meter "TYPE GALLUS" (for
Oxygen) or equivalent connected to the vent pipe.
Measurement shall be taken over the next 24 hours.
Acceptable losses corresponding to this period of 24 hours shall be to a maximum of 50 litres

of liquid Nitrogen at -196oC at an atmospheric pressure of 760mm of Mercury.
For various measuring conditions, the correction formula mentioned in the manual of the
volumetric gaseous meter must be applied.
NOTE: If during a test, the obtained results are greater than the allowable maximum values, it
is recommended to retest. If these values are confirmed, advise the Company Engineer.
Safety Rules
It is up to user to ensure that the equipment is maintained. Consequently, he is responsible for
all accidents which occur due to his negligence.
Serious burns can be obtained by contact with cryogenic liquids or "cold" pipework. A person
working with cryogenic liquid should always wear correct protective clothing and footwear,
safety hat, eye and / or face protection and a pair of dry gloves, which can be easily removed
should some liquid permeate the gloves or if stuck to cold cryogenic pipework.
The "tucking" in of trouser leggings in to boots should be avoided.
Burns caused by cryogenic fluids are treated in the same manner as heat burns.
Page 79 of 224
TRAINING DEPARTMENT
ELEVATIONS OF LIQUID NITROGEN TANKS

Front view of the Air liquide rpb 8000 hlr tank.
5 +14 NOT PRESENT

ON THIS TYPE OF TANK
15
1
4
2
13 6
3
9
7
8 10
11 16
12 17 12
Side view of the tank.
LIQUID
NITROGEN
Page 80 of 224
TRAINING DEPARTMENT
Front view of the cryolor cnt 8000 - 2.5 tank.
Side view of the tank.
LIQUID
NITROGEN
Page 81 of 224
TRAINING DEPARTMENT
ZWICK NITROGEN UNITS OPERATING GUIDELINE
This guideline is for the Zwick 90K, 180K and 270K units.
WARNING:
All pre-job check lists should be satisfactorily completed in accordance with the Base
procedures prior to commencing operation with this unit.
In particular - check all fluid levels are in accordance with the following list:
Engine oil: Between max and min on dipstick.

Hydraulic oil: Must be on scale of tank level indicator.
Diesel: Sufficient for the job - normally full.
Engine coolant: Visible through radiator fill cap.
Funk gear box oil: Between max and min on dipstick.
Cryopumps g'box oil: Oil level to be visible in the circular sight glass on the
'warm end' of the pumps(1/4").
Air pressure: Pressure at 110 - 120 psi . If too low for starting, re-
pressurise from truck system by jumper hose or from
customer supply.
ENGINE WARM-UP
Turn engine throttle out 3 turns anti-clockwise.
Check that Amot valve on Pyroban is in open position. Or set the Pyroban levers if fitted to the
'Start' position (on old units reset the sentinal system)
Press in starter valve until engine is heard to fire.
Once started, adjust throttle in order that engine idles at 1000 rpm.
Prior to commencing cool-down with nitrogen the following engine conditions must apply
during idling at 1000 rpm:
Engine oil pressure 20 -30 psi.
Water temperature 170 oF
Coolant pressure 30 psi.
Hydraulic charge pressure 250 psi.
NOTE: The unit should remain idling during cool-down. There is no need for increased revs of
the engine since the nitrogen is driven through the system by pressure from the tank and the
boost pump.
Page 82 of 224
TRAINING DEPARTMENT
Nitrogen Cool-down and pumping
WARNING:
The cryogenic seals in the boost pump are designed to operate at temperatures equal to the
liquid nitrogen (-196 oC). Prolonged operation of the pump prior to it reaching this temperature
will result in severe damage to the seals.
Condition the nitrogen in the tank as described in the liquid nitrogen good housekeeping section
prior to commencing cool-down.
Check that the hydraulic isolation valve on the boost pump is open.
Open boost pump vent and ensure boost pump is operational by briefly increasing the hydraulic
supply so that rotation can be seen. This will prevent the pump freezing up if operating in damp
conditions.
NOTE: The pump is allowed to turn over very slowly (about 10 RPM) while cool-down takes
place
Open the tank suction & return valves and pump unit inlet & return valves.
Open high pressure priming valve for main nitrogen pump(s) on unit.
Visually follow the nitrogen circuit to check for leaks.
Once liquid nitrogen is received at the boost pump vent, turn on the boost pump and increase
hydraulic pressure to 550-650 psi. Close the liquid nitrogen vent valve and if prime cannot be
achieved within 10 seconds, turn off the boost pump and allow more liquid nitrogen to flow
from the vent. Wait 60 seconds before repeating this section until prime is obtained.
Upon gaining prime (indicated by an increase in the boost pump discharge pressure) adjust the
boost pump speed until the discharge pressure is reading 1 bar above the nitrogen tank pressure.
Upon receiving permission to pump, raise engine speed gradually to 1800 rpm (depending upon
pump rate required).
Prime the liquid nitrogen main pumps by opening the high pressure return to the tank and
pumping until the cold end and the return lines are white.
Close the high pressure priming valves to the main pumps and check for the resultant pressure
rise on the liquid nitrogen discharge gauge. If no pressure rise occurs, re-open the high pressure
priming valve, check the boost pressure (increase if necessary) and close the high pressure
priming valve.
Page 83 of 224
TRAINING DEPARTMENT
Start the pump(s) to pressure up the line to equal the well-head or vessel pressure prior to
opening the valve to the system.
Turning the pump control valve anti-clockwise such that the hydraulic pressure gauge reads
3200 psi will start the pump(s).
Adjust the main pump rate to that specified in the specific job program.
NOTE: If using a 180K unit, the total rate required should be obtained equally from both
pumps.
The temperature of the nitrogen output from the main pumps can be varied by opening the
tempering valve to reduce the temperature.
At all times during pumping all temperatures and pressures must be monitored. The following
figures should be used as a guideline:
Oil Pressure 60 psi

Water Temperature 190 oF
Engine Tachometer 1800 - 2100 rpm
Hydraulic Pressure 3200 - 4200 psi
Hydraulic Temperature 100 - 165 oF (Usually 10 oF than engine water)
Charge Pump Pressure 225 - 300 psi
Coolant Pressure 250 psi
Hydraulic Filter Pressure < 30 psi
GN2 line temperature 100 oF (hand hot)
Fuel pressure 40-60 psi
Boost pump loss of prime
Should loss of boost pump prime occur stop the main pump(s) and the boost pump.
Open the boost pump vent until liquid nitrogen is received. Repeat the cool-down process. Close
the boost pump prime valve followed by the high pressure prime valve. The liquid nitrogen
boost pressure will indicate the occurrence of prime.
If it is not possible to regain prime check the following items:
Nitrogen Tank pressure
Condition of nitrogen according to good house keeping section
Liquid nitrogen level in the tank.
Page 84 of 224
TRAINING DEPARTMENT
SYE NITROGEN UNITS OPERATING GUIDELINE
WARNING:
All pre-job check lists should be satisfactorily completed, in accordance with the Base
procedures, prior to commencing operation with this unit.

Water brake tank: Must be on scale of tank level indicator.
Cryopumps oil: Must be on scale of tank level indicator.
customer supply.
ENGINE WARM-UP
Ensure large water brake valve is closed.

Check that Amot valve on Pyroban is in open position
Or set the Pyroban levers if fitted to the 'Start' position;
Press in starter valve until engine is heard to fire. Hold in the Pyroban levers until the oil
pressure is stable for 30 seconds.
Once started adjust throttle in order that the unit idles at 1000 rpm.
Prior to commencing cool-down with N2 the following engine conditions must apply during
idling at 1000 rpm:
Engine oil pressure 20 - 40 psi.
Coolant pressure 50 psi.
Hydraulic charge pressure 225 - 300 psi.
Page 85 of 224
TRAINING DEPARTMENT
Cool-down and pumping
The cool-down of the N2 lines can commence, once the engine is running satisfactorily. The
unit should remain idling during cool-down. There is no need for increased revs of the engine
since the N2 is driven through the system by pressure from the tank and the boost pump.
WARNING:
liquid point of nitrogen (-196 Co). Prolonged operation of the pump prior to it reaching this
temperature will result in severe damage to the seals.
Open the tank inlet & outlet valves and inlet & return valves on the pump unit.
Visually follow the nitrogen flow loop to check for leaks.
Open the boost pump vent to the engine exhaust to enable cool-down of the boost pump.
Open the high pressure priming valve to vent to the exhaust to cool-down the main nitrogen
pumps.
Ensure the tempering valve(s) is/are closed
Turn the nitrogen centrifugal isolating valve to run (if isolating valve is fitted), and ensure the
boost pump is running by briefly increasing the hydraulic supply so that rotation can be seen.
This will prevent the boost pump freezing up if operating in damp conditions.
When large quantities of nitrogen gas can be seen at the exhaust, increase the hydraulic supply
to the boost pump to gain prime.
If prime cannot be achieved, reduce the hydraulic supply and wait 60 seconds before repeating.
Upon gaining prime (indicated by an increase in the boost pump discharge pressure) close the
boost pump vent and adjust the boost pump speed until the discharge pressure is reading 1 bar
above the nitrogen tank pressure.
Allow the main nitrogen pump ends to become cool and well frosted before closing the high
pressure priming valve.
Upon receiving permission to pump, raise engine speed gradually to 1500 rpm.
Start the main pump(s) to pressure up the line equal to the well-head or vessel pressure prior to
opening the system inlet valve.
Upon pumping, check for the resultant pressure rise on the liquid nitrogen discharge gauge. If no
pressure rise occurs check the boost pressure (increase if necessary).
Adjust the pump rate to that specified in the specific job programme.
Page 86 of 224
TRAINING DEPARTMENT
Open the water brake control valve and adjust so that the engine water temperature is raised to
150 oF. Adjust the water brake valve to keep the temperature required.
Adjust the output temperature of the nitrogen by means of the tempering valve. Open to
decrease, and close to increase temperature.
At all times during pumping the following temperatures and pressures must be monitored. The
following figures should be used as a guideline:
Oil Pressure 60 psi
Engine Tachometer 1500 - 2100 rpm Max.
Hydraulic Temperature 100 - 165 oF
Coolant Pressure 50 - 80 psi
GN2 line temperature 100 oF
Should loss of boost pump prime occur stop both cryopumps and the boost pump. Regain prime
by repeating cooldown procedure.
If prime cannot be regained check the following items:
Condition of nitrogen according to the good house keeping section
Page 87 of 224
TRAINING DEPARTMENT
HYDRARIG 180K UNITS OPERATING GUIDELINE
WARNING:
All pre-job check lists should be satisfactorily completed in accordance with the Base
procedures prior to commencing operation with this unit.
Cryopumps g'box oil: Oil level to be visible in the circular sight glass on
the 'warm end' of the pumps(1/4").
customer supply.
ENGINE WARM-UP
Ensure that the large water brake valve is fully open and the small water brake valve is fully
closed.
Check that Amot valve on Pyroban is in open position
Or set the Pyroban levers if fitted to the 'Start' position;
Press in starter valve until engine is heard to fire.
Once started, allow to run for 10 minutes to warm up the adjust so that unit runs at 1800 rpm.
Adjust the large water brake valve until the water brake pressure gauge reads 35 psi (if water
brake is fitted)
Page 88 of 224
TRAINING DEPARTMENT
Prior to commencing cool-down with nitrogen the following engine conditions must apply,
during idling at 1800 rpm:
Engine oil pressure 20 - 40 psi.

Water brake pressure 35 psi.
Coolant pressure 50 - 80 psi.
Hydraulic charge pressure 225 - 300 psi.
The unit should remain idling during cool-down. There is no need for increased revs of the
engine since the N2 is driven through the system by pressure from the tank and the boost pump.
Nitrogen cool-down and pumping
WARNING:
liquid nitrogen (-196 Co). Prolonged operation of the pump prior to it reaching this temperature
Condition the nitrogen in the tank as described in the Nitrogen Tank Operation Procedures prior
to commencing cool-down.
Open high pressure priming valve for the boost pump on unit.
Ensure tempering valve (small valve) on water brake is closed.
Open tank valves and unit inlet valves.
Visually follow the circuit of nitrogen to check for leaks.
Ensure boost pump is operational by briefly increasing the hydraulic supply so that rotation can
be seen. This will prevent the pump freezing up when operating in damp conditions.
Once liquid nitrogen is received at the vent, turn on the boost pump and increase hydraulic
pressure to 550-650 psi.
Close the liquid N2 vent valve and if prime cannot be achieved within 10 seconds, turn off the
boost pump and allow more liquid N2 to low from the vent. Wait 60 seconds before repeating
this section until prime is obtained.
Upon gaining prime (indicated by an increase in the boost pump discharge pressure)
immediately close in the vent valve and adjust the boost pump speed until the discharge pressure
is reading 1 bar above the tank pressure.
Upon receiving permission to commence pumping, start the main pump(s) to pressure up the
line to equal the well-head or vessel pressure prior to opening the valve to the system.
Page 89 of 224
TRAINING DEPARTMENT
If no pressure rise occurs re-open the high pressure priming valve. Check the boost pressure
(increase if necessary) and close the high pressure priming valve. Adjust the pump rate to that
specified in the specific job program.
At all times during pumping the following temperatures and pressures must be monitored. The
Oil Pressure 60 psi
Water Brake Pressure 35 psi
Hydraulic Temperature 100 - 165 oF
Coolant Pressure 50 - 80 psi
GN2 line temperature 100 oF
Should loss of boost pump prime occur stop main nitrogen pump. Open prime valve until
nitrogen can be seen at the exhaust. Repeat cooldown procedure. Close the boost pump vent
valve followed by the main pump prime valve. The liquid nitrogen boost pressure will indicate
the occurrence of prime.
Page 90 of 224
TRAINING DEPARTMENT
PRIOR DIESEL SPLIT PIECE PUMPS (180K) OPERATING GUIDELINES
Unit Numbers 185 & 187

The Prior Diesel Split Piece unit was developed to allow mobilisation to offshore installations
where the lifting capacity of the offshore cranes is less than that required to lift a full size
nitrogen pump, or has been down graded from its original specification.
The complete pump package comprises a Detroit diesel engine unit enclosed in an offshore
lifting frame and a separate Triplex pump unit in an offshore lifting frame.
When the units are deployed, the frames are bolted together with drop down bolts. These bolts
help to align the unit and prevent any movement due to vibration.
The engine skid contains the engine, radiator and fan, fuel system, air start system, clutch and
control panel, exhaust and exhaust cooling system and hydraulic loader. There is also provision
for the 3GP system to be fitted.
The pump skid comprises of the triplex pump, cryogenic boost pump, gearbox and hydraulic
pumps as well as all the hydraulic hoses and low and high pressure nitrogen pipework.
When the skids are mated together, the units are connected by a drive shaft, which is protected
by a 2 piece guard.
This guard MUST be fitted before the engine is started.
There are a further 4 connections to be made:

2” Quick release coupling from the engine water system to the LN2 skid.
2” Quick release coupling water system return.
¼” Air connection to the control panel.
⅜” Air connection to the OPPS connection.
There is a 3-way valve on the engine unit that must now be switched to the “LN2” position. This
will allow the water to circulate around the system to the vapouriser coil, oil cooler and back to
the engine.
While the engine is running, the PTO (Power Take Off) switch can be operated which will
operate the gearbox and allow the drive shaft to turn and activate the hydraulic pumps via the
gearbox. The unit will now be ready for operation and the pump can be controlled from the
panel on the LN2 skid.
An over-pressure switch is fitted to the main triplex hydraulic pump relief valve. If an over
pressure occurs, the switch will send a signal to the relief valve, which will open and dump the
pressure and flow to the triplex drive motor. This will stop the triplex pump from turning.
Warning
If an over pressure does occur, the triplex operating control must be turned in to the off position
prior to resetting the switch.
If this is not done, the triplex will start turning as soon as the switch has been reset.
Page 91 of 224
TRAINING DEPARTMENT
The hydraulic load system is controlled from the main engine control panel and is variable from
0 to 3000 psig depending on the flow and pressure of the LN2 being pumped.
Note that the hydraulic loader may be used to bring the engine to operating temperature, but
must be set to zero pressure when not pumping LN2, as the hydraulic oil temperature may
increase to beyond its working temperature.
WARNING:
All pre-job checklists should be satisfactorily completed in accordance with the Base procedures
prior to commencing operation with this unit.
Triplex gearbox oil: Oil level to be visible in the circular sight glass on the
'warm end' of the pumps.
pressurise from supply.
Page 92 of 224
TRAINING DEPARTMENT
Nitrogen Cool-down and pumping
WARNING:
liquid nitrogen (-196 oC). Prolonged operation of the pump prior to it reaching this temperature
Check that the hydraulic isolation valve on the boost pump is open.
Open boost pump vent and ensure boost pump is operational by briefly increasing the hydraulic
supply so that rotation can be seen. This will prevent the pump freezing up if operating in damp
conditions.
NOTE: The pump is allowed to turn over very slowly (about 10 RPM) while cool-down takes
place
Open the tank suction & return valves and pump unit inlet & return valves.
Open high pressure priming valve for main nitrogen pump(s) on unit.
Visually follow the nitrogen circuit to check for leaks.
Once liquid nitrogen is received at the boost pump vent, turn on the boost pump and increase
hydraulic pressure to 550-650 psi. Close the liquid nitrogen vent valve and if prime cannot be
achieved within 10 seconds, turn off the boost pump and allow more liquid nitrogen to flow
from the vent. Wait 60 seconds before repeating this section until prime is obtained.
Caution: Do not allow the drip tray to completely fill or overflow, this unit does not vent to
the engine exhaust.
Upon gaining prime (indicated by an increase in the boost pump discharge pressure) adjust the
boost pump speed until the discharge pressure is reading 1 bar above the nitrogen tank pressure.
Upon receiving permission to pump, raise engine speed gradually to 1800 rpm (depending upon
pump rate required).
Prime the liquid nitrogen main pumps by opening the high pressure return to the tank and
pumping until the cold end and the return lines are white.
Close the high pressure priming valves to the main pumps and check for the resultant pressure
rise on the liquid nitrogen discharge gauge. If no pressure rise occurs, re-open the high pressure
priming valve, check the boost pressure (increase if necessary) and close the high pressure
priming valve.
The temperature of the nitrogen output from the main pumps can be varied by opening the
tempering valve to reduce the temperature.
Page 93 of 224
TRAINING DEPARTMENT
At all times during pumping all temperatures and pressures must be monitored. The following
figures should be used as a guideline:
Oil Pressure 60 psi
Water Temperature 90oC (≈190 oF)
Hydraulic Temperature 40 – 75oC or ≈100 - 165 oF (Usually 10 oF than engine water)
Coolant Pressure 250 psi
GN2 line temperature 40oC or ≈100 oF (hand hot)
Fuel pressure 40-60 psi
The rating of the high pressure pipe-work is for a working pressure of 1,000 BarG.
The cold ends are 1 ¼” for a maximum flow of 1,800 scf/m.
When pumping between 689 BarG and 1,000 BarG the pump flow is down rated to 500 scf/m
due to the rod loading of the main bearings of the triplex pump.
If 500 scf/min is exceeded, when pumping at these pressures, then the triplex camshaft will
be overloaded and severe damage could occur.
Should loss of boost pump prime occur stop the main pump(s) and the boost pump.
Open the boost pump vent until liquid nitrogen is received. Repeat the cooldown process. Close
the boost pump prime valve followed by the high pressure prime valve. The liquid nitrogen
boost pressure will indicate the occurrence of prime.
Page 94 of 224
TRAINING DEPARTMENT
FIRED UNITS ZWICK 240K (UNIT 110) OPERATING GUIDELINE
WARNING:
All pre-job check lists should be satisfactorily completed in accordance with Base procedures
'warm end' of the pumps just below nut for cable drive.
customer supply.
ENGINE WARM-UP
Turn engine throttle out 3 turns anticlockwise.

Check Sentinel oil pressure switch is set on. Switch must be turned so that the longer end of the
indicator is pointing downwards. (Switch is set to trip at pressures below 10 psi).
Press in starter button until engine is heard to fire. Repeat if necessary.
Once started, adjust throttle to 1,000 rpm and warm up engine systems for 10 - 15 minutes. Then
increase to maximum (1800 rpm).
Engine will warm up under full hydraulic loading until running temperature is achieved at which
point the Amot Valve will divert coolant to the radiator. If the coolant temperature exceeds 190
oF an automatic Rexroth valve on the radiator fan engages the fan motor to provide extra
cooling.
The following engine conditions must apply at this time:
Engine oil pressure: 40 - 60 psi

Coolant temperature: 170/180 oF
Coolant pressure: 30 - 60 psi
Hydraulic pressure: 3200 psi (both circuits)
Fuel pressure: 2 - 5 bar (if less, check filters)
Hydraulic charge pressure 225 - 300 psi
Page 95 of 224
TRAINING DEPARTMENT
Nitrogen cool-down and pumping
WARNING:
The cryogenic seals in the boost pump are designed to operate at temperatures close to the
boiling point of liquid nitrogen (-196 oC). Prolonged operation of the pump at temperatures
above this point prior to full achievement of cool-down will result in damage to the seals.
The cryogenic seals in the boost pump are designed to operate at suction pressures (tank feed
pressures) up to 8 bar. Where tanks designed for higher operating pressures than this (MSV'S,
Cryodiffusion RMP type, etc) are used to feed this unit, care must be exercised not to over-
pressure the boost pump as rapid and permanent damage will occur.
Condition the nitrogen in the tank as described in the Nitrogen Tank Operating Procedures prior
to commencing cool-down. The tank chosen to feed the unit may be a road tanker, an MSV, an
offshore tank or the unit's own rig tank. Returns may be back to that tank or into the rig tank.
Open tank valves, pump unit inlet valves, valves in the return line and all valves in the chosen
liquid nitrogen flow loop. At this stage all flow loop valves are open and all vents closed.
Start centrifugal boost pump on slow turnover (typically 60 rpm, 200 psi hydraulic). Open the
vent on the discharge side of the centrifugal pump. Cool loop down gently until liquid nitrogen
issues from vent.
Maintain slow turnover during cool-down to prevent pump freezing up (particularly in damp
conditions). Monitor at all times during cool-down as pump may stick; at the same time check
the loop for liquid nitrogen leaks.
Once liquid nitrogen issues from the vent, close vent and increase centrifugal pump hydraulic
pressure to 450 psi. Nitrogen discharge pressure should be 3-4 bar (45-60 psi). If prime cannot
be achieved within 15 seconds, back off the boost pump and allow more liquid nitrogen to flow
from the vent. Repeat this section until prime is obtained (indicated by an increase in boost
pump discharge pressure). Open high pressure prime valves (vents) on each GMPD cryogenic
pump to cool down cold ends.
Pre-set hydraulic sequence valves in each loop will back pressure the oil to load the engine. This
unit is fitted with sequence valve unloaders to allow adjustment of hydraulic temperature. Set
these unloader valves to max position i.e.. full engine loading and oil throttling for max heat
generation.
Open rig main discharge valve (Hamer valve). Start pumping by turning pumps control valves
anticlockwise until a hydraulic pressure of 3100 psi shows; at this point the pumps should start
turning. Further turns on the valves will increase pump rate to the desired flow shown on each
pump tachometer.
Close the high pressure priming valves and check for resultant pressure rise on the liquid
nitrogen discharge gauge for each pump. If no pressure rise occurs re-open the priming valves,
check boost pump discharge pressure (increase if necessary) and close priming valves again.
Repeat until prime achieved on each GMPD cryogenic pump.
Page 96 of 224
TRAINING DEPARTMENT
If starting to pump against a back pressure in the discharge line carry out the above sequence
with the HP returns valve open and gradually close to bring the cryogenic pumps up to that
pressure. Commence pumping to the job.
If pumping against low pressures (typical of most industrial jobs), adjust main rig discharge
valve to back pressure the rig to 3500 psi and keep it under load.
Adjust the main pump rate to that specified for the job. Total flow rate should be obtained
equally from both GMPD cryogenic pumps.
The temperature of the nitrogen discharged from the rig can be varied by opening and closing
the tempering valve.
This injects liquid nitrogen directly into the warm discharge gas. Open the valve to reduce
temperature and close it to raise temperature.
Operating temperatures and pressures MUST be monitored at all times during pumping. The
Oil pressure: 20 - 40 psi (20 on idle)
Fuel pressure: 2 - 5 bar
Coolant temperature: 170/180 oF
Coolant pressure: 250-290 psi
Engine tachometer: 1800-2100 rpm
Hydraulic pressure: 3000-3500 psi (both circuits)
Hydraulic temperature: 120-180 oF
Hydraulic charge pressure: 225-300 psi
HP hydraulic filter Pressure monitors (2): 0 psi (change at 30 psi)
GN2 line temperature: 100 o F (hand hot)
Page 97 of 224
TRAINING DEPARTMENT
Loss of boost pump prime
If loss of boost pump prime occurs - stop both GMPD cryogenic pumps.
Open GMPD cryogenic and boost pumps prime valves until liquid nitrogen vents.
Close boost prime valve first followed by the high pressure prime valve.
Boost pump discharge pressure will indicate occurrence of prime.
If prime is still not achievable, check the following items:
Nitrogen tank pressure
Nitrogen contents indicator
'Warm' liquid nitrogen can often be avoided, if the nitrogen tank is to be completely emptied, by
cracking the tank vent whilst running and keeping tank pressure low. Another method is to run
returns to a separate tank and separately condition the liquid for pumping once it is full.
Page 98 of 224
TRAINING DEPARTMENT
FIRED HP UNITS 90K (UNIT 101) OPERATING GUIDELINE
WARNING:
Hydraulic oil: Also between max and min on dipstick.
Heater header tank: Level inside sight glass.
'warm end' of the
Air pressure: Pressure at 110 - 120 psi . If too low for starting,
re-pressurise from truck system by jumper hose or from
customer supply.
Propane: Check spare bottle has red seal plug intact.
CHECK Ensure other side of double ended discharge manifold is

capped off securely.
ENGINE WARM-UP
Engine throttle on this unit is lever operated and pneumatic. Move lever to midway position.
Check Sentinel oil pressure switch is set on. Switch must be turned so that the longer end of the
indicator is pointing downwards.
Start Engine
Once started, adjust throttle to 1000 rpm and warm up engine systems for 10 - 15 minutes.
Page 99 of 224
TRAINING DEPARTMENT
HEATER WARM-UP
Increase RPM on engine to 1,500.

Screw heater hydraulic control in to start boiler skid. Set control to maximum at 1200 psi
hydraulic pressure.
Atomising air is fed directly to the burner from the engine compressor and can be varied from
20 - 40 psi depending on heater load.
Check that the supply pressure is 20 psi.
Turn on the propane supply to the pilot at the bottle. The ignition system is continuously on
when the heater is running so the pilot should light immediately.
Turn on the diesel supply to light the main burner and adjust to a setting just high enough to
avoid smoke from the exhaust stack.
Once the main burner is fully lit and stable - turn off the pilot.
Monitor the rise in water temperature until the heater gauge reads 140 oF and the nitrogen
vaporiser gauge reads 140 oF.
Water loop is now warmed up and ready for nitrogen vapourisation. Turn diesel supply off.
Prior to commencing cool-down with nitrogen the following engine and heater conditions must
apply:
Air pressure: 100-120psi
Heater hydraulic pressure: 1000 psi (drops to 500 psi when oil is warm)
Heater water temperature: 170 oF
Heater water pressure: 20-40 psi
Atomising air pressure: 20-40 psi
Engine RPM - WARNING:
Keep engine rpm up during cool-down and while running to ensure a good water supply to
heater and vaporiser. If too low heater will boil over and rig will "white line" at same time.
Page 100 of 224
TRAINING DEPARTMENT
NITROGEN COOL-DOWN AND PUMPING
WARNING:
The cryogenic seals in the boost pump are designed to operate at temperatures close to the
boiling point of liquid nitrogen (-196 oC). Prolonged operation of the pump at temperatures
above this point prior to full achievement of cool-down will result in damage to the seals.
WARNING:
The cryogenic seals in the boost pump are designed to operate at suction pressures (tank feed
pressures) up to 8 bar. Where tanks designed for higher operating pressures than this (MSV'S,
Cryodiffusion RMP type, etc) are used to feed this unit, care must be exercised not to over-
pressure the boost pump as rapid and permanent damage will occur.
prior to cooling down.
Operating Procedures prior to commencing cool-down. The tank chosen to feed the unit may be
a road tanker, an MSV, an offshore tank or the unit's own rig tank. Returns may be back to that
tank or into the rig tank.
Open tank valves, pump unit inlet valves, valves in the return line and all valves in the chosen
liquid nitrogen flow loop.
At this stage all flow loop valves are open and all vents closed.
Start centrifugal boost pump on slow turnover (typically 60 rpm, 200 psi hydraulic) and open
the vent on the discharge side of the centrifugal pump. Cool loop down gently until liquid
nitrogen issues from vent.
Maintain slow turnover during cool-down to prevent pump freezing up (particularly in damp
conditions).
Monitor at all times during cool-down as pump may stick; at the same time check the loop for
liquid nitrogen leaks.
pressure. Nitrogen discharge pressure should be 50-60 psi. If prime cannot be achieved within
15 seconds, back off the boost pump and allow more liquid nitrogen to flow from the vent.
Repeat this section until prime is obtained.
Recheck water temperature is above 150 oF. Re-light heater as per heater section. Re-heat water
loop if required. Adjust diesel to a low setting to maintain water temperature.
Open high pressure prime valve (vents back to tank) on the GMPD cryogenic pump to cool
down cold ends.
Open valve on main hydraulic feed into GMPD cryogenic pump motor. Pump will now gently
free wheel on slight hydraulic supply.
Page 101 of 224
TRAINING DEPARTMENT
Check HP returns valves are open. Screw in GMPD cryogenic pump control valve and start to
pump on recycle.
Close the high pressure priming valve and check for resultant pressure rise on the liquid
nitrogen discharge gauge for the pump. If no pressure rise occurs re-open the priming valve,
check boost pressure (increase if necessary) and close priming valve again. Repeat until prime is
achieved on the GMPD cryogenic pump.
Gradually close HP returns valve (GMPD will slow as throttling takes effect if properly primed).
Open rig main discharge valve at the same time. Commence pumping to the job.
Adjust the main pump rate to that specified for the job on pump tachometer.
The temperature of the nitrogen discharged from the rig can be varied by increasing or
decreasing the diesel pressure to the burner. (Max 15 psi, black smoke if too high).
Operating temperatures and pressures MUST be monitored at all times during pumping. The
Air pressure: 100-120 psi
Heater hydraulic pressure: 1000 psi (drops to 500 psi when oil is warm)
Boost pump hyd pressure: 500 psi
Heater water pressure: 30-40 psi
Atomising air pressure: 20-40 psi
Boost pump discharge: 1 bar above tank pressure
GN2 line temperature: 10 oC
Rig tank pressure: 1.5-2 bar
Page 102 of 224
TRAINING DEPARTMENT
Loss of boost pump prime
If loss of boost pump prime occurs - stop the GMPD cryogenic pump.
WARNING: Watch heater water temperature for any sign of imminent boil over.
Open boost pump prime valves until liquid nitrogen vents.
Close boost prime valve.
Boost pump discharge pressure will indicate occurrence of prime.
If prime is still not achievable, check the following items:
Nitrogen condition
Once boost pump prime is regained, check for GMPD prime.
Page 103 of 224
TRAINING DEPARTMENT
UNIT 103 (OPEN FIRED)
WARNING:
In particular - check all fluid levels and switches are in accordance with the following list:
Engine manual stop: Set in the run position.
Heater header tank: Level inside sight glass.
Main centrifugal Oil level to be visible in the circular sight nitrogen
pump glass on the pump gear box.
Air reservoir drain: Closed. (if open, air throttle inoperable).
Battery isolation Switch: On.
Engine 12v isolator: On.
Engine 24v Isolator: On.
ENGINE WARM-UP
Engine throttle on this unit is lever operated and pneumatic. Move lever to midway position.
Check Sentinel oil pressure switch is set on. Switch must be turned so that the longer end of the indicator is
pointing downwards.
Start Engine. (If the air pressure is 0 then hold the throttle open by hand.
Once started, adjust throttle to 1000 rpm and warm up engine systems for 10 - 15 minutes.
Page 104 of 224
TRAINING DEPARTMENT
HEATER WARM-UP
Close hydraulic bypass valve to feed hydraulic drive to heater and start fan, fuel pump, magneto
and water pump.
Close hydraulic bypass valve to feed hydraulic drive to auxiliary water pump. Both hydraulic
drives are direct and adjustable only by engine rpm.
Check gland packing on both water pumps after starting.
Atomising air is fed directly to the burner from the engine compressor.
Open the air supply pressure to 20 psi minimum.
The ignition system is continuously on when the heater is running. Spark should be visible at all
times.
Turn on the diesel supply to light the main burner, once alight open the boiler air inlet valve,
adjust to a setting just high enough to avoid smoke from the exhaust stack.
Monitor the rise in water temperature until the heater gauge reads 160 oF and the nitrogen
vaporiser gauge reads 150 oF .
Water loop is now warmed up and ready for nitrogen vaporisation. Turn diesel supply off.
Prior to commencing cool-down with nitrogen the following engine and heater conditions must
apply:
Engine oil pressure: Green 'eye' showing
Coolant temperature: Green 'eye' showing
Engine RPM: 1500
Air pressure: 100-120 psi
Heater hydraulic pressure: 500 psi
Heater water pump pressure: 60-80 psi
Aux water pump pressure: 60-80 psi
Atomizing air pressure: 20-40 psi
Prior to commencing cool-down, check that Low Temperature Cut off dial has the red needle set
to required trip temperature (usually 40 - 60 oF). Black needle indicates actual discharge
nitrogen temperature.
Check that LTC operates by setting red needle to a high setting - autovalve will close and alarm
will sound.
NOTE: When setting the LTC in winter the rig pipe-work will often be below the normal trip
temperature and consequently the system will remain tripped. To set - adjust the red needle to
below ambient. LTC will open the auto valve and allow nitrogen to be discharged from the rig.
Later when pipe-work has warmed up, reset red needle to usual trip temperature.
DO NOT FORGET TO RESET or LTC will remain disarmed.
Page 105 of 224
TRAINING DEPARTMENT
NITROGEN COOL-DOWN AND PUMPING
WARNING:
The cryogenic seals in the main centrifugal nitrogen pump are designed to operate at
temperatures close to the boiling point of liquid nitrogen (-196 oC). Prolonged operation of the
pump at temperatures above this point prior to full achievement of cool-down will result in
damage to the seals.
WARNING:
The cryogenic seals in the main centrifugal nitrogen pump are designed to operate at suction
pressures (tank feed pressures) up to 8 bar. Where tanks designed for higher operating pressures
than this (MSV'S, Cryodiffusion RMP type, etc) are used to feed this unit, care must be
exercised not to over pressure the boost pump as rapid and permanent damage will occur.
Condition the nitrogen in the tank as described in the Nitrogen Tank Operating Procedures prior
to commencing cool-down. The tank chosen to feed the unit may be a road tanker, an MSV, an
offshore tank or the unit's own rig tank.
Open tank valves, pump unit inlet valves and all valves in the chosen liquid nitrogen flow loop.
At this stage all flow loop valves are open and all vents closed.
Ensure control knob for main centrifugal nitrogen pump is wound right out (i.e.. pump is fully
turned) off before closing bypass valve on hydraulic pump on front of engine. (Drives hydraulic
motor on main centrifugal nitrogen pump).
Start main centrifugal nitrogen pump on slow turnover (typically 60 rpm, 200 psi hydraulic) and
open the vent on the discharge side of the centrifugal pump. Cool pump feed line down gently
until liquid nitrogen issues from vent. Maintain slow turnover during cool-down to prevent
pump freezing up (particularly in damp conditions). Monitor at all times during cool-down as
pump may stick; at the same time check the line for liquid nitrogen leaks.
Ensure main rig discharge valve is open to customer system and that LTC is set.
pressure. Nitrogen discharge pressure will rise suddenly above tank pressure to a level
depending on the customer system being fed. If prime cannot be achieved within 15 seconds,
back off the pump and allow more liquid nitrogen to flow from the vent. Repeat this section
until prime is obtained.
Recheck water temperature is above 150 oF. Re-light heater as in heater section. Re-heat water
loop if required. Adjust diesel to a setting to maintain water temperature.
Control nitrogen flow with pump speed and by carefully back pressuring the rig with the main
3" manual valve to achieve fully damped flow and improve vaporiser performance. Adjust flow
rate to required level using rig flow-meter or inline flowmeter as appropriate.
Page 106 of 224
TRAINING DEPARTMENT
If starting to pump against a back pressure in the discharge line, divert pump LN discharge,
using cryogenic hoses, back to tank. Start up flow on recycle with all discharge valves open and
rig check valve holding against the back pressure. Increase pump delivery and close in on
recycle to divert flow through the check valve and out against the back pressure.
If pumping against low pressures and high flow is not needed then use of decant feed from the
high pressure rig tank (or an MSV) can be considered. Warm up heater as before. Condition
nitrogen as before, but to a higher pressure; sufficient to adequately achieve required decant
flow.
Open valves as before except that main centrifugal nitrogen pump suction and discharge valves
should be closed and the pump bypass valve open. Commence feeding nitrogen to required rate.
(Decant is the preferred and safer method for feeding nitrogen foam generators where stop/start
operation is usual).
The temperature of the nitrogen discharged from the rig can be varied by increasing or
decreasing the diesel pressure to the burner. (Max 40 psi, black smoke if too high).
Operating temperatures and pressures MUST be monitored at all times during pumping.
Page 107 of 224
TRAINING DEPARTMENT
The following figures should be used as a guideline:
Engine oil pressure Green 'eye' showing

Coolant temperature Green 'eye' showing
Engine RPM 1500-2000
Air Pressure 100-120 psi
Heater hydraulic pressure 500-1000 psi
Heater water temperature 200 oF
Heater water pump pressure 60-80 psi
Aux water pump pressure 60-80 psi
Burner fuel pressure 0-20 psi depending on the job
Atomising air pressure 20-40 psi
GN2 line temperature > 50 oF
Loss of prime
If loss of prime occurs - stop the main centrifugal nitrogen pump.

WARNING:
Watch heater water temperature for any sign of imminent boil over.
Open main pump prime valve. Repeat priming steps. If prime is still not achievable, check the
following items:
Adjust nitrogen tank pressure up if necessary. DO NOT EXCEED 8 BAR.
Maintain tank pressure while pumping. DO NOT EXCEED 8 BAR.
Check condition of liquid nitrogen in the tank.
Page 108 of 224
TRAINING DEPARTMENT
ELECTRIC UNITS (MEV II) OPERATING GUIDELINE
Prestart Checks
Accurately level the vaporiser in both horizontal planes when spotted on-site.
Check the heat exchanger glycol level in the sight glass is full. Top up with 50% glycol solution
through relief valve port if required.
Check the 400 A load switches on the front of the thyristor control panel are in the OFF
position.
Check that wire no. 18 inside the thyristor control panel is connected to the correct terminal
(415 V, 440 V or 550 V) respective to the customer supply voltage to be used on-site.
Check that both 110 V and 240 V consumer unit circuit breakers behind the thyristor control
panel are in the OFF position.
Check that the low temperature isolation valve is closed.
Connect the LN tank pressure signal hose between the tank and the unit and open the isolation
valve.
Power On Guidelines
Connect main power supply cable to one of the two sockets. If flow requirement exceeds 300 A,
a second cable may be necessary.
Switch on main isolator (400 A load switch).
Switch on all the 240 V circuit breakers.
Switch on the 110 V circuit breaker No 2. (marked "heater", this powers up anti-condensation
heaters in the unit's autovalve electric actuators and in the immersion heater terminal box)
Circuit breaker MUST be switched on 30 minutes before powering up the 815 temperature
controller.
Switch on extractor fan and set to "extract". Fan must be running at all times as a sensible
precaution against minor leaks of nitrogen inside the unit.
Switch on fan heaters. These must be running at all times to avoid condensation on cabin
electrical equipment and to maintain stable cabin temperatures.
Switch on Oxygen alarm.
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TRAINING DEPARTMENT
Preparation for nitrogen flowing
Switch on circuit breaker No 3 on the 110 V consumer unit. (marked "panel", supplies power to
the control panel)
Check that chart recorder is in the ON position and that all panel digital displays are illuminated.
Control panel is now ready for operation.
Bring the heat exchanger up to required operating temperature by powering up the Eurotherm
815 temperature controllers. Required temperature will depend on required flow. Open flap in
front of each controller to reveal 3 buttons.
To set chosen heat exchanger temperature, open flap and press the scroll (right hand side,
marked P) button once.
Controller will display the letters SP (Set Point) and a small green flashing light.
Depress UP/DOWN buttons to select chosen temperature on the display.
Controller will now revert to displaying the current heat exchanger temperature.
While heat exchanger is warming up, set up all trip alarm Hi and Lo settings. (Hi & Lo settings
are displayed by depressing the relevant one of two small white buttons and adjusting the small
potentiometer adjacent to the button. Levels are ranged 0 - 100 %. Adjust gently, pots are
fragile.) See section on Trip Alarms for further details
Switch on circuit breaker No 4 on the 110 V consumer unit. (marked "valve feeds", supplies
power to all the autovalves)
Set required upper and lower tank pressure limits on tank pressure controller No 2. Set as for the
trip alarms - display is in psi units.
Once heat exchanger has reached operating temperature, open feed and return valves on LN
tank. Slowly open manual valve to pressure raise circuit. If tank pressure is below set upper
pressure limit, pressure raise autovalve will open.
With both heat exchanger temperature and LN tank pressure at chosen working levels, the unit
is ready to flow nitrogen gas.
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TRAINING DEPARTMENT
Nitrogen flowing guidelines
Check power failure autovalve is OPEN.

Check low temperature isolation autovalve is CLOSED.
Press button No 6 on the Eurotherm flow controller until the display shows "SETPOINT". (this
references directly to the gas flow control valve and should be set to 0%)
Manually and carefully open the low temperature isolation valve by 1/4 turn.
With the Eurotherm 825 controller still displaying SETPOINT, press the increase button and
slowly increase the setpoint in 10% stages to the chosen flow level. (controller range 0 - 100%,
flow range 0 - 40 m3/min, e.g. 25% represents 10 m3/min),The unit is now operational.
TRIP ALARM SETTINGS
Absolute Pressure:
Monitors main gas line pressure, upstream of flow meter and ranges 0 to 200 psi. (e.g. 50%
represents 100 psi / 85.5 psi)
Flow Temperature:
Monitors main gas line temperature and ranges 0 to 300 Co. (e.g. 10% represents 30 oC)
Heat Exchanger Temperature (one for each of two exchangers):
Monitors glycol water temperature in the heat exchanger and ranges 0 to 100 oC. (which
converts directly to a display of 0 - 100%)
Flow Rate:
Monitors gas flow rate and ranges 0 to 40 m3/min. (e.g. 25% represents a flow of 10 m3/min)
Tank Pressure (two alarm units allowing two tanks feeding):
Monitors LN tank pressure and ranges 0 to 200 psi. (e.g. 50% represents a tank pressure of 100
psi)
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TRAINING DEPARTMENT
Stabilising flow
The variable area flow meter must operate at a minimum upstream pressure of 60 psi.
The flow control valve operates ideally under a differential pressure of 10 -15 psi across it.
Compare customer line pressure (external gauge) with absolute pressure set at the flowmeter and
throttle if appropriate.
Gas temperature should be stable in the range 25 - 35 oC.
If not, adjust the 815 temperature controller in 1 oC stages until optimum temperature is
achieved.
Check that LN tank pressure is stable with a maximum variance of 2 psi.
Once the 4 stages above are established, log readings of flow, pressure, tank pressure,
temperature etc. and note consumption of LN.
Re-calibrate the D300 function converter output channel, using the hand programmer.
Shut down procedures
Shut the outlet valves on the LN tank and bleed all hoses. Wait 5 minutes for all liquid to clear
the system. With the 825 flow controller showing SETPOINT, depress the decrease button and
reduce the setpoint to 0%. The flow control valve will close.
Close the manual nitrogen gas outlet valve.
Switch off all circuit breakers on the 100 V consumer unit.
Switch off all circuit breakers on the 240 V consumer unit.
Switch off the main 400 A isolator on the thyristor control panel.
The unit is now shutdown. Isolate customer supply before disconnecting cable.
Switch off UPS interuptable power supply.
Page 112 of 224
TRAINING DEPARTMENT
AMBIENT VAPORISERS (UNIT SFV 15 & 16) OPERATING GUIDELINE
WARNING:
Starfin ambient vapourisers are very simple devices which allow decant liquid feed from
pressurised nitrogen tanks to be converted to gaseous nitrogen flows without the need for prime
movers, power supplies or site services.
They can however be misused dangerously in two ways:
If flow from the pressurised nitrogen tank exceeds the rated capacity of the starfin in use then
cold gas or even cryogenic liquid will be discharged from the starfin into hoses, fittings and
customer plant. It is very likely that all or any of these are constructed of materials which
embrittle at the low temperatures resulting from this excess flow. It is also very likely that they
will be under internal pressure from compressed nitrogen and can then easily fail explosively.
Starfins will always deliver more than their rated flow when first used, since extra heat for
vaporisation is available as the metal in the unit cools down and since there is little icing on the
fins initially, to reduce heat transfer efficiency with the ambient air. Later when the benefits of
these two effects has gone starfins settle down to their rated flow. Flow will be rated to typical
weather conditions and care should be exercised in winter when the cold ambient air and/or ice
build up may be insufficient to allow rated flow. In any event the discharge temperature of the
nitrogen can never exceed that of the air and will usually be 5-10 degrees below it. This should
be born in mind when using starfins in winter conditions. For these reasons, starfins should
NEVER be operated unattended.
Do not isolate starfins with liquid trapped inside as this can cause an explosion due to the
expansion of the liquid. Starfins are designed to a maximum allowable working pressure.
Usually this is well in excess of the MAWP of the liquid nitrogen tank feeding it and so
overpressure is impossible. Do not use a pump to force liquid nitrogen through the vaporiser, it
is possible to overpressure the starfin using the pump discharge pressure with explosive
consequences. For this reason starfins should always be fitted with a discharge manifold
containing:
pressure gauge
relief valve set to MAWP and designed to rated flow
vent valve
block valve (downstream of all of the above)
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TRAINING DEPARTMENT
RIG UP
Spot nitrogen tank and starfin,
Connect tank to starfin (use drip trays, timber boards, charged water hose if operating on steel
decking).
Run discharge hose lengths to injection point. Connect hoses and tie to local strong points. Run
hoses away from main access routes where practical.
Rig injection manifold containing:
check valve
vent valve (downstream of check valve) onto plant block valve if injecting into customer plant.
Open nitrogen tank discharge valve and control flow to suit job and to avoid "white lining".
Note the flow control should be by the discharge valve on the vaporiser, this allows full
residence time for the liquid and cold gas in the vaporiser.
RATINGS
SFV 15 & 16 are each rated for 800 m3/hr and 20 barg MAWP.
Page 114 of 224
TRAINING DEPARTMENT
STEAM VAPORISERS OPERATING GUIDELINE
Steam vaporisers are very simple and effective nitrogen vaporisers. The units can give high
volume and high temperature nitrogen very easily. The nitrogen is usually supplied from a high
pressure mobile storage vessel
Due to the design of the system the unit is self regulating with regard to the amount of steam
used.
The steam condenses on the coils inside the vaporiser and falls to the bottom of the system as
liquid condensate. In the bottom of the unit is a float that is lifted as the condensate fills the
chamber allowing the condensate to flow out to the drain, this is usually referred to as the steam
trap.
Preparation for using the units is as follows.
Determine quantity of LN2 to be vaporised and confirm that the customer can give the required
Kg of steam per hour.
Confirm what the discharge temperature required is. Will the customer steam be delivered to
the unit above that temperature.
Ensure that there is a disposal system for the steam condensate.
Set the Spirax steam regulator valve to deliver the required pressure of steam.
Confirm that all chiksans have high temperature seals in them. Normal chicksan seals and
grease cannot stand the high temperatures that may be generated with the steam vaporiser
Prior to flowing nitrogen ensure that the system is primed with steam using the steam trap
bypass. If this is not carried out the regulating action of the system will not be able to work
correctly and steam may not reach the vaporiser
Set LTC (Low Temperature Cut-out) to minimum temp 5 - 10 oC connect air lines to LTC
Page 115 of 224
TRAINING DEPARTMENT
OPPS - MECHANICAL SHUTDOWN PANEL
The over pressure shutdown panel has been designed to shutdown a nitrogen pump unit in the
event of an excessive pressure being reached. This will protect plant and equipment which is
being pressurised at a remote location from the pump unit. It has a secondary function in that it
allows the pump operator to monitor directly the pressure increase within remote process plant
etc.
Facilities on the panel include vent points for all connections, chart recorder connection and
connections capable of accepting 10" standard test gauges. This particular shutdown panel
should be used for nitrogen operations only as the process connections to the pilot valves do not
have any filtration.
EQUIPMENT DESCRIPTION
The shutdown panel is an open frame construction manufactured from Stainless steel. It is fitted
with a protection plate on the back to provide protection to the filter and to partially enclose the
high pressure pipework.
Overall dimensions of the panel are 750 mm wide, 625 mm high and 510 mm front to back, with
an approximate weight of 75Kgs.
The top plate provides a housing for all valves, mounted in a logical manner, along with pilot
selector valve and shutdown air signal pressure gauge. There is also fitted an identity plate.
At the rear of the top plate are two mounting points for process pressure gauges. These are
spaced to allow fitting of 10" standard test gauges and normal 4" gauges. Gauges are only fitted
when required during an operation and must be disconnected prior to shipping the panel. The
gauges, referred to as process pressure gauges in this manual, can be located to face in any
direction. The panel need not then have to be located to face front on to the operator if space is
restricted.
Within the framework of the panel are mounted six, pilot operated, three port, two position slide
valves. These are configured normally open and are mounted horizontally such that the
adjusting handle is pointing forwards towards the operator.
The first two low range pilots are supplied by Axelson with the remaining four being supplied
by the panel manufacturer Brisco Engineering. The pilots are adjustable over the pressure range
for each as will be indicated on the OPPS.
Adjustment is made by turning the adjustment handle, which faces out towards the operator.To
increase the trip setting of a pilot then turn the handle clockwise, screwing the handle in. To
decrease the trip setting then screw the adjustment handle out.
All pilot valves are fitted with a locknut at the back of the adjustment handle. This lock nut must
be backed off prior to attempting adjustment of the pilot valve.
After adjustment has been made then the lock nut should be nipped up against the handle.
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TRAINING DEPARTMENT
Do not over tighten the lock nut. Adjustment of the pilot valves can be done by hand. At
the most, when at full adjustment, then a small spanner may be required. Do not use
large spanners or pipe wrenches.
Also within the framework are all connections, an inlet air filter, high pressure line relief valve
and an actuation, or shutdown, valve.
The panel connections are split into two groups on opposite sides of the panel so that vents and
chart recorder outlet are on one side, with inputs on the other side.
The input connections are; air supply, process or sensing pressure, calibration pressure, and
shutdown connection from the pump.
Pilot valve ranges are as follows;
10 -- 125 psig Axelson
75 -- 550 psig Axelson
450 -- 850 psig Brisco
Maximum operating pressures for the panel are;
Process or sensing pipework 6000 psig (413Bar) & 10,000 psig (690 bar)
Instrument air 150 psig (10 bar)
Shutdown air connection 150 psig (10 bar)
The Shutdown panel has a dedicated set of high-pressure lengths of 1/4 inch R9R hose for
connecting to the calibration point and to the process system. Under NO circumstances must
these hoses be used for anything other than nitrogen operations in conjunction with the portable
Shutdown panel.
Air regulator/filter
The inlet air regulator/filter is a Norgren compact bowl type for removal of water and fine
particle filtration. The bowl is an auto drain type and should not require manual draining.
Regular observation of the bowl should be made to check fluid level. The air pressure to the skid
is adjusted by the handle on top of the device.
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TRAINING DEPARTMENT
GENERAL OPERATION OF PANEL
Location of Panel
The panel should be located close to the pump unit in a position where the operator can observe
the pressure gauge on the panel and operate the pump unit. The unit should be sited so that it
will not be easily damaged by other ongoing operations in the area.
Air Supply to Panel
Ideally the panel should be supplied with instrument air fed from the process involved in the
operation. On a platform, or a rig, this would be the standard instrument air system. One
advantage of using instrument air is that failure of instrument air would also shutdown the pump
unit.
Another advantage is that instrument air can sometimes be of better quality.
In the event that instrument air is not available then any air supply up to 150 psi (10 bar) can be
used. It should be ensured that air points are blown out to remove accumulated solids or water
prior to connecting air lines. All temporary air lines should also be well blown out prior to
connecting onto the panel.
The air supply is regulated within the panel to 30 psi. This should ensure that the actuation valve
will close but minimise the amount of air required to vent off through the pilot valves.
Prior to using the panel, this pressure should be checked and if not 30 psi then alter the regulator
to obtain this pressure.
In the event of failure of the regulator/filter then connect a temporary filter and regulator into the
air hose and regulate the pressure to the panel from there.
Check that the air supply to be used will be stable and not 'robbed' by other nearby users
otherwise shutdown of the pump unit will occur.
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TRAINING DEPARTMENT
Connection of Panel to Pump Unit
The shutdown panel is connected to the air shutdown system on the pump unit with a length of
1/4" hose. This connects the 'shutdown connection from pump' port on the panel to a suitable
point on the pump unit. The connection on the pump unit should be a 1/4" 4JIC, isolated with a
1/4" quarter turn ball valve. This connection on the pump unit must be suitably labeled for easy
identification by operators.
Note : It is very important that the shutdown air connection on the panel is only connected to the
shutdown air system on the pump unit. This is a low pressure system and under no
circumstances should this be connected to anything else. To prevent this, the shutdown air
connections are JIC and dedicated hose remains connected to this port.
The connection point on the pump unit will be into the restricted air supply which on venting
will allow the fuel rack to close. This air supply is maintained through a 0.025 inch diameter
orifice and is easily vented to shut off fuel to the engine.
The panel should be charged with air and the connection to the pump made prior to starting the
pump unit.
Each time that the panel is used the filter bowl should be checked.
OPPS Set –up procedure
Locate the nitrogen pump spread following standard BJ Rig-up procedures, siting the OPP
Panel and Haskel pump as close to the operators control panel as practicably possible.
Attach a 150psig (10Barg), air supply to the panel, securing all connections with whip checks
(and R-pins for crows feet hoses). Check that the air supply valve and air gauge isolation valves
are open and the air vent valve is closed. The selector valve outlet pressure gauge should now
be showing a pressure of 30 psig. The selector valve outlet pressure gauge reading can be
adjusted using the air regulator on the inlet to the air supply connection.
Connect the ¼” hose run from the test system to the sensing port on the OPP using whip checks
at each threaded connection as per standard BJ rig-up procedure. Connect a suitably ranged
gauge and chart recorder to their respective ports on the panel.
Only one range of instrumentation shall be attached to the panel at any one time. It is not
acceptable for example to attach both ranges of gauge required for a two-part pressure
test and simply isolate the lower ranged gauge using the gauge isolation valve on the panel
mount. This is in case the isolation valve passes and over pressurises the lower ranged
gauge.
Attach a ½” hose to the calibration port, with enough length to reach the discharge of the
Haskel pump.
The OPP is connected to the shutdown air system on the nitrogen pump via a ¼” JIC hose. This
is a low-pressure air system and therefore it is important that this connection is made to the
correct port on the OPP. It is for this reason that the shutdown connection has a JIC fitting, so
that it is different to all the other threaded connections on the panel, which are BSP instead.
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TRAINING DEPARTMENT
Gauge Connections and Cross-Overs
The pressure gauges that BJPPS get supplied on workscopes can terminate in either a BSP or a
NPT connection. Those that are supplied with the BSP connection are all supplied with a cross-
over to NPT and a small ‘dowty seal’ which sits inside the female part of the cross-over.
Care must be taken to ensure that incompatible threads are not ‘forced’ together or
assembled incorrectly. It appears that sometimes a BSP gauge c/w cross-over is connected to
the OPPS and when the gauge is removed for the next test the cross-over is left on the OPPS.
An NPT gauge is then connected to the cross over resulting in the threads being damaged.
As can be seen below it is fairly easy to identify between the two varieties, extra care must be
taken to ensure that incompatible threads are not forced together.
NPT Gauge Connection BSP Gauge Connection
Page 120 of 224
TRAINING DEPARTMENT
Operation
The panel is set up with the appropriate pressure pilot selected depending on the required
sensing pressure. During normal operation the instrument air will pass through the selected pilot
to the actuation, or shutdown, valve and hold it in the closed position. This maintains pressure
from the pump unit's shutdown system within the hose that connects the two. Should the process
pressure rise to the set pressure of the selected pressure pilot then it will actuate. This will allow
air, which was holding the actuation valve in the closed position, to vent. The actuation valve
will then move to the open position and vent off pressure from the pump unit's shutdown system
via the connecting hose.
This allows the fuel rack on the pump to close, cutting the engine on the unit preventing any
further pressurisation of the test system. On some pump units (for example the split – piece
units) the OPPS will only cut supply to the hydraulic lines when the trip pressure is reached.
This cuts out the triplex pump, hence, preventing any further pressurisation of the system. This,
however, does not cut the pump engine and so the unit will remain running. The pump operator
must be made aware of this set-up when using when using these particular units
NOTE The Shutdown panel should not be used to shut down a pump unit under normal
operations. The operator should continue to monitor pressures and stop the pump unit when a
specific pressure is reached.
The Shutdown panel should be set up to stop the pump only if a pressure is reached which is
above the test pressure that is required. This shutdown pressure should be chosen carefully with
regard to the required test pressure, Relief valve settings, Burst disk settings, Maximum
allowable working pressure and other pressure limitations. The pressure chosen should be 4% of
the required test pressure, above the test pressure or half way between test pressure and the
relief valve setting as a general guide.
When using the pilot operated shutdown panel, in conjunction with a Nitrogen pump unit, then
the rate of pressure rise within the test system should be limited. The rate of pressure rise should
be limited to 10% of the maximum test pressure per minute.
If the pressure pilot selected is not the lowest range one then, as the pressure rises, the operator
may hear the lower range pilots activating. This will only vent the small length of pipe between
these pilots and the selector valve. Only when the pilot that is selected activates will the
pressure through to the actuation valve be vented.
Venting of the pressure holding the actuation valve in the closed position can be observed by the
pressure fall off on the top plate gauge. This gauge is labelled 'Selector valve outlet pressure'
Suitably ranged gauges should be mounted on the gauge blocks on the top panel for observing
process pressures. A 10 inch test gauge should be available for during calibration of pilots.
A chart recorder can be connected to the dedicated port on the panel to record pressures during
pressurising operations.
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TRAINING DEPARTMENT
OPPS CALIBRATION
There are two methods for calibrating an OPP and they depend on the trip pressure required for
the test. This is because the gas cylinders supplied to calibrate the OPP are generally pressurised
to 200Barg. Therefore for OPP settings above 150Barg the line pressure must be boosted to the
required level using a Haskel pump.
Calibration method for settings below 150Barg
1. Hook up gas quad to Haskel inlet, leaving the gas quad isolation valve closed.
2. Connect calibration hose from OPP to Haskel discharge.
3. Screw the Haskel regulator out fully by rotating anti-clockwise (Or Use a HP
regulator direct from the gas quad if no Haskel pump is supplied for the job).
4. Open maintaining valve bypass and discharge isolation valve on Haskel.
5. Select Calibrate mode on OPP.
6. Select pressure range required.
7. Check air supply, air gauge and test gauge port isolation valves are open.
8. Open calibration port isolation valve.
9. Close the chart recorder, sensing port and gas vent isolation valves.
10. Check selector valve outlet pressure gauge is regulated to around 30 psi.
11. Open gas quad isolation valve.
12. Use the Haskel regulator to control the flow of gas into the OPPS (Or Use a HP
regulator if no Haskel pump is supplied for the job).
13. Raise the pressure in the OPPS to the required trip setting.
14. A pilot trip is indicated by a fall in pressure on the selector outlet pressure gauge.
15. If the pilot trips early vent the gas pressure and screw the pilot handle clockwise
to increase the trip pressure, if not screw the handle anti-clockwise to reduce the trip
pressure until the pilot dumps.
16. Vent off gas and re – check trip pressure by repressurising from step 12.
17. Open sensing port and chart recorder isolation valves.
18. Close calibration port isolation and reset OPPS to normal mode.
19. Ensure OPPS shutdown line to the pump is open.
20. Function test the OPPS to ensure that it is capable of shutting down the nitrogen
pump.
21. Close the Gas Quad Isolation valve and ensure that all lines are fully
depressurised.
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TRAINING DEPARTMENT
Calibration method for settings above 150Barg
1. Hook up gas quad to Haskel inlet, leaving the gas quad isolation valve closed.
2. Connect calibration hose from OPPS to Haskel discharge.
3. Close maintaining valve bypass and open discharge isolation valve on Haskel.
4. Select Calibrate mode on OPPS.
5. Select pressure range required.
6. Check air supply, air gauge and test gauge port isolation valves are open.
7. Open calibration port isolation valve.
8. Close the chart recorder, sensing port and gas vent isolation valves.
9. Check selector valve outlet pressure gauge is regulated to around 30 psi.
10. Open gas quad isolation valve.
11. Operate the Haskel pump to pressurise the OPPS, ensuring that the pressure in the
line does not exceed the rating of the gauge fitted to the OPPS. Ensure that you have
a clear view of the test gauge and are in position to turn off the Haskel
immediately or you get someone to help monitor the pressure for you.
12. A pilot trip is indicated by a fall in pressure on the selector outlet pressure gauge.
13. If the pilot trips early vent the gas pressure and screw the pilot handle clockwise
to increase the trip pressure, if not screw the handle anti-clockwise to reduce the trip
pressure until the pilot dumps.
14. Vent off gas and re – check trip pressure by repressurising from step 11.
15. Open sensing port and chart recorder isolation valves.
16. Close calibration port isolation and reset OPP to normal mode.
17. Ensure OPPS shutdown line to the pump is open.
18. Function test the OPPS to ensure that it is capable of shutting down the nitrogen
pump.
19. Close the Gas Quad Isolation valve and ensure that all lines are fully
depressurised.
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TRAINING DEPARTMENT
Maintenance of Panel
Maintenance required to the Panel is minimal. The pilot valve adjustment screws should be kept
very lightly lubricated with copperslip compound to allow easier adjustment and to protect the
threads. The air filter element should be replaced at regular intervals or when contaminated.
Regular checks should be made on the water level within the bowl and functioning of the
automatic drain.
The relief valve should be tested at least every year to ensure it remains within acceptable limits.
Prior to being sent out on an operation the Panel should be fully function and leak tested with
nitrogen. When leak testing check the instrument air system, the shutdown port system and the
high pressure gas inlet side. Check also that the vent and relief port are fitted with 'bug' caps.
These remain on the ports at all times.
The seals within the pilot valves can be replaced by a suitably trained person or the valve can be
returned to the manufacturer for seal replacement. If replacing seals in these valves then ensure
this is done within a clean area.
After use the panel should be dried and cleaned off with rags and then sprayed over with water
repellent, protective spray.
OPPS tie in point selection
Rig up ¼" sensor line from the shutdown panel to the process plant which is to be pressurised.
This should not be at the same connection point as the main injection hose as this will give a
“back pressure reading” and will not give a true system reading.
Care should be taken to ensure that the sensor line will see the system pressure in the process
line between the injection hose inlet point and the sensor line connection point. (as close as
reasonably practicable)
Care should be taken to ensure that there are no closed valves or actuated valves that could be
“closed in” at or during pressurisation.
For the aforementioned reason the sensor line should not be connected beyond the vessel /
pipework being pressurised.
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TRAINING DEPARTMENT
FAILURE OF PILOT VALVE
In the unlikely event that the selected pilot valve fails then the pump unit will shutdown as
pressure will be vented off from the actuation valve.
The Shutdown panel can still be used if an other pilot valve is selected depending on what has
failed with the faulty pilot valve. If it is the spring of a valve then the valve will merely be
inoperable and the rest of the panel may still be used.
If a pilot has failed due to internal seal failure then air pressure will be continually vented
through the failed pilot. To continue using the Shutdown panel in this circumstance would
require disconnection and plugging of the air lines to the affected pilot valve.
OFFSHORE FUNCTION TEST
Prior to starting pumping operations, on a particular operation, the client should witness a
function test of the pilot operated shutdown panel.
This would normally require to be done only once to ensure operability and correct hook up to
the nitrogen unit.
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TRAINING DEPARTMENT
OPPS SCHEMATICS
Page 126 of 224
TRAINING DEPARTMENT
EMOS - ELECTRONIC MANAGEMENT OVERPRESSURISATION SYSTEM
BJ Services 's Electronic Management Overpressure System is used for monitoring nitrogen
discharge temperature and system pressure during nitrogen pumping operations. The system is
set up to shut down the liquid nitrogen pump if minimum temperature or maximum pressure
exceed the desired parameters.
DESCRIPTION OF THE COMPONENTS
On the front panel are mounted:
I.S. Temperature Display
This is an intrinsically safe MTL 684 4 - 20mA 4 1/4 digit indicator. It is loop powered and once
calibrated for the correct temperature and temperature units (i.e. oC or oF) will display the
correct temperature.
I.S. Pressure Display
This is an intrinsically safe MTL 684 4 - 20mA 4 1/2 digit indicator. It is loop powered and once
calibrated for the correct pressure transducer and pressure units (i.e. bar or psi) will display the
current pressure.
Power Switch
A latching rotary switch. This switches on the 24V DC supply to the system. In the "OFF"
position 24V will still be supplied to the batteries as long as the mains is "On".
Mains LED
A BEKA intrinsically safe green LED cluster. When this is on 110V mains is being supplied to
the system.
Battery LED
A BEKA intrinsically safe green LED cluster. When this is on, the batteries are either being
charged (normal case) or supplying power to the system (in the event of mains failure, the mains
red LED would be off).
Solenoid Switch
A latching rotary switch. Rotating to the "ON" position opens the solenoid valve. Rotating to the
OFF position puts the solenoid under the control of the system.
Solenoid LED
A BEKA intrinsically safe green LED cluster. When this is "ON" the solenoid is activated.
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TRAINING DEPARTMENT
Alarm Mute Switch

A momentary push button switch. Pressing this switch when the audible and visual alarm have
been activated will silence the horn, but the visual alarm will continue flashing until the alarm
condition has ceased.
Alarm Test Switch
A momentary push button switch. While this switch is depressed, the horn will sound and the
alarm LED will flash. This is used to verify the alarm is operating.
Alarm LED
A BEKA intrinsically safe amber LED cluster. This flashes to indicate a pressure alarm
condition. There are four entries to the cabinet for electrical connection. These are fitted with
glands and clearly labelled as 110v Mains, Pressure Transducer I.S. Earth and Temperature
Transducer.
110V Mains Cable Entry
The 110v A.C. mains cable powers the system and must always be connected to the mains, even
if powered from the batteries.
Transducer Cable Entry
This connects to the Pressure/Temperature Transducer.
I.S. Earth
This provides a low impedance return to earth for the intrinsically safe equipment.
It must always be connected before the system is powered up.
Page 128 of 224
TRAINING DEPARTMENT
INTRODUCTIONA system has been designed to assist N2 pumping operations to give up to

date information on a number of parameters - namely SYSTEM PRESSURE and GAS
DISCHARGE TEMPERATURE. Once correctly set an over pressurisation of a customer's
process system or the process of "White lining" of the high pressure hose will be prevented.
This system is called "Electronic Management Overpressure System" or E.M.O.S.
The best way to describe the system is as an extension of the N2 converter’s "Pyroban"
safety system.
The intrinsically safe overpressure display and alarm system is designed to operate safely in a
zone 2 hazardous area while monitoring and displaying a pressure reading received from a zone
1 process system under test and a gas temperature reading received from the N2 converter’s gas
discharge point.
Should the pressure rise above a point set by the operator, an audible and visual alarm will
activate. Should the pressure rise above a second pre-set point a solenoid valve will open
allowing a connected air supply to flow through the valve and out of the E.M.O.S system. When
this occurs the air pressure drop within the N2 converter’s "Pyroban" safety system is detected
resulting in the unit shutting down.
Similarly, if the temperature falls below a preset value the alarm will activate and should it fall
below a second preset value, the solenoid valve will open and again the unit will stop pumping.
The system is powered from a 110v mains supply with battery backup facility in the event of a
mains power failure.
Intrinsically safe, armoured cables are used to transmit signals from the pressure and
temperature transducers to the main unit where it is converted to give a visual LCD indication.
IMPORTANT: The use of the E.M.O.S system does in no way relieves the operator from his
responsibilities when using N2 pumping equipment. The E.M.O.S system is no way a substitute
for an operator maintaining vigilance during these operations.
The operator must always continue to monitor and act accordingly when reviewing the N2
equipment's instrumentation panel in addition to the E.M.O.S system display.
Page 129 of 224
TRAINING DEPARTMENT
TECHNICAL DESCRIPTION
The front of the door of the cabinet is mounted with L.C.D displays, LED indicators and control
switches.
All electrical and pneumatic connections to the system are EExd gland or bulkhead connected
and are located on one side of the cabinet.
Louvres are located at the top of the cabinet which houses the explosion proof batteries and
intrinsically safe alarm horn.
The lower part of the cabinet houses the EExd box containing the power supply, I.S. barriers,
alarm and control switches and potentiometers mounted on its exterior.
The EExm II T4/T5 solenoid valve is also mounted inside the cabinet, located on the left hand
side above the EExd box.
Access Into Cabinet
The front panel of the cabinet is a door which is hinged on the right and kept closed by two 1/4
turn locks located to the left, at top and bottom.
The key is attached by a length of cable, to the left hand side of the cabinet and held in place by
a spring bracket when not in use.
Inside the Unit
An explosion proof EExd box containing the power supply unit, intrinsically safe barriers and
control circuitry is mounted inside the cabinet.
The lid of this box is hinged on the bottom and fixed down by bolts. When operating in a
hazardous area, this lid must be firmly closed by all the bolts. A coating of non setting grease
must be present between the mating surfaces of the box lid and the box. This must be re-applied
each time the explosion proof box is opened.
The electrical cables enter this box through special flameproof glands.
On the lid of the EExd box are mounted two switches and three potentiometers.Power
Isolator Switch
This isolates the power from the mains and the battery. This should be in the "OFF" position
whenever mains power is "Off" (to conserve the battery), or the EExd box is opened or any
maintenance work is required on the system.
Alarm Set Switch
Turning the this switch to the "ON" position changes the pressure display from reading the
pressure transducer signal to reading the alarm set point, adjustable by the Alarm Display
Potentiometer. Turning to the "OFF" position switches the display back to reading the pressure
transducer signal.
Page 130 of 224
TRAINING DEPARTMENT
Alarm Display Potentiometer

When the Alarm Set switch is "ON", this potentiometer adjusts the reading on the pressure
display from minimum - maximum allowing "Alarm Points A and B" to be set.
Alarm Point "A" and Alarm Point "B" Potentiometers
These, in conjunction with the "Alarm Display Potentiometer", allow the respective alarm points
to be set for the pressure.
* Alarm Point A sets the pressure when the solenoid valve will open.
* Alarm Point B sets the pressure when the alarm horn and flashing LED will
operate.
Power Supply Unit
This is and ERL ER515-24-110V, 60W, 2.3A power supply unit (PSU). It converts the 110v ac
mains supply to the 24v dc required for powering all the electronics. Apart from the 24v dc (+)
and (-) battery terminals the PSU has (+) and (-) battery terminals which connect to a 24v lead
acid battery.
This enables the PSU to act as an uninterruptible power supply, charging the batteries when the
mains is on and using the batteries as a power source when the mains is off.
The PSU is also fitted with fuses. A 2A antisurge 20 x 5mm fuse at the main input side and a
2.5A quick blow 20 x 5mm fuse at the dc output side.
The PSU also has a single terminal marked 'mains' on the output side. This outputs 8.2v if the
mains supply is switched on.Terminals
There are ten rail mounted terminals in total. They are as follows.
No Type Connected to
1 Earth Terminal 110v Mains Earth
2 Through Terminal 110v Mains Neutral
3 Fused Terminal 110v Mains Live
4 I.S. Terminal
5 I.S. Terminal
6 Diode Terminal
7 Through Terminal 24v Battery
8 Through Terminal Ov Battery
9 Diode Terminal 24v Solenoid
10 Through Terminal Ov Solenoid
Terminal 3 has a 2A antisurge 20 x 5mm fuse and terminals 6 and 9 have IN4001 diode.
Page 131 of 224
TRAINING DEPARTMENT
Intrinsically Safe Barriers

These provide a means of limiting the amounts of current and voltage that may appear outside
the EExd box. Connected to intrinsically safe system.
The barriers are as follows.
No Type Connected to
1 MTL 708+ Alarm Horn
2 MTL 787S+ Display
3 MTL 779+ Alarm LED Solenoid LED
4 MTL 779+ Battery LED Mains LED
5 MTL 3013 Power Switch Solenoid Switch
6 MTL 3013 Alarm Test Switch Alarm Mute Switch
7 MTL 3041 Pressure Transducer
8 MTL 3041 Temperature Transducer/Display
Barriers 1 to 4 are Zener diode barriers and require a high integrity, low impedance return path
to earth to provide intrinsically safe protection.
These Zener barriers have non replaceable fuses. If they blow, the whole barrier must be
replaced.
Barriers 5 to 8 are galvanic isolators and as well as being barriers, provide specific functions.
Barriers 5 and 6 have in built relays which operate when the switch in the hazardous area closes.
Barriers 7 and 8 are 4 - 20mA repeater power supplies - each supplying power to their
respective transducer and outputting the return signal to the control circuitry.
The galvanic isolators have replaceable fuses which are located in the top of the barriers.
Trip Amplifier
These are "PR Electronics" dual channel trip amplifiers. They monitor the 4 - 20mA loop and
trigger a relay per channel when the current goes above or below the set alarm point. The alarm
points for the pressure transducer are set by the potentiometers on the EExd box lid - Alarm
Point A and Alarm Point B.
The alarm points for the Temperature Transducer are set from the top of trip amp.
In built hysteresis ensurers the relays do not switch off again at the same point, but at a point
which is slightly less than it comes on. This prevents it quickly tripping on and off around the
trip points.
Note that these potentiometers are wired into the pressure trip amp which has been specially
modified.
The alarm points for the temperature transducer can only be set from inside the EExd
box, using the screw potentiometers marked Relay A and Relay B on the top of the
temperature trip amp.
Page 132 of 224
TRAINING DEPARTMENT
Relays
There are 2 x four pole changeover relays in the EExd box. One operates when the Alarm Set
switch is on and the other operates when the mute switch is pressed with alarm on.
Solenoid Valve
This is a Honeywell-Lucifer 3 port 2 way valve with a port size of 3" and an EExm II T4/T5 24v
dc, solenoid coil. The valve is normally closed. The 3" BSP ports are connected via "Prestlock"
fittings to 6 mm polyurethane tubing.
Each tube then connects, at the other end, to a bulkhead connector. These are located on the
bottom right hand side of the stainless steel cabinet. The bulkhead connectors provide a 3" NPT
female connection to the air supply. These connectors are clearly marked as "AIR IN", "AIR
OUT" and "AIR EXHAUST". The exhaust port does not require an air connection. In case of
any electrical failure, most solenoids have a manual override button.
Pressure Transducer
The pressure transducer is a "DRUCK" PTX 500-01. It is intrinsically safe, has detachable
military style electrical connectors and a 3" NPT male connection to connect to the pressurised
media. When a voltage is supplied by the system, the transducer will output a 4 -20mA signal
proportional to the measured pressure. This transducer is suitable and certified for operation in a
Zone 1 environment.
Pressure Transducer rig-up
Rig up sensor line from the shutdown panel to the process plant, which is to be pressurised
(taking care not to “twist” connection wires). This should not be at the same connection point as
the main injection hose as this will give a “back pressure reading” and will not give a true
system reading. Care should be taken to ensure that the sensor line will see the system pressure
in the process line between the injection hose inlet point and the sensor line connection point,
(as close as reasonably practicable) and that there are no closed valves or actuated valves that
could be “closed in” at or during pressurisation. For the aforementioned reason the sensor line
should not be connected beyond the vessel / pipework being pressurised.
Temperature Transducer
The temperature transducer is intrinsically safe and outputs a 4 - 20mA signal proportional to
the measured temperature. It is supplied with a 2" NPT connection to screw into the N2
converter’s discharge manifold and IS cable with end connector to connect to the temperature
transducer cable. This transducer is suitable and certified for operation in a Zone 2 environment
only.
Page 133 of 224
TRAINING DEPARTMENT
OPERATION
The system comes complete with a mains and I.S. earth cable, both which must be connected
before the system can be powered up. Failure to do this will result with the battery backup
facility being totally drained and NO I.S earth leakage protection.
Mains
This cable must be connected to a 110v ac supply only. The free end has an EExd approved
110v connector. If a different supply voltage is used the unit will be damaged. Ensure correct
supply voltage or correct "step up" or "step down" transformer is used.
I.S. Earth
As an intrinsically safe system, it must have a high integrity, low impedance return path to earth.
The significant proportion of any fault current that occurs at the barriers will be routed from the
barrier busbar, down this cable and returned to the neutral star point bond and hence back to the
distribution transformer.
A separate 2 core earth cable is fitted to the system for this purpose.
To summarise; ensure that the earth cable is securely connected to a suitable earthing
point.
Temperature Transducer Cable
The temperature transducer cable from the EMOS unit is a 2 core screened and armoured I.S.
cable. It is terminated in a military style connection suitable for connection to the temperature
transducer only.
Pressure Transducer Cable
The pressure transducer cable is exactly the same specification as the temperature transducer
cable. The only difference being the end connection which will only connect to the pressure
transducer or the extension cable supplied.
Air Connections
The air supply to the solenoid valve must not exceed 10 bar and should be fitted to the 3" NPT
female connector marked "AIR IN". When the solenoid valve is open, the air will exhaust from
the 3" NPT female connector marked "AIR OUT" to which the appropriate air line should be
fitted. The connector marked "AIR EXHAUST" should not be connected to anything, as its
purpose is to exhaust air to the atmosphere.
Now, fitted to most if not all BJ Services's N2 converters are two quick release fittings (simple
male and female couplings) suitable for the "AIR IN" and "AIR OUT" rubber hose connectors to
the right of the converter’s control panel. These fittings are fitted in to the high pressure Pyroban
safety switch.
Page 134 of 224
TRAINING DEPARTMENT
CONVERTER AIR OUT = E.M.O.S AIR IN"

POWERING UPOnce all connections are made to the process system, the EMOS system is
ready for powering up. Ensure all switches on the stainless steel cabinet door and inside the
cabinet on the EExd box door are in the "OFF" position.
EEx-d BOX
Switch on the external mains supply.
Locate the "POWER ISOLATOR SWITCH" on the EExd box lid and turn it to the "ON"
position.
The red mains LED and green battery LED should now be lit, indicating that the mains is on and
the battery is connected and therefore now charging.
Left in this state, the batteries will be charged, while the rest of the system remains off.
If pressure/temperature alarm settings are to be viewed, the system switch (on the panel door)
must be switched "On". This is achieved by the following.
Turn the "SYSTEM SWITCH", located on the cabinet door to "ON".
The system is now ready for use. The pressure and temperature displays must now be checked
and set for the appropriate transducer range (i.e. 0 min to 5000 psi max or 0 min to 7500 psi max
etc and -30 min to + 100 oC max etc). This is extremely important and must not be
overlooked.
PRESSURE AND TEMPERATURE ALARM DISPLAY SETTING
The pressure and temperature displays require setting up depending on:

a) Transducer range of measurement (for example 0 min to 5000 psi max or -30 min to +
100oc max).
b) Units of pressure/temperature required (PSI or Bar / oC or oF) .
To do this, you must first know the maximum and minimum values that can be measured by
the transducer in the appropriate engineering units. Look on to the body of the transducer or
associated documentation.
Page 135 of 224
TRAINING DEPARTMENT
PRESSURE OR TEMPERATURE L.C.D DISPLAY
To enter the configuration mode, press CONFIG and ENTER together. Once in the
configuration mode, pressing > or ? increases or decreases the viewed value. Pressing ENTER
stores that value and moves on to display the next configurable parameter.
The parameters that may be configured are:
- mode selection L or S select L
- resolution selection 1, 2 or 5 select 1
- decimal point select as position selection
(means none) appropriate
- 0% value select minimum value transducer
will measure (usually 0 psi / - oC)
- 100% value selected maximum value
transducer will measure (i.e 5000 psi)
After pressing ENTER on the last parameter (100% value), the display reverts to 'normal' mode
and the new parameters will be stored.
A check on the 0% and 100% values should be made on each display, every time the system is
powered up before operational measurements are taken just to make sure that they have not been
"inadvertently" altered.
IMPORTANT: If the maximum and minimum values have been altered, for example on a
range of 0 to 5000 psi and you use a pressure transducer of the range 0 to 10,000 psi, the actual
pressure reading value will differ from the actual pressure.
"CHECK THE RANGE - SET THE RANGE"
Page 136 of 224
TRAINING DEPARTMENT
PRESSURE ALARM SETTING
The alarm setting controls are located on the front of the EExd box. There are two alarm set
points:
Alarm Point A - above this set pressure, the solenoid will operate ("shut down").
Alarm Point B - above this set pressure, the alarm will sound and flash ("pre-alarm").
To Set These Two Points:
Ensure the system is completely powered up, then turn the "ALARM SET" switch to "ON".
The value now showing on the display is set and altered by adjusting the "ALARM DISPLAY
POTENTIOMETER" and is effectively simulating the signal from the pressure transducer. At
this point ensure both "ALARM POINT A & B POTENTIOMETERS" are fully wound
anticlockwise.
Turn the "ALARM DISPLAY POTENTIOMETER" until it reaches a value required for a pre-
alarm point (i.e 1000 psi).
Turn clockwise then anticlockwise "ALARM POINT B" potentiometer until the AMBER LED
just flick "On" and "Off" - do this a number of times to ensure a greater degree of accuracy then
lock the knob in to place.
Adjust the "ALARM POINT A" potentiometer clockwise for a shut down point (i.e 1200 psi)
until the GREEN LED goes "Off". Then turn anticlockwise until the exact point the LED turns
"On" and "Off"- do this a number of times to ensure a greater degree of accuracy then lock the
knob in to place.
NOTE: Because of hysteresis in the trip amplifier, the point where the alarm comes on, is not
the same point that the alarm will go off. It is therefore important to set the LED just to come on
while turning in the anticlockwise direction for maximum accuracy in setting alarm points.
After setting both alarm points, double check the settings by turning the "ALARM DISPLAY
POTENTIOMETER" anticlockwise until both LEDs (solenoid and alarm) are seen to turn off.
Turn the potentiometer clockwise will trigger the LED's at their respective alarm settings at the
appropriate points (i.e 1000 and 1200 psi respectfully). If the alarms do not activate at the
correct settings repeat the process until they do. This is extremely important for obvious reasons.
After the alarm points are double checked, return the "ALARM SET" switch to "OFF".
The display will return to reading the transducer pressure (which should be zero). The alarm
points will remain at that setting until changed by the operator.
Lock the cabinet door in position.
The system is now ready for operations.
IMPORTANT: It is important to note that the alarm points should be checked every time the
unit is powered up and before actual operations.
IMPORTANT: Care must be taken not to move "ALARM POINT POTENTIOMETERS" after
setting them. These will change the alarm points even if the "ALARM SET" switch is "OFF".
Page 137 of 224
TRAINING DEPARTMENT
TEMPERATURE ALARM SETTINGS
The alarm settings are located on top of the temperature trip amp inside the EEx-d box.
Therefore, the set points must only be altered in a safe area. It is recommended that the
temperature values (which have been pre-set at 0oC pre-alarm and shut down at -10oC) are not
altered whilst on site rather that they are altered in the workshop. The pre-set values are
adequate enough to prevent "whiteligning" of the high pressure hose and as such should not
need to be altered under normal North Sea operations.
The method of changing the settings are similar to that of pressure with the only difference
being instead of using the potentiometers on the front of the Eex-d BOX you must use the two
relays ("RELAY A" and "RELAY B") located on the temperature trip amps situated inside the
Eex-d box.
GENERAL INFORMATION
Solenoid Valve
The solenoid valve may be operated by two or three methods.
Automatically by the pressure / temperature reaching an alarm point.
Manually and electrically, from the valve solenoid switch located on the front of the cabinet.
To switch it on using this method, turn the switch to the "ON" position.
Manually, and mechanically, from the small red button located on the front of the solenoid
valve. This should only be necessary if some electrical failure occurs. To switch it on using this
method:
- First remove the protective plastic cover by pulling it.
- Depress the button fully to latch it on.
- Depress the button fully again to latch it off.
- Replace protective plastic cover.
On certain units this facility may not be available.
Alarm Horn
The alarm horn operates automatically by the pressure rising or temperature falling below their
respective alarm points. There are two controls located on the cabinet door associated with its
operation.
The "ALARM MUTE" button will silence the alarm horn if it has been triggered. If the pressure
has triggered the alarm, the flashing alarm LED will remain on until the alarm conditions has
ceased. Any subsequent re-triggering of the alarm will not be affected (i.e. alarm will sound as
normal).
The "ALARM TEST" button tests the alarm horn and flashing LED. It will function as long as
the button is pressed.
An alarm test should always be carried out at the start of each monitoring operation.
Page 138 of 224
TRAINING DEPARTMENT
LCD Display
The pressure/temperature display continuously displays the transducer pressure/temperature
values when the power is "ON" and the ALARM SET switch is OFF.
There are several buttons on the front of the display which unless the unit is set in calibration
mode will function as follows:
Pressing 100% displays the pressure that 20mA from the transducer represents (maximum
value).
Pressing 0% displays the pressure that 4mA from the transducer represents (minimum value).
Any other characters displayed, other than numbers may indicate a fault. Refer to
troubleshooting.
Battery Operation and Charging
The system has batteries installed in the top of the cabinet, so that in the event of a mains
failure, it will switch to battery power automatically and remain operational long enough to
ensure safe shutdown of the pumping system and/or provide continuous monitoring.
If the batteries are fully charged, the system should continue operating for several hours
dependant upon what state it is activated in.
As the alarm horn and solenoid valve consume most power it would be sensible, if running on
battery power to continuously man the system. In the event of the alarm horn sounding, silence
it with the ALARM MUTE button to conserve battery power.
While the "POWER ISOLATOR SWITCH" is "ON" (i.e. mains and battery LED's are on) the
batteries are being trickle charged.
To fully charge the batteries from a discharged state may require 24-36 hours of trickle
charging.
The batteries will discharge naturally after prolonged periods of non use.
If the batteries have been discharging for a long period of time it is recommended that the
system is left powered up with the"POWER ISOLATOR SWITCH" "ON", but the "SYSTEM
SWITCH", on the front of the cabinet turned "OFF". This is because fully discharged batteries
draw reasonably large currents while initially charging. Having the rest of the system powered
up may cause overload on the power supply and cause it to shut down.
IMPORTANT: It is good working practice to charge the system's battery for 24 hrs prior to use.
Page 139 of 224
TRAINING DEPARTMENT
Temperature Probe
When inserting this probe into the N2 converters discharge manifold it is important to remember
to ensure that the probe's tip must be in direct contact with the gas stream. The further away the
probe's tip is from the gas stream the less accurate the temperature reading will be.
As part of the inventory you must ensure that a 1/2" 3 way block valve with a 1/4" drilled and
tapped hole in the blank end is taken with you for the transducer to fit in to.
This block valve has proved extremely successful and is therefore is ideal for this purpose.
Cable Connections
The weakest link in the E.M.O.S system are the cable connections. The connections used are
male and female fitting so that inadvertent connection can not happen. If the connections are
damaged the cable may not be useable unless a repair can be done on site. Care should therefore
be taken when connecting the pairs up and when winding in the length of cables. It is
recommended to protect the coupling with PVC tape.
LCD Displays
When setting up the alarm settings you may notice that the display may "wander" +/-1 to 2 psi.
This is perfectly normal and is due to natural electronic wandering. Nothing may be done to
counteract this phenomenon.
CALIBRATION
The system is supplied as fully calibrated but re-calibration at regular intervals is recommended
to ensure accurate operation.
There are five items of equipment which can be calibrated.
Displays
These are calibrated for the transducers supplied with the system.
Pressure Transducer
This is calibrated by the manufacturer. This item should only be calibrated by the manufacturer
or alternative specialised sub-contractor.
Page 140 of 224
TRAINING DEPARTMENT
Trip Amps
Two potentiometers located on the top of the temperature trip amp set the temperature value
where the alarm and solenoid will operate.
These potentiometers are marked.
RELAY A - below this set temperature, the solenoid will operate.
RELAY B - below this set temperature, the alarm will sound.
PSU
The output of the power supply unit is set for 24v dc. This is altered by the small potentiometer
near the output terminals on the PSU.
Component Box
This requires calibration to give a correct 4 - 20mA output.
Temperature Transducer
This is calibrated by the transducer manufacturer to the temperature noted on the transmitter
located inside the head of the transducer, and any subsequent calibration should be carried out
by the manufacturer or other specialised sub-contractor.
MAINTENANCE
To prolong the life of the system and ensure correct functioning, it should be checked regularly
for the following:
i) All external cables are free from kinks and there is no damage to their outer sheaths.
ii) The door seal is intact.
iii) The display and LED's are kept clean.
iv) The EExd box is checked.
v) System operation is carried out in accordance to the operations manual.
Fuses
There are seven fuses in the system, all contained inside the EExd box. The fuses are as follows:
Power Supply Unit Input 2A Antisurge 20 x 5mm
Power Supply Unit Output 2.5A Quickblow 20 x 5mm
Mains Input 2A Antisurge 20 x 5mm
The remaining four fuses are for the 3013 and 3041 barriers.
Several spare fuses and consumable parts are enclosed in the mini manual contained in the
interior front door.
When replacing fuses, ensure that only the values and types specified for each unit are fitted,
since substitution of alternative types may impair the safety of the system.
Page 141 of 224
TRAINING DEPARTMENT
Barrier Maintenance
Zener Barriers (i.e. barriers 1 to 4) limit the current to the hazardous area. They do have a fuse
inside them as part of the circuitry, but if this fuse blows, the whole barrier must be replaced.
Galvanic Isolators (i.e. barriers 5 to 8) work in a slightly different way from Zener barriers and
have replaceable fuses.
The MTL 3013 has a 80mA fuse and the MTL 3041 has a 200mA fuse. The fuse is located in a
removable holder situated on the top of the unit. To release the holder, lift it up using a small
screwdriver, and withdraw it as far as it will go to allow the fuse to be replaced.
When replacing fuses, ensure that only the values and types specified for each unit are fitted,
since substitution of alternative types may impair the safety of the system.
Page 142 of 224
TRAINING DEPARTMENT
EMOS SYSTEM - OPERATIONAL

PRESSURE
TRANSDUCER
7 7
TEMPERATURE
1 1 TRANSDUCER
7 7 .
PRESSURE
PROTECTIVE BARS
DO NOT
FOR USE
LIFTING
TEMPERATURE
5 AIR "IN" 5 WARNING

110v SUPPLY ONLY
.
3 3 I.SCOMTEC
OVERPRESSURE
DISPLAY
SYSTEMAND ALARM
iiClTn
ooech
ss
o mm
ng
g y no
I.S
EARTH
3 AIR "OUT" 3 AIR
"EXHAUST"
EARTH STUD
110v SUPPLY
EMOS UNIT
. PROTECTIVE B ARS
DO NOT USE
FOR LIFTING
PRESSURE TEMPERATURE
3400 69
WARNING
110v SUPPLY
ONLY
. COMTEC
I.S OVERP RESSURE
DISP LAY AND ALARM
SYSTEM
Page 143 of 224
TRAINING DEPARTMENT
EMOS UNIT - FRONT VIEW
. PROTECTIVE BARS
DO NOT USE
FOR LIFTING
PSI / BAR oC / oF
.. ..
WARNING
110v SUPPLY ONLY
. COMTEC
I.S OVERPRESSURE
DISPLAY AND ALARM
SYSTEM
ON / MAINS BATTERY VALVE VALVE ALARM ALARM ALARM

OFF ON / OFF MUTE TEST
EMOS UNIT - SIDE VIEW
.. ..
PRESSURE 110v I.S TEMPERATURE

TRANSDUCER SUPPLY EARTH TRANSDUCER
. AIR
"OUT"
AIR
"EXHAUST"
AIR
"IN"
EARTH
STUD
Page 144 of 224
TRAINING DEPARTMENT
EMOS UNIT - CONNECTIONS
. TRANSDUCE
PROTECTIVE BARS
DO NOT USE
FOR LI FTING
PRESSUR TEMPERATU
TEMPERATU
TRANSDUCE
.
WARNING
110v SUPPLY ONLY
COMTE
110v
SUPPL
I.S C
DISP LAY AND
OVERPR ESSUR E
ALARM SYSTE
M
I.S
EARTH
AIR
AIR
"EXHAUST
AIR
EMOS - INSIDE UNIT
VENTILATION FILTER VENTILATION FILTER

BATTERIES ALARM
SOLENOID
Eex-d
BOX
CABLES
Page 145 of 224
TRAINING DEPARTMENT
EMOS - Exe-d BOX
ALARM
. .
POINT B
ALARM
POINT A
. .
POWER ALARM
ISOLATOR SET
ON / OFF ON / OFF
ALARM
DISPLAY
. .
. . . . . .
EMOS - Exe-d BOX ASSEMBLY
BAR 2 4 - 20 mA LOOP
BAR 8 TEMP TRANS

BAR 7 PRES TRANS
BAR 5 SWITH ISOL
BAR 6 SWITH ISOL

MTL 700 SERIES
MTL 700 SERIES
MOUNT BLOCK
BAR 1 - ALARM
MOUNT BLOCK
BAR 3 LED
END STOP
PSU
4 - 20 mA PCB
END STOP
PR ESSU R E
MATRIX LB
TEMP
RELAY 1
RELAY 2
T R IP A M P T R IP A M P
Page 146 of 224
TRAINING DEPARTMENT
EMOS - LOOP POWERED I.S. INDICATORS
MTL 684 I.S INDICATOR
WARNING
CLEAN WITH NON
1000.
ABRASIVE LIQUIDS
CONFIG mA MTL
LKLFJWEROIHOHOIPIEJHIG
VJNWKJHOIHGOIWHGIHOI
0% 100% ENTER
Page 147 of 224
TRAINING DEPARTMENT
3GP SYSTEM
3GP PRINCIPLE OF OPERATION
Concept
3GP is a totally new concept for providing explosion protection for diesel engines. Pyroban
have combined traditional explosion protection techniques with new thinking to provide a
totally new 'Engine Safe' concept.
Focus has been placed on reliability, engine uptime and maintenance reduction in the
development of 3GP. Pyroban have been able to present a concept which gives the operator an
engine uptime no different from that of an unprotected engine which meets the requirement of
the leading global standards.
The 3GP concept, though new to off-shore industries, has been proven in on-shore applications
since its introduction in 2001.
3GP also enables emission compliant electronically governed engines to be introduced into off-
shore applications without the burden of high maintenance flametraps.
3GP Philosophy
Reliability, improved uptime and reduced maintenance dependency is achieved by

the 3GP 'Safe Engine' concept in two key ways:
• The elimination of exhaust flametraps
• The introduction of an engine control and monitoring system for diesel engines which are to
be operated in Zone 2 areas
Page 148 of 224
TRAINING DEPARTMENT
Flametraps have traditionally been a mandatory requirement, located in the engine exhaust
system, their function being to extinguish any flames as a result of engines ingesting explosive
atmospheres.
Pyroban have extensively researched the effects of flammable gas ingestion into diesel engine
air inlet ducts over a number of years and as a result, 3GP incorporates gas and speed detection,
which through certification, has enabled Pyroban to eliminate exhaust flametraps for Zone 2
equipment.
By the removal of the exhaust flametrap the benefits are considerable:
• Eliminates the need for 8 hour flametrap change-outs
• Increases the life expectancy of the engine as back pressure is reduced
• Ensures COSHH compliance as well as that of manual handling regulations
• Increases reliability, uptime and reduces off-shore maintenance
GAS DETECTION
The gas detection system within 3GP is certified to EN50054 gas performance testing standard.
It also incorporates a unique forced gas calibration test, ensuring that the detection system is
fully operational.
Sensor heads are located in the air inlet duct to ensure that in the unlikely event of detecting an
explosive atmosphere, the system alarm will sound at 10% LEL propane (Lower Explosion
Limit) and then, if the hazardous atmosphere level exceeds 25% LEL, the engine will shutdown.
Page 149 of 224
TRAINING DEPARTMENT
Overspeed Detector
In parallel to the gas detection system, 3GP also includes an overspeed detection system which
monitors engine speed and which will shutdown the engine when a runaway situation is
detected.
Control and Monitoring Features
3GP offers a high level of flexibility to the operator and can be configured to monitor both
certification required signals such as temperatures and oil pressure, as well as parameters from
other equipment, by becoming the safety control and monitoring system for an entire package.
Principle of Operation
The system is an electronic engine shutdown system and when fitted to a diesel engine in an
offshore environment, allows it to be used safely in a Zone 2 hazardous area without the need to
fit exhaust flametraps. The system is designed to be either factory fitted or retrofitted in the field
to protect mobile diesel driven equipment. The system can be Pyroban configured to meet
specific customer requirements for either a one or two-engine application.
The design philosophy is to detect flammable material in the atmosphere and prevent the engine
being a source of ignition. This eliminates the requirement for an exhaust flametrap that would
otherwise incur a high level of maintenance downtime and be detrimental to the environment.
The engine is automatically shutdown upon detection of:
• Flammable gas in the atmosphere
• An over-temperature
• Engine over-speed
Engine shutdown is achieved by removing the fuel supply. In the case of engine over-speed, or a
flammable gas being detected, the air inlet valve is also closed.
A sample gas is used to verify correct operation and to calibrate the gas sensing head(s) every
time system 3GP is started. Satisfactory completion opens air and fuel supply valves or, powers
the engine ECM allowing the engine to be started.
It is not necessary to turn off 3GP every time the engine is shutdown. If 3GP is run continuously
for 30 days without calibration, the message GAS HEAD CAL DUE will be displayed.
All system components are mounted in IP66 or greater (ingress protected against dust and heavy
seas) stainless steel enclosures.
Page 150 of 224
TRAINING DEPARTMENT
Gas Detection Principle
The gas sensing head will detect Group IIA and IIB hydrocarbon gases and utilises pellistor
sensors. A pellistor is a very fine platinum wire coiled to form a heating element similar to a
light bulb. This element is then coated in a porous catalyst
To create a gas sensing arrangement, an active and a reference pellistor are connected to form a
wheatstone bridge. The reference device has its element sealed to prevent hydrocarbons
contacting the element. In clean air, both pellistors pass the same current and the bridge is
balanced. When hydrocarbons reach the active pellistor they burn on the element which changes
the current flowing through it and unbalances the bridge creating an output.
Gas sensing head operation may be impaired by certain materials necessitating more frequent
replacement. Typical materials are silicones, chlorine and some lead petrol additives. Pyroban
are able to eliminate the need for an exhaust flametrap because the gas detection system
performs a system calibration to check system integrity every time 3GP is started and detects
flammable vapour well before dangerous concentrations are reached.
Page 151 of 224
TRAINING DEPARTMENT
TYPICAL SINGLE ENGINE INTERCONNECTIONS
Page 152 of 224
TRAINING DEPARTMENT
Equipment
The system comprises the following components:
• · Main enclosure containing control electronics

• · Test gas bottle with regulator and pressure sensor
• · Air inlet air shutdown valve pneumatically or hydraulically operated
• · Remote user display
• · Up to 4 gas sensing heads
• · Emergency Stop
• · Engine Run/Stop
• · Beacon (optional extra)
• · Sounder (optional extra)
Override Facility
The system is fitted with an override facility to by-pass the safety system. This facility must
only be used when the area is known to be non-hazardous or in conjunction with a Permit To
Work system. The emergency stop input can not be overridden.
Control Unit
The system will always attempt a calibration when the ON/OFF switch is turned to ON after it
has been OFF for more than 10 minutes. Off periods of less than 10 minutes will not initiate a
recalibration.
If any of the Pyroban engine switches are in a fault condition, the display will show the
appropriate message and abort the calibration or start-up procedure.
Page 153 of 224
TRAINING DEPARTMENT
Emergency Stop
Overrides all other conditions and shuts the engine down.
Calibration Gas Bottle & Regulator

The pressure regulator incorporates a pressure switch to indicate a low level of the calibration
gas. A single bottle distributes gas to each head.
Gas Sensing Head (GSH)

The GSH consists of pellistor sensors coupled with signal conditioning electronics. An integral
solenoid valve enables automatic calibration. Calibration is initiated by turning the engine OFF
for more than 10 minutes and then ON again. Up to four gas sensing heads may be fitted.
Sensing Head Location

The primary Gas sensing head(s) are mounted remotely in the diesel engine inlet tract(s) and
sited, appropriate to the engine configuration, to give the best shutdown response time whilst
being afforded adequate protection from the environment. Care should be taken to ensure the
GSH is mounted at a point with adequate airflow, i.e. not mounted in a dead spot.
Gas Sensing Head (mounted in inlet tract)
The Gas Sensing Head (GSH) must be mounted in the engine air inlet duct. For naturally
aspirated engines, this can be between the air cleaner and cylinder head. Turbo charged engines
with flame traps downstream of the turbo, typically ATACC must have the GSH mounted
before the aircleaner as shown below:
Page 154 of 224
TRAINING DEPARTMENT
REGULATOR SETTING
The regulator output should be set to 0.9 to 1.0 bar as follows:
1. Using a tee piece, fit a pressure gauge to the gas tube.

2. Remove the domed nut covering the adjuster.
3. Adjust the regulator to read 0.9 - 1.0 bar. Undo screw to reduce the pressure, wind in to
increase pressure.
4. Following the adjustment, release pressure in the gas line and repeat the adjustment 2 to 3
times checking to ensure you have repeatability.
Low Pressure Switch
The pressure switch that indicates low calibration gas is set to 15 bar. A full test gas
bottle will indicate 200 bar approximately.
Leak Testing
The following procedure will test for leaks between the test cal gas bottle and the gas
sensing head:
5. Open the test gas bottle valve to charge the system.

6. Close the valve and take a note of the reading on the pressure gauge.
7. The reading should not decay over the next 30 minutes.
8. Should a leak be indicated, use a proprietry leak detecting fluid or apply soapy
water checking for bubbles.
Page 155 of 224
TRAINING DEPARTMENT
OPERATING
Start-up
Before the engine can be started, the 3GP system must be calibrated. To do this:
1. Turn ON the calibration gas bottle valve, which can be left ON.
2. Check the user display to confirm there is not an error message CAL GAS BOTTLE LOW.
This message indicates a replacement test gas supply will be required shortly. If the test gas
runs out, it is not possible to start and operate the engine as a safety system.
3. Turn the Run/Stop switch to RUN. (The system is calibrated every time the Run/Stop switch
is turned on).
4. The display will Show GAS SENSOR WARM UP followed by TEST GAS INJECTION and
TEST GAS DIFFUSION.
5. If any other message is displayed, find the heading below for an explanation of the message
and the action to take.
6. When the calibration is successful, you will see the message SYSTEM ACTIVE.
7. If you see SYSTEM FAULT, the calibration has failed. Turn the Run/Stop switch to
STOP then to RUN again to attempt another calibration.
8. Start the engine
NOTE : - IT IS POSSIBLE THE FIRST CALIBRATION AFTER FITTING A NEW

GAS BOTTLE WILL FAIL UNTIL ALL THE AIR IS PURGED FROM
THE CALIBRATION GAS SUPPLY PIPE.
Page 156 of 224
TRAINING DEPARTMENT
Stopping the Engine
1. Standard shutdowns not involving hazardous conditions will be performed by turning the
Run/Stop switch to STOP.
2. Emergency shutdown is achieved by pressing the Emergency Stop button.
3. Automatic shutdown can be achieved by (if fitted - BJ Units do not have the full spec at the
moment):
• · An over-temperature condition
• · Engine over-speed
• · Platform ESD
• · Auxiliary input I/O signal switches
• · Hazardous gas detected at gas sensing head(s)
The top line of the display will show SYSTEM SHUTDOWN and a message identifying which
condition caused the shutdown will be displayed on line 3 of the user display. The message will
be displayed until the system is restarted even though the condition causing the fault has cleared,
i.e. an over-temperature exhaust will shut the engine down and then as the engine cools, the
over-temp condition will disappear but the message will remain displayed.
If more than one condition caused the shutdown, they will be displayed in a rolling sequence.
Safety Over-temperature Shutdown
Over temperature inputs 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.
Safety Over-speed Shutdown
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.
Platform Emergency Shutdown (ESD)

The platform has it’s own emergency shutdown system. The Pyroban equipment can be linked
in to this shutdown system.
Auxiliary Input I/O Signal Switches
Auxiliary inputs are defined as per customer requirements. They will be configured to either
give a warning or to initiate a shutdown. A shutdown can be achieved by fuel or fuel and air cut-
off.
Page 157 of 224
TRAINING DEPARTMENT
Inputs are either normally open or normally closed. A time delay may be introduced or complex
decision making can be specified.
The message LOW OIL PRESSURE may appear referring to the engine’s lubrication system.
This is not normally acted upon by the 3GP system and is for information only although it can
be configured to shut the engine down.
Gas Shutdown
The message GAS SHUTDOWN HEAD (x) tells you which of the 4 possible heads initiated the
shutdown. This message on line 2 of the user display, indicates that a hazardous gas equal to or
above to the concentration of the test gas has been detected (25% LEL).
Further Gas Detection Display Messages:
GAS ALARM HEAD (x) – this is a warning message that a gas concentration of greater than
10% LEL is detected. No action is taken by the safety system, it is a warning only.
GSH CAL FAIL HEAD (x) – The calibration failed and you cannot start the engine.
GSH OUTPUT LOW HEAD (x) – The gas sensing head output is outside the normal level.
Contact Pyroban.
Emergency Shutdown
Electronically Controlled Engines

If the emergency stop is operated, the Engine Management System power is removed and hence
the fuel supply is removed stopping the engine immediately.
Mechanically Controlled Engines

The inlet air valve is closed.
Run/Stop Switch
Turning the Run/Stop switch to Stop shuts down the engine(s). At this point, a delay of 5
seconds is initiated after which power is removed from each gas sensing head and the inlet air
shutdown valve. A small amount of residual power will be used by the microprocessor and
logic.
When the Run/Stop switch is in the Stop position (switch open) the display top line will read
SYSTEM OFF. To activate the system, put the Run/Stop switch to the Run position (switch
closed).
One of two messages will be displayed:
Page 158 of 224
TRAINING DEPARTMENT
System shutdown
The calibration has been aborted because at least one of the shutdown inputs is active. Line 3 of
the display will show which shutdown input was seen as active.
Switch the Run/Stop switch back to the Stop position and rectify the problem.
OR
Gas sensor warm up, test gas injection followed by test gas diffusion.
The system is automatically calibrating the gas sensing heads which will take approximately one
and a half minutes. At the end of the process the top line will display one of the two following
messages:
ENGINE SAFE
The system is active and the engine may be started.
OR
SYSTEM FAULT
The calibration failed. Line 2 of the display will show which gas sensing head has failed and the
nature of the fault. Check the test gas bottle valve is open and the bottle is not empty. Position
the Run/Stop switch to the Stop position to reset the system and then return it to the Run
position. If the fault persists contact Pyroban.
To start the engine, turn the Run/Stop switch to Run to initiate the calibration process and when
complete, SYSTEM ACTIVE will display and it will be possible to start the engine(s).
Recovery from Shutdown
If a shutdown has occurred, it is necessary to reset the system by turning the Run/Stop switch to
Stop then to Run. This will initiate a calibration and when complete, the engine(s) may be
started as normal.
Safety System Override
The override function should only be activated if the local atmosphere is known to be non-
hazardous. None of the safety systems will be active. The fuel supply is permanently on and the
air valve permanently open (unless the emergency shutdown is latched active). The Run/Stop
switch can be used to start and stop the engine.
Page 159 of 224
TRAINING DEPARTMENT
To put the system in to override:
Open the cover on the lower left-hand side of the user display and press the Override button for
approximately 5 seconds. The message HOLD TO SET OVERRIDE will appear until the
override is set when Line 1 of the display shows SYSTEM IN OVERRIDE.
Whilst in override, line 4 of the display shows the current engine speed as a percentage of the
calibrated over-speed set point.
To return to the normal non-override state, press the override button for approximately 5
seconds until the override state is cleared as indicated by line 1.
Note: If the Run/Stop switch is in the RUN position, the system will immediately
begin a calibration.
Fault messages
Speed sensor
If the system detects there is engine oil pressure but there is no signal from the engine speed
sensor, the system will shut the engine down and indicate a SPEED SENSOR FAULT on line 3
of the display.
Gas sensing head signal
If a gas sensing head output falls below the normal range, the system will shut the engine down
and a GSH OUTPUT LOW HEAD (x) will be indicated on line 2 of the display.
Warning messages
Gas head cal due

It is intended that the 3GP system be switched off between each use of the engine. This ensures
the gas detection system is recalibrated and correct operation is verified at each use. If the 3GP
system is run continuously for 30 days, the warning GAS HEAD CAL DUE will be displayed
on line 2. This message may be cleared by putting the Run/Stop switch to the Stop position,
hence stopping the engine and forcing another calibration.
Gas alarm
If the concentration of flammable material in the atmosphere reaches a level equivalent to 10%
of the lower explosive limit of propane, a GAS ALARM warning will be shown on the display.
This message is not latching and will clear if the level of flammable material falls below 10%
LEL.
Page 160 of 224
TRAINING DEPARTMENT
Engine Over-speed Set Point
The procedure to set engine over-speed is as follows:
1. Put the system into override by opening the cover on the lower left-hand side of the user
display then press the Override button for approximately 5 seconds. The message HOLD TO
SET OVERRIDE will appear until the override is set. Line 1 of the display shows SYSTEM IN
OVERRIDE. WHILST IN OVERRIDE, LINE 4 OF THE DISPLAY SHOWS THE CURRENT
ENGINE SPEED AS A PERCENTAGE OF THE CALIBRATED OVER-SPEED SET POINT.
2. Although the engine speed is displayed, it is only meaningful if it has previously been
calibrated.
3. Run the engine up to its normal maximum rated operating speed.
4. Press the engine speed calibrate button for whichever engine is to be calibrated (Engine 1 or
Engine 2) for approximately 5 seconds. The message HOLD TO CAL SPEED will appear on
line 4.
5. Once calibrated, the engine speed indicated will change to 100%.
6. Disengage the override function by pressing the override button for approximately 5 seconds
until the override state is cleared as indicated on line 1.
7. If the Run/Stop switch is at Run, a gas sensing head calibration will be carried out.
Page 161 of 224
TRAINING DEPARTMENT
Checking Over-speed Shutdown
1. Recalibrate the over-speed shutdown value as described above, to less than 90% of the
maximum engine normal rated speed.
2. Stop the engine and take the system out of override.
3. Start the system and then the engine in the usual manner. Gradually increase the engine speed
until it shuts down on over-speed.
4. This will occur at 110% of the value calibrated in step 1 above.
5. When testing is complete, recalibrate the engine speed to the correct value.
Further Line 4 Messages
MUST BE IN OVERRIDE - will be displayed if an attempt is made to calibrate an engine’s

speed whilst override is not engaged.
ENGINE 2 NOT ENABLED – is displayed if an attempt is made to calibrate engine 2 on a

single engine system.
ENGINE START - will be displayed when the Air Start is activated. The Air Start cannot be
activated until the engine protection system is active or the system is in override.
NOTE: THIS FUNCTION WILL ONLY OPERATE WHEN AN ELECTRICAL START

RELAY IS FITTED.
Page 162 of 224
TRAINING DEPARTMENT
ENGINE TROUBLESHOOTING GUIDE
# TROUBLE PROBABLE CAUSE REMEDY
A. Engine Starter not 1. No Air Pressure. 1. Check system air

turning over pressure.
2. Faulty Start Button.
2. Ensure start valve is
pressurising diaphragm
valve.
3. Check Diaphragm Valve 3. Remove air pilot line

(Dump Valve to Starter) to be and push start button.
sure it is opening and delivering If good air pressure and
air supply to starter. volume come through
pilot line re-install pilot
line. Remove supply
hose to starter, push
start button. If
diaphragm valve opens
and discharges large air
volume the valve is ok.
Go to Cause 5.
4. Check the Emergency
Kill "Flapper" to see if 4. Reset Emergency Kill
it is in closed position. Flapper.
5. Starter seized.
5. If you are sure starter is
getting good air volume
and pressure but starter
will not turn, remove and
repair or replace as
necessary.
6. Utilise auxiliary engine starter

as a short term measure prior
to carrying out repairs to
primary starter.
Page 163 of 224
TRAINING DEPARTMENT
1. Slow cranking speed. 1. Refer to A.

B. Engine Cranks
but will not start
2. Engine not getting fuel. 2. Check fuel tank level,
fuel filters, fuel lines,
supply and return and fuel
pump.
3. Emergency kill activated. 3. Reset
4. Check normal kill 4. Repair or remove and

cylinder to see if it is replace normal kill
stuck in kill position. cylinder.
5. Throttle linkage binding. 5. Check linkage and make

adjustments as
necessary.
6. Poor quality fuel, 6. Drain fuel, change

incorrect fuel or water in filters and replace fuel.
fuel.
7. Improper oil viscosity. 7. Drain oil, change filters

and replace oil.
Page 164 of 224
TRAINING DEPARTMENT
C. Engine Misfiring 1. Poor quality fuel. 1. Drain fuel, change

filters and replace fuel.
2. Air in fuel system. 2. Check for air in fuel

system mainly on
suction side of fuel
pump.
3. Broken or leaking fuel 3. Check for fuel leaks and

lines. replace defective parts.
4. Restrictions in fuel lines. 4. Check fuel flow.

Replace fuel lines as
necessary.
5. Low fuel pressure. 5. Check fuel level and

kinks in fuel lines.
Change fuel filters.
6. Defective fuel injectors 6. Contact authorised

or pump. engine repair
representative
Page 165 of 224
TRAINING DEPARTMENT
D. Engine Stalls 1. Manicoolers or Flame 1. Remove & clean.

traps choked up.
2. Fuel tank vent plugged. 2. Check tank vent and

repair as necessary.
3. Low fuel supply. 3. Refer to C, Item 5.
4. High parasitic loading 4. Check for engine

(eg. LN2 pump hydraulic loading during starting.
pump speed control).
E. Erratic Engine 1. Air leaks in fuel section 1. Check for air leaks and
Speed line. repair as necessary.
2. Throttle linkage loose. 2. Check throttle linkage.
3. Engine governor 3. Contact authorised repair

problems. representative.
F. Low Power 1. Restrictions in air 1. Check air pressure in air

intake system, clogged air inlet manifold. Replace
filter. air filter and make
necessary repairs to air
system.
2. Poor fuel quality. 2. Refer to B, Item 6.
3. Damaged restrictions in 3. Check linkage, adjust or

throttle linkage. replace if necessary.
4. Emergency kill flapper 4. Check flapper, reset or

partially closed. repair as necessary.
5. Normal kill cylinder 5. Reset cylinder or repair

partially extended. as required.
6. Manicooler flame traps 6. Remove and clean flame traps

blocked by carbon build up or manicoolers (as appropriate).
Page 166 of 224
TRAINING DEPARTMENT
G. Engine 1. Coolant level low. 1. Determine cause,

Overheating replace defective parts
and replace coolant.
2. Expansion tank cap 2. Replace expansion cap.

defective.
3. Defective thermostat. 3. Replace thermostat.
4. Defective coolant 4. Replace coolant pump.

pump.
5. Inspect fan speed.
5. Fan not engaging fully Repair as necessary
(full RPM) or turning.
H. Low Engine Oil 1. Oil leakage, low level. 1. Check for leaks and
Pressure repairs as necessary.
2. Incorrect oil viscosity. 2. Drain oil, change filters

and replace oil.
3. Defective oil gauge. 3. Replace oil gauge.
4. Clogged oil filter. 4. Replace oil and filters.
5. Defective oil pump. 5. Contact authorised repair

representative.
I. Oil in Coolant 1. Defective oil cooler or 1. Contact authorised repair
seals. representative.
2. Blown head gasket. 2. Contact authorised repair

representative.
Page 167 of 224
TRAINING DEPARTMENT
J. Coolant in Oil 1. Defective oil coolant 1. Contact authorised repair

core or seals. representative.
2. Blown head gasket. 2. Contact authorised repair

representative.
3. Defective coolant pump. 3. Contact authorised repair

representative.
4. Cylinder sleeve seals
failure. 4. Contact authorised repair
representative.
Page 168 of 224
TRAINING DEPARTMENT
NITROGEN PUMPING SYSTEM TROUBLESHOOTING GUIDE
A. Low flow rate to 1. Low tank pressure. 1. Increase tank pressure.

unit from LN2
Tank 2. Supply valve not fully 2. Open valve fully on LN2
open. tank and skid.
3. Return valve closed or 3. Open valve fully on LN2

partially closed. tank and skid.
4. Suction strainer on LN2 4. Clean or replace

tank clogged. strainer.
5. Suction strainer on skid 5. Clean or replace

clogged. strainer.
6. Clogged piping or 6. Inspect piping and hoses

transfer hoses. to ensure free flow.
B. Frozen Valve 1. Moisture in stem packing 1. Thaw valve and dry out
packing.
C. Boost pump will 1. Hydraulic valve closed at 1. Open valve.
not turn boost pump.
2. Locked up from ice 2. Turn the shaft coupling
formation. with a pipe wrench. Do
not use excessive force.
If pump will not turn,
thaw out, and dry out
pump.
3. Suction valve to 3. Open valve.
hydraulic pump closed.
4. Defective hydraulic 4. Disconnect motor supply
pump. hose. Plug hose and
cap monitor. Test
pump pressure if pump
does not build pressure.
Check system relief
valve. If relief valve is OK,
remove and replace pump.
Page 169 of 224
TRAINING DEPARTMENT
D. Triplex pump will 1. Overpressure shutdown 1. Reset to operating

not rotate is active or tripped. position.
2. No hydraulic charge 2. Check flushing valve by

pump pressure. plugging off outlet
flushing valve. If
pressure is good remove
flushing valve and
repair or replace as
required.
3. Check pump drive 3. Replace damaged or

coupling to ensure drive broken drive coupling.
components are not
slipping of input shaft.
4. Check main system 4. Remove triplex dump

pressure. If pressure drive coupling. Attempt
rises above required to to rotate triplex. If
drive triples one of the hydraulic motor and
following is locked up : reduction gear box
(a) Hydraulic drive rotate, the triplex is
motor, (b) reduction gear locked-up. If the motor
box or (c) Triplex pump. and reduction gear box
do not turn, remove
motor from the gear box
and attempt to rotate
motor. If the hydraulic
motor rotates, the gear
box should be repaired
or replaced. If the
hydraulic motor does
not turn repair or
replace the hydraulic
motor.

Page 170 of 224
TRAINING DEPARTMENT
E. Dyno will not 1. Check hydraulic drive

build heat in the system. If hydraulic
coolant circuit. system is turning pump,
but pump is not building
pressure, repair or
replace coolant pump.
2. Check return filter for

blockage. Check lines for
obstructions. Check back
pressure system for closed
gate valve or
malfunctioning back
pressure relief valve.
3. Open Dyno load valve

enough to reduce RPM
of engine by 200 RPM.
If it is not possible to
reduce engine remove
Dyno supply hose and
measure supply flow at
maximum engine RPM.
Flow must be 25 GPM
to generate full load at
Dyno.
Page 171 of 224
TRAINING DEPARTMENT
TANK TROUBLESHOOTING GUIDE
A. Low rate to 1. Low tank pressure. 1. Build pressure on LN2 Tank.

pumping skid
2. One or more valves 2. Check supply and return
required for liquid valves to make sure
supply not fully open. they are fully open.
3. Ice or contamination in 3. Check for ice or

supply line filters. contamination in LN2
supply filters/strainers.
B. Frozen valve stem 1. Moisture in stem 1. Thaw and dry valve
packing. packing and packing
gland with dry nitrogen
gas.
C. Valve leaking 1. Foreign material or ice 1. Disassemble valve and
vapour and liquid on valve seat. repair or replace as
required.
D. Tank will not 1. Line to pressure 1. Clear obstruction and/or
build or maintain building coil obstruction. open valve.
pressure. Ice or valve closed.
2. Low liquid level. 2. Fill Tank.
3. Leak to atmosphere. 3. Locate leak and repair.

E. Excessive tank 1. Defective pressure 1. Check indicator, replace
pressure gauge. if necessary.
2. Road relief not 2. Repair or replace road

functioning. relief as required.
3. Pressure building valve 3. Close valve.

open.
Page 172 of 224
TRAINING DEPARTMENT
EMOS - TROUBLESHOOTING
The following is a quick guide to troubleshooting any problems with the system.
The system does not power up.

The mains and battery LED do not light.
Ensure the POWER ISOLATOR switch is turned to ON.

Check the mains input fuse, the power supply input fuse and the power supply output fuse.
An LED does not function.
Check the connections to the LED are secure.

Check the connections to the appropriate barrier are secure.
Check the barrier for correct operation.
The pressure display is blank.
Check the POWER ISOLATOR switch is turned to ON.

Check the POWER switch is ON
Switch the ALARM SET switch to ON. If the display does not operate.
Check the connections to the display.
Check barrier 2 is functioning correctly.
If the display does operate, switch the ALARM SET switch back to OFF and check:
The transducer cable is connected from the cabinet to the cable reel.
The transducer is connected to the cable.
The transducer cable is connected to barrier 8.
Barrier 8 is functioning properly.
The temperature display is blank
Check the POWER ISOLATOR switch is turned ON.

Check the POWER switch is ON.
Check all cables to the temperature transducer are secure.
Check barrier 8 is functioning correctly.
The display is showing non numeric characters.
Refer to operations manual.
Page 173 of 224
TRAINING DEPARTMENT
The pressure indicated by the pressure display is incorrect and not moving.
Check the ALARM SET switch is OFF.
Check transducer for damage.
Replace transducer.
Solenoid is not operating.

Check air connections to the cabinet are the correct ones.
Test the solenoid using the switch on the front of the cabinet.
Test the solenoid with the manual override switch.
Check the connections to the solenoid.
Check the connections to terminals T6 and T7.
Alarm is not operating
Check alarm using the ALARM TEST button.
Check connections to barrier 1.
Check barrier 1 is operating.
Page 174 of 224
TRAINING DEPARTMENT
NITROGEN EQUIPMENT SCHEMATICS
PLUMBING FOR CRYLOOR LN2 TANK

1 - LIQUID LEVEL GAUGE.
2 - PRESSURE GAUGE.
3 - FILL VALVE [95%].
4 - RELIEF VALVES.
5 - TRANSPORT VALVE.
6 - VENT VALVE.
7 - CHECK VALVE.
8 - OUTBOARD SHUT OF VALVE.
9 - PUMP RETURN VALVE.
10 - INBOARD SHUT OFF VALVE.
11 - PRESSURE BUILDING VALVE.
12 - PRESSURE BUILDING COIL.
13 - VACUUM SYSTEM.
14 - FILL VALVE AT 85%.
15 - BURSTING DISC.
16 - IN-FILL NOZZLE.
17 - DISCHARGE NOZZLE.
18 - BACKFILL (REAR FILL).
Page 175 of 224
TRAINING DEPARTMENT
5 +14 NOT PRESENT

ON THIS TYPE OF TANK
15
1
4
2
13 3 6
9
18 8 7
10
11 16
12 17 12
PLUMBING FOR L’AIR LIQUIDE LN2 TANK
1 - LIQUID LEVEL GAUGE.

2 - PRESSURE GAUGE.
3 - FILL VALVE [95%].
4 - RELIEF VALVES.
5 - TRANSPORT VALVE.
6 - VENT VALVE.
7 - CHECK VALVE.
8 - OUTBOARD SHUT OF VALVE.
9 - PUMP RETURN VALVE.
10 - INBOARD SHUT OFF VALVE.
11 - PRESSURE BUILDING VALVE.
12 - PRESSURE BUILDING COIL.
13 - VACUUM SYSTEM.
14 - FILL VALVE AT 85%.
15 - BURSTING DISC.
16 - IN-FILL NOZZLE.
17 - DISCHARGE NOZZLE.
18 - BACKFILL (REAR FILL).
Page 176 of 224
TRAINING DEPARTMENT
NITROGEN TANK - SCHEMATIC
1 - LIQUID LEVEL GAUGE: 10 - INBOARD DISCHARGE VALVE:

2 - PRESSURE GAUGE: 11 - PRESSURE BUILDING VALVE:
3 - FILL VALVE [95%]: 12 - PRESSURE BUILDING COIL:
4 - RELIEF VALVES: 13 - VACUUM SYSTEM:
5 - TRANSPORT VALVE 14 - FILL VALVE AT 85%:
6 - VENT VALVE: 15 - BURSTING DISC:
7 - CHECK VALVE: 16 - IN-FILL NOZZLE:
8 - OUTBOARD DISCHARGE VALVE: 17 - DISCHARGE NOZZLE :
9 - PUMP RETURN VALVE: 18 - BACKFILL NOZZLE :
19 - GAS WITHDRAWL VALVE:
NITROGEN TANK - SCHEMATIC

GAS WITHDRAWL RETURN VALVE
19 CHECK VALVE
9
VENT VALVE
SAFETY VALVES @ 3 BAR 7
4 6
OVERFILL VALVE
3 +14
16
BURST
TANK
DISC
PRESSURE
15 2
TANK
LEVEL
VACUUM
1
POINT
PRESSURE COIL SAFETY VALVES @ 10 BAR
13 11
10
12 17
18 8
BACK FILL LINE OUTBOARD
DISCHARGE
VALVE
AMBIENT HEAT
Page 177 of 224
TRAINING DEPARTMENT
BULKER SCHEMATIC
Page 178 of 224
TRAINING DEPARTMENT
NITROGEN TRANSPORT SCHEMATIC LEGEND UNIT # 2724B & 2725B
V-1 Main supply valve to boost pump suction

V-2 Return valve from boost pump to tank
V-3 Bypass valve
V-4 95% full valve
V-5 Isolation valve
V-6 Vapour phase valve for level gauge
V-7 Liquid phase valve for level gauge
V-8 Equalising valve for level gauge
V-9 Liquid valve for pressure build
V-10 Isolation valve for road relief
V-11 Main N2 tank pressure vent valve
V-12 Main discharge valve from boost pump
V-13 Vent valve for pressure build
V-14 Main N2 fill valve
V-15 Discharge line & fill line vent valve
V-16 Isolation valve for boost pump pressure indicator
V-17 85% full valve
V-18 Diverter valve to burst disks
V-19 Top fill valve
V-20 N/A
V-21 N/A
PI-1 Tank Pressure Indicator
PI-2 Boost Pump Pressure Indicator
SV-1 N2 Tank PSV
SV-2 Hose PSV
SV-3 Boost Pump suction line PSV
BD-1 Burst Disk #1
BD-2 Burst Disk #2
R-1 Road relief valve
HC-1 Hose Connection
HC-2 Hose Connection
CV-1 Check valve
PB-1 Pressure Build Coil
P-1 Boost Pump
S-1 Screen
VV-1 Vacuum valve
TV-1 Vacuum transmitter valve
TT-1 Vacuum transmitter connection
RF-1 Lost vacuum indicator cap
Page 179 of 224
TRAINING DEPARTMENT
NITROGEN UNIT - MAIN COMPONENTS
A IR
D IE S E L T A NK INT A K E
(F A R S ID E ) A ND E NG INE
E M E R G E NC Y E X HA US T
HYD R A UL IC O IL A IR BARBER
R E C E IVE R L IQ UID
T A NK S HUT D O W N VE NT
ASSEMBLY
A IR C O NT R O L
INL E T F L A M E P A NE L
ARRESTER
H IGH
D ISC H AR G E
C H AR T
R EC O R D ER
PR ESSU R E R A D IA T O R
EMOS
A IR L INE C O NNE C T IO NS
C O NNE C T IO N
CToe m
c hmn iosl s
o igoyn i
E NG INE R .P.M T R IP L E X
T R IPL EX
BLOCK PU M P
SPEED
P UM P
VA P O R IS ING
POT
C O O L A NT
T A NK
M A IN HE A T M A NIF O L D BARBER COOLDOW N T E M P E R ING L IQ UID

W ATER BREAK E X C HA NG E R COOLER R E S E T L E VE R VA L VE VA L VE IN
A ND
FLAME TRAP BOOST
B O O S T P UM P P UM P
F O R K L IF T FLAMETRAP O IL HE A T D YNO
SLOTS E X C HA NG E R IS O L A T IO N VA L VE
STORE
VA L VE
NITROGEN UNIT - TYPICAL CONTROL PANEL
SAFETY SHUT-DOWNS
HIGH WATER LOW OIL
TEM PERATURE PRESSU RE
HIGH EXH AU ST LOSS OF
TEMPERATURE COOLANT
NITROGEN
DISCHARGE
TEM PERATURE
HIGH NITROGEN
NITROGEN
DISCHARGE DISCHARGE DISCHARGE
CHART PRESSURE VALVE
RECORDER AND
"OPEN / CLOSE"
BUTTON
BOOST PU MP
PRESSURE
PU MP SAVER LIQUID NITROGEN

COOLANT CIRC UIT
CHARGE PUMP
TEM PERATURE
HYDRAULIC
PRESSURE
AND CONTROL VALVE
PRESSURE OIL
LUBE PRESSU RE
R.P.M
OIL TEMPER ATURE
WATER TEMPERATURE
TRIPLEX
PUM P
SPEED
AIR
PRESSU RE
M AIN PERMISSIVE ENGINE THROTTLE VALVE

PUMP CHARGE "START" SPEED
HYDRAULIC
SPEED PRESSURE ENGINE
PRESSURE EM ERGENCY ENGINE
CONTROL
AND "START" CONTROLS
ENGINE KILL
NITROGEN PUMP
CONTROLS
Page 180 of 224
TRAINING DEPARTMENT
Nitrogen Pump Unit – Cryogenic Schematics
NITROGEN PUMP UNIT - CRYOGENIC SCHEMATIC
PUMP SAVER GAUGE

COLD END
LN2 BOOST PUMP PRESSURE GAUGE
LN2 DIVERTER VALVE
COOL DOWN
BLEED VALVE
BOOST PUMP . . .
BOOST PUMP
BY PASS VALVE
TEMPERING
. .
ENGINE
VALVE EXHAUST PIPE
. COLD END
RECIRCULATION
RAPID "COOL DOWN" VALVE
VALVE . SUCTION
STRAINER
VENT VALVE
SUCTION
STRAINER
10 BAR HOT WATER COOLER WATER 10K

LN2 RELIEF VALVES "IN" "OUT" RELIEF VALVE
DISCHARGE
VALVE
LN2
BLEED VALVE
.
. . . . .
. . . . . . . . . .
GAS BLEED HIGH PRESSURE
VAPOURISING POT VALVE GAS DISCHARGE
LN2 LOW PRESSURE LN2 LOW PRESSURE BOOST PUMP
INLET VALVES OUTLET VALVES BYPASS
CONVERTOR "START-UP" AND "COOL-DOWN"

PUMP SAVER GAUGE
COLD END
LN2 BOOST PUMP PRESSURE GAUGE LN2 DIVERTER VALVE
"OPEN"
COOL DOWN
BLEED VALVE
"OPEN" BOOST PUMP . . .
BOOST PUMP
BY PASS VALVE
. .
ENGINE
EXHAUST PIPE
"CLOSED"
COLD END
. RECIRCULATION
VALVE
TEMPERING RAPID "COOL DOWN" . "OPEN"
VALVE VALVE
VENT VALVE
"CLOSED" "OPEN"
"OPEN"
DISCHARGE
VALVE
"CLOSED"
.
. .
. . .
. . . . . . . . . .
. GAS BLEED
VALVE
LN2 LOW LN2 LOW
PRESSURE PRESSURE "OPEN"
INLET VALVES OUTLET VALVES
"OPEN" "OPEN"
Page 181 of 224
TRAINING DEPARTMENT
C O N V E R T O R " G A I N E D P R IM E "
PUMP SAVER GAUGE
CO LD END
LN2 BOOST PUMP PRESSURE GAUGE
COOL DOW N
BLEED VALVE
"C LO S E D " BOOST
PUMP
. . .
. .
E N G IN E
E X H A U S T P IP E
.
.
VENT VALVE
"C LO S E D "
.
.
.
. .
.
. . .
. . . . . . . . . . .
GAS BLEED
VALVE
"O P E N "
C O N V E R T O R O P E R A T IO N A L
PUMP SAVER
GAUGE
COLD END
LN2 BOO ST PUM P PRESSURE GAUGE
BOOST
PUMP
. . .
. .
E N G IN E
E X H A U S T P IP E
COLD END
. R E C IR C U L A T IO N
VALVE
T E M P E R IN G " V A R IA B L E "
.
VALVE
"O P E N /
CLO SE"
HOT W ATER COOLER W ATER

" IN " "O U T"
D IS C H A R G E
VALVE
"O P E N "
.
.
.
. .
.
. . .
. . . . . . . . . .
.
GAS H IG H P R E S S U R E
V A P O U R IS IN G P O T BLEED G A S D IS C H A R G E
VALVE
"C L O S E D "
Page 182 of 224
TRAINING DEPARTMENT
C O N V E R T O R " S H U T -D O W N "
PUMP SAVER
GAUGE
CO LD END
LN2 BOOST PUM P PRESSURE GAUGE
COOL DOW N
BLEED VALVE
"O P E N " BOOST
PUMP
. . .
. .
E N G IN E
.
E X H A U S T P IP E COLD END
. R E C IR C U L A T IO N
VALVE
"O P E N "
.
T E M P E R IN G R A P ID " C O O L D O W N "
VALVE VALVE
"O P E N " "O P E N " VENT VALVE
"O P E N "
D IS C H A R G E
VALVE
"C LO S E D "
.
.
. . .
. . . . . . . . . . .
GAS BLEED
VALVE
LN2 LOW LN2 LOW
PRESSURE PRESSURE "O P E N "
IN L E T V A L V E S OUTLET VALVES
"O P E N " "O P E N "
CONVERTOR READY FOR SHIPMENT

COLD END
COOL DOWN
BLEED VALVE
"CLOSED"
BOOST PUMP . . .
. .
ENGINE
EXHAUST PIPE
.
TEMPERING
VALVE .
"CLOSED"
DISCHARGE
VALVE
.
. . . . .
. . . . . . . . . .
VAPOURISING POT
LN2 LOW PRESSURE LN2 LOW PRESSURE
INLET VALVES OUTLET VALVES NOTE:
ALL VALVES MUST BE SHUT AND PROTECTIVE CAPS FITTED
Page 183 of 224
TRAINING DEPARTMENT
N2 PUMPER SCHEMATIC
Page 184 of 224
TRAINING DEPARTMENT
WELL SERVICE NITROGEN CALCULATIONS
TECHNICAL CALCULATIONS.
1 GAS LIFT DESIGN
2 D.S.T. CUSHION DESIGN
3 DISPLACEMENT DESIGN
4 NITRIFIED TREATMENT DESIGN
5 FOAM CLEANOUT DESIGN
6 NITRIFIED CLEANOUT DESIGN
7 FOAMED CEMENT
Page 185 of 224
TRAINING DEPARTMENT
1 GAS LIFT DESIGN.
DATA :-
InnerString O.D_____",Wt._____Lbs/Ft,Vol_______B/Ft,Disp_______B/Ft
Outer String O.D_____",Wt______Lbs/FT,Vol_______B/Ft
Inner String Depth ________Ft M.D. ________Ft T.V.D.
Fluid Depth_______Ft M.D_______Ft T.V.D.,Wt_______p.p.g_______Psi/Ft
Temperature Gradient ______Deg F per 100 Ft.
CALC :-
M.D_______Ft / T.V.D_______Ft = _______(1) Deviation Factor
M.D_______Ft - Fluid level______Ft M.D. = _______Ft(2) Fluid in Hole
O.S.Vol______B/Ft - I.S.Disp_______B/Ft = ______B/Ft(3) Annular Vol.
( (3)______B/Ft + I.S.Vol_______B/Ft ) X (2)______Ft = ______Bbls(4) Fluid Volume
(4)______Bbls / 2 = _______Bbls(5) Overbalance Volume
(5)_______Bbls / (3)_______B/Ft = _______Ft(6) Height of fluid left in Annulus
(6)______Ft / (1)______D.F. X Fluid Hyd______psi/Ft = _______psi.(7)

Hydrostatic of Fluid in Annulus
( I.S.Depth______Ft M.D./ 200 X T.G____F/100ft ) + 60 =_____Deg F(8)

Av. Temperature
TABLE SCF/Bbl Space using (7)______psi & (8)____F = ______SCF/Bbl(9)
(9)______SCF/Bbl X (5)______Bbls = _________SCF(10) N2 Volume
Page 186 of 224
TRAINING DEPARTMENT
1. GAS LIFT DESIGN (Continued)
TABLE WHP Multiplier using Tbg Depth_______Ft T.V.D. = ________(11)

Wellhead Press. Multiplier
( Depth______Ft. T.V.D. X H.G______psi/Ft ) /______(11) = _______psi

Max Tubing Head Press.
RESULTS :- N2 Volume required for Kickoff = _________SCF Nitrogen
The N2 Vol. given in this result is the minimum amount of N2 required to displace a well to
Overbalance Point, the point at which the N2 Press. & Vol. is sufficient to displace the well to the
inner string depth. Allow for additional heavy fluid to be produced from the formation and add at
least 25% for slippage and losses.
Page 187 of 224
TRAINING DEPARTMENT
2 D.S.T. CUSHION DESIGN.
The D.S.T. calculation is probably the most simplest of all nitrogen calculations. As a nitrogen
operator, it will probably be the most frequent.
To help understand the calculation it is better to visualise exactly what you are trying to do with the
nitrogen.
This illustration shows a

TO N2 CONVERTER
well ready to be perforated
and the formation contents
4 1/2", 19.2 LBS/FT TUBING flowed back to surface for
assessment in productivity.
At this stage the well is
filled with kill fluid which
D.S.T. STRING
exerts a hydrostatic
pressure of 5023 psi. This
KILL FLUID
PRIOR TO
KILL FLUID 9.2 LB/GAL BRINE
situation is called
N2 CUSHION "overbalance", i.e. the
fluid column pressure
overbalances the
formation pressure.
If the well was to be
perforated in this situation,
perforation debris could
CIRC. VALVE enter the newly made
perforations and block
CIRCULATING
TVD:- 9000
VALVE CLOSED
MD:- 1O000 them. Additionally,
TEST VALVE because of the
CLOSED RETRIEVABLE
overbalance, the well
PACKER
would not flow.
One solution is to circulate
T.C.P. GUNS the well with a lighter fluid
so the well fluid
FORMATION FORMATION hydrostatic pressure
TVD:- 10500 4900 PSI "underbalances" the
KILL FLUID
KILL FLUID
MD:- 11500
TEMP. GRAD:- formation.
1.6 Deg. F/100ft
Page 188 of 224
TRAINING DEPARTMENT
The other of course is to displace part of the well with nitrogen. Which solution is chosen is entirely
dependant on how much drawdown is required during perforating.
The drawdown will depend on the formation type, formation permeability and perforation size.
This illustration shows

TO N2 CONVERTER the initial purge of the
fluid contents, by
TEST STRING
4 1/2"; 19.2 LBS/FT TUBING
nitrogen, into the
annulus. The fluid is
displaced down the test
COMMENCEMENT
string, through the
OF circulating valve,
PRESSURIZED N2 GAS
ANNULUS
VOLUME installed in the test
D.S.T. STRING string and out into the
MONITERED
IN PITS
N2 CUSHION
annulus. The
displacement volume
will be monitored in the
displacement tanks or
mud pits underneath the
rig. This will tell
exactly how much fluid
you have displaced out
CIRCULATING CIRC. VALVE from the tubing.
VALVE OPEN TVD:- 9000 Displacement should
TEST VALVE
MD:- 10000 stop 500 feet from the
CLOSED circulation valve to
prevent the over
displacement of
nitrogen into the
annulus and also to give
FORMATION FORMATION a water cushion
KILL FLUID
between the nitrogen

KILL FLUID
TVD:- 10500 PRESSURE
MD:- 11500
4900 PSI
and the formation.
TEMP. GRAD:-
1.6 Deg. F/100ft
500 feet may sound a
lot in height, but when
most of the calculation's
figures are driven from
volumes, 500 feet of
tubing turns out to be only around 6 bbls of fluid volume, in this particular well that figure translates
into 6586 scf of nitrogen. If the nitrogen pump rate was 1500 scf/min, 500 feet now translates into
less than four and a half minutes of pumping. This puts the success and the safety aspect of the job
into perspective.
You do not want nitrogen in the annulus because you will reduce it's function as a hydrostatic
barrier. The reduction of hydrostatic pressure in the annulus could also put a greater differential
across the packer after the well is perforated.
Page 189 of 224
TRAINING DEPARTMENT
This forces involved could unseat the packer, allowing the well to flow up the annulus and into the
mud pits. This would put the rig and it's crew into a extremely dangerous condition.
Although the first stage of the operation is the displacement, the first stage of the calculation is
finding the surface pressure of the nitrogen. To establish this we have to work from the bottom of
the well up to the top.
We know the formation pressure is 4900 psi and the customer in this scenario wants to have the
well underbalanced by 200 psi. This means that the bottom hole hydrostatic barrier will have to be
reduced from it's present figure of 5023 psi to one of 4700 psi.
We can do this as stated previously, by changing the heavier fluid to a lighter one or in our case,
replacing the contents with nitrogen and form a lighter hydrostatic barrier. To enable this to happen
a circulating sleeve is installed which can open and allow communication into the annulus from the
tubing. The circulating sleeve, in our case is 1500 feet above the formation, therefore the fluid
below it cannot be removed until the well is flowed back. We therefore have to include the
hydrostatic pressure of the 1500 feet (TVD) of the heavier fluid in our calculation. In this case it is
as follows:
Hyd. Press = Height of Column (TVD) x Weight of Fluid (LB/GAL) x 0.052
1500 x 9.2 x 0.052
717 PSI.
With this figure we can now find what the required hydrostatic pressure is required at the circulating
sleeve or the top of the water cushion (fluid left below circ. sleeve).
Required Hyd. Press. =Formation. Press. - Cushion Hyd. Press. - Underbalance
4900 - 717 - 200
3983 PSI.
As nitrogen weighs very little in comparison to a fluid, the hydrostatic pressure exerted by a
nitrogen column would not have much effect as a hydrostatic barrier.
Therefore we have to add additional pressure to the nitrogen to give the required hydrostatic
pressure as the formula for Bottom Hole Pressure (BHP) is:
BHP = Hydrostatic Pressure + Surface Pressure (WHP)
In our case we know the bottom hole pressure required at the cushion is 3983 psi all we have to do
is find the surface pressure.
This is found using tables:
Page 190 of 224
TRAINING DEPARTMENT
"BHP DUE TO COLUMN OF NITROGEN AT VARIOUS WHPs & TEMP. GRADIENTS"

As nitrogen is a gas and has to be compressed to establish a pressure we will have different tables
representing a range of different pressures. In addition to this the amount of nitrogen gas required to
establish a given pressure for a given depth, this figure will be determinable on the temperature of
the gas.
To select the correct table we must find the correct temperature gradient. Temperature gradients are
common for an area, not usually individual wells. The common temperature gradient for the North
Sea is 1.6°F/100 feet.
By using the correct table we move down the left column of figures depicting the (TVD) of the
column. In our case it is 9000 feet.
Next we move along until we come to a figure that is close to our BHP. In this case the close
number is 3831 psi but it is not high enough. We then have to move to the next column which is
4447 psi. This figure is too high therefore our bottom hole figure of 3983 psi has to be found
somewhere in between. We do this by averaging out the numbers until we can get a closer figure.
A BHP of 4139 psi, (3831 + 4447) / 2, will give a W.H.P. of 3250 psi.
A BHP of 3985 psi, (3831 + 4139) / 2, will give a W.H.P of 3125 psi.
We now have the first part of the answer. The required nitrogen wellhead pressure that will give a
200 psi drawdown on the formation is 3125 psi.
The next stage is to find out how much nitrogen is required to displace the fluid down to the
circulating valve. (We are using the depth of the circulating valve purely as a datum point for the
worked example. In a real situation the depth to the cushion would be outlined for you by the
engineer).
Since the previous part of the calculation dealt with pressure we used the True Vertical Depth
measurement of the well. This part of the equation deals with volumes therefore we have to use the
Measured Depth of the well or how long the well is.
The first step is to establish how much fluid the well contains or how many barrels (bbls). The unit
of volume for tubulars is barrels per foot (bbls/ft). Since we are displacing to the circulating valve,
it is this volume that we require.
This figure will be dependant on the size of the tubing in the well and also the wall thickness of the
tubing (lbs/ft). Tubing diameters are measured on outside diameters but internal volumes will be
dependant on inside diameters.
These figures are found in any tubing/casing books.
Page 191 of 224
TRAINING DEPARTMENT
Our particular string is made up of 4 1/2", 19.2 lbs/ft tubing. After consulting the tubing tables it
has a volumetric capacity of 0.01287 bbls/ft. The measured depth to the circulating valve is 10000
feet, therefore the volume of fluid in the tubing to the circulating valve is:
10000 ft. (M.D.) x 0.01287 (BBLS/FT) = 128.7 bbls.
The next step is to establish how many scf of nitrogen will displace one barrel of well fluid. As
stated previously nitrogen volumes are totally dependent on temperature and pressure, therefore to
quantify the nitrogen volumes we have to use an average temperature and pressure taken from
throughout the length of the well.
To find the average temperature along the length of the hole:
(M.D. x TEMP. GRADIENT) / 200) + AMBIENT TEMPERATURE
(10000 x 1.6 / 200) + 50
= 130° F average temperature.
To find the average pressure:
(NITROGEN WELLHEAD PRESSURE+NITROGEN BOTTOM HOLE PRESSURE)/2
(3125 + 3983) / 2 = 3531 PSI
Using these figures of av.press and av. temp. we can finalise the number of scf n2 / bbl of fluid. To
do this we now have to consult another set of tables:-
"SCF N2 PER BARREL OF SPACE AT VARIOUS TEMPERATURES AND PRESSURES"
The initial step is go down the left hand column until we come to the figure close to the average
pressure of 3531 psi. This time it falls between 3500 and 4000, so as before we will have to average
it out until a figure is achieved that will represent the scf/bbl for this particular pressure and
temperature. Unfortunately the tables do not read 130° F, therefore we have to find the scf/bbl at
120° F and 140° F then take the average between the two:
Using 120° F:
SCF/BBL AT 3550 PSI:- (1095 + 1120) / 2 = 1107 scf/bbl

Page 192 of 224
TRAINING DEPARTMENT
Using 140° F:

SCF/BBL AT 130° F = (1062 + 1103) / 2 = 1082 scf/bbl

Therefore the total volume of nitrogen required to displace the contents of the well down to the
circulating valve =
TUBING VOLUME (BBLS) x SCF PER BBL OF SPACE
= 128.7 BBLS x 1082 SCF/BBL
= 139253 scf of Nitrogen.
In addition to this figure, 10000 scf should be added to allow for cooling down the converter.
To allow for transportation losses etc., 25% of the total volume should be added. It is far better to
arrive on the rig with too much nitrogen than not enough.
Therefore the total amount of nitrogen required to do the job is:-
(139253 + 10000) x 1.25 = 186566 scf of nitrogen.
This is translated into one tank of nitrogen, assuming it is the larger tank which is sent. The
estimated tank volumes are what the tank can potentially hold if it were filled up to the maximum.
As nitrogen operators, we know that this is not possible as it would result in spillage from the vents.
Also the rate at which your are to pump at will also dictate the efficiency at which you can draw
from the tank. Slow pumping will result in more N2 wastage as opposed to fast pumping.
Page 193 of 224
TRAINING DEPARTMENT
CALCULATION WORKSHEET:
DATA :-
Tubing String O.D. _____",Wt._____Lbs/Ft,Vol._______B/Ft
Depth to Watercushion ______Ft M.D., ______Ft T.V.D.
Pressure at Watercushion _______psi.
Temperature Gradient ______deg F per 100 Ft
CALC :-
TABLE BHP at WHP using Temp. Grad. ____F/100 Ft,Depth______Ft T.V.D.
& Press at Watercushion ______psi = ______psi(1) Tubing Head Pressure
( THP(1)_____psi + Cush. BHP Press._____psi ) / 2 = _____psi(2) Av. Press.
(M.D._____Ft X T.G.____F) / 200)+ 50 = ______deg F(3) Av. Temp.
TABLE SCF/Bbl Space using (2) _____psi & (3) _____F = _____SCF/Bbl(4)
M.D._____Ft X Tbg.Vol.______B/Ft = ______Bbls(5) Vol. of empty Tbg.
(5) _____Bbls X (4) _____SCF/Bbl = _______SCF(6) N2 Volume
RESULTS :-
Static Tubing Head Pressure Required = (1) _______ psi.
Nitrogen Requirement for Cushion = (6) ________SCF N2
The N2 Vol. given in this result is the calculated pumped volume .

Allow at least 25% extra for Losses.
Page 194 of 224
TRAINING DEPARTMENT
3 DISPLACEMENT DESIGN.
DATA :-
Tubing String O.D. _____",Wt._____Lbs/Ft,Vol._______B/Ft
Depth to Perforations ______Ft M.D., ______Ft T.V.D.
Injection Pressure required at Perforations _______psi.
Temperature Gradient ______deg F per 100 Ft
Average Pump Rate required at Perfs.______BPM
CALC :-
TABLE BHP at WHP using Temp. Grad. ____F/100Ft,Depth______Ft T.V.D.
& Injection Press. ______psi = ______psi(1) Tubing Head Press.
( THP(1)_____psi + Inj.Press._____psi ) / 2 = _____psi(2) Av. Press.
M.D._____Ft / 200 X T.G.____F/100Ft + 60 = ______deg F(3) Av. Temp.
TABLE SCF/Bbl Space using (2) _____psi & (3) _____F = _____SCF/Bbl(4)
M.D._____Ft X Tbg.Vol.______B/Ft = ______Bbls(5) Vol. of Tubing
(5) _____Bbls X (4) _____SCF/Bbl = _______SCF(6) N2 Volume
Av. Pump Rate _____BPM X (4) ______SCF/Bbl = _______(7) SCFM
RESULTS :-
Static Tubing Head Pressure Required = (1) _______ psi. at end of Displacement.
Nitrogen Requirement for Displacement = (6) ________SCF N2
N2 Rate Required for Displacement = (7) ______SCFM

Page 195 of 224
TRAINING DEPARTMENT
4 NITRIFIED TREATMENT DESIGN.
DATA :-
Depth to Perforations _______ Ft. T.V.D.
Fluid Hydrostatic Gradient ______ psi. / Ft.
Bottom Hole Injection Pressure _______ psi.
Bottom Hole Temperature ______ deg.F and Gradient _____ F / 100Ft Nitrogen Pump
Rate_________ SCFM
CALC :-
N2 rate______ / TABLE SCF/Bbl @ BH T & P ______SCF = _____Bbls (1) N2
1 / ( 1 + (1)_____Bbls ) = ______(2) Fluid Fraction
Depth______Ft X F.G.______psi/Ft X (2)_____F.F. = ______(3) Fluid Hyd
TABLE WHP Multipliers at ______Ft TVD = ______(4) Wellhead Press Mult
(BHIP_____psi -(BHIP_____psi / (4)____WHPM)) X (1-(2)____FF) =____(5)
N2 Hydrostatic
BHIP______psi - (3)____F.H. - (5)_____N2 H.= _______psi (6) W.H.Press
N2 rate______/ TABLE SCF/Bbl @ 70F & (6)psi ____SCF =_____Bbls (7) N2
( (7)____Bbls N2 + (1)____Bbls N2 ) / 2 = _____(8) Av. N2 Vol.
1 / ( 1 + (8) _____Bbls ) = _____(9) Av. Fluid Fraction
Depth_____Ft X F.G._____psi/Ft X (9)_____Av.FF = ______(10) Fluid Hyd
(BHIP_____psi -(BHIP_____psi/ (4)____WHPM)) X(1-(9)____FF) =____(11)

N2 Hydrostatic
BHIP_____psi - (10)_____FH - (11)_____N2 H. = ______psi(12) W.H.Press
RESULTS :-
Wellhead Pressure = (12) ________psi.
The Projected WHP derived from this calculation does not take into account the Nitrogen / Fluid
Friction which will depend on Tubular size and pump rates.
Page 196 of 224
TRAINING DEPARTMENT
5 FOAM CLEANOUT DESIGN.
DATA :-
Depth to Cleanout Depth ________Ft T.V.D.
Fluid Gradient Pressure ________psi / Ft (FGP)
Formation Pressure ________psi (FP)
Bottomhole Temp _____deg.F , Grad. Temp. ______F / 100Ft
Foam Quality at Bottomhole Temp. & Press. _____% FQ
Fluid Pump Rate ______Bbbls / Min. (FPR)
RESULTS :-
Foam Rate at Bottomhole Temp. & Press. = (3) _______B.P.M.
Nitrogen Pump Rate = (4) _______S.C.F.M.
Choke Back Pressure = (15) _______psi. WHP
Foam Rate at Choke = (18) _______B.P.M.
Foam Quality at Choke = (19) ______% FQ
These figures do not take into account the effect of friction on the Choke Pressure during the job .
However the effect is minimal except where high pump rates and or high FQs are used. This is the
basic calculation used in the handheld computer form of the Foam Cleanout Program with the
difference being the calculation steps to determine the FQ profile are greatly increased to improve
accuracy. The full Foam Cleanout Program Utilises data for friction due to foam and further
increases the calculation steps to increase accuracy.
CALC:-
TABLE WHP Multipliers @ _______Ft. TVD = ______(1)

TABLE SCF / Bbl Space @ BHT & Press. = ______SCF / Bbl(2)
Page 197 of 224
TRAINING DEPARTMENT
5. FOAM CLEANOUT CALCULATION (Continued)
(FPR)______BPM / (1-0.____FQ) = ______(3) BPM Foam Rate
(2)______SCF/Bbl X (3)_____BPM X 0.____FQ = ______SCFM (4) N2 Rate
Depth______Ft X FGP_____psi/Ft X (1-0.____FQ) =______psi(5) Fluid Hyd
FP______psi - (FP_____psi / (1)_____WHPM) = ______psi(6)
(6) ______psi X 0._____FQ = ______psi (7) N2 Hyd
FP_______psi - (5)______psi - (7)______psi = _______psi (8) WHP
TABLES SCF / Bbl Space @ (8)psi & 70F = _______SCF / Bbl (9)
( (2)_____SCF / Bbl + (9)______SCF / Bbl ) / 2 = ______SCF/Bbl (10)Av
(4)______SCFM / (10)______SCF/Bbl Av. = ______Bbls. N2 (11)
(11)_____Bbls N2 / (FPR_____BPM + (11)_____Bbls N2) = ______(12)Av.FQ
Depth_____FtX FGP_____psi/Ft X (1-(12)0._____FQ) = _____(13) F. Hyd
(6)_____psi X (12)_____FQ = ______psi (14) N2 Hyd
FP______PSI - (13)_____psi - (14)_____psi = _______psi (15) WHP
TABLES SCF/Bbl Space @ (15) psi & 70F = _______SCF / Bbl (16)
(4)______SCFM / (16)_______SCF/Bbl = _______Bbls N2 (17)
(17)______Bbls N2 + FPR_____BPM = ______BPM (18) Foam Rate @ WHP&T
(17)______Bbls N2 / (18)______BPM = ______FQ (19) @ WHP&T
Page 198 of 224
TRAINING DEPARTMENT
6 NITRIFIED CLEANOUT DESIGN.
DATA :-
Well Volume to cleanout depth ________Bbls
Cleanout Depth ________Ft. TVD
Fluid Gradient Pressure _______psi / Ft (FGP)
Control Formation Pressure ________psi (FP)
Bottomhole Temp ______deg F , Grad. Temp. ______F / 100Ft
Nitrogen Pump Rate ________SCFM
Fluid Pump Rate _______BPM
Fluid Slug Size ______Bbls
RESULTS :-
Bottoms-up Time = (12) _______ mins.
N2 Vol. per Slug = (7) _______ SCF.
N2 Pump Period per Slug = (8) ______ Mins.
Fluid Pump Period per Slug = (9) ______ Mins.
Page 199 of 224
TRAINING DEPARTMENT
This equation as in the Foam Cleanout Calc. does not take into account the friction which may be
considerable depending on the size of tubulars and pump rate. Further more there has been no
allowance for the surface pressure required to flow the well through the choke, however in reality
the calculation is made using the formation control pressure which can be reduced by the pressure
required at surface.
CALC :-
TABLES WHP Multipliers @ ______Ft TVD & ______F/100ft = ______WHPM(1)
FP______psi - ( FP______psi / (1)______WHPM ) = _______psi (2) N2 Hyd
6. NITRIFIED CLEANOUT DESIGN (Continued)
FGP_____psi/ft X Depth______ft = ______psi (3) Fluid Hyd.
TABLESSCF/Bbl Space@Av.P.(FP/2) &Av.T.(BHT+70/2)= _____(4)SCF/Bbl
(FP______psi - (2)_____psi) / ( (3)______psi - (2)____psi) = _____(5)

Fluid Component
( 1 - (5)_____) = ______(6) N2 Component
(Slug____Bbls / (5)_____) X (6)_____ X (4)_____SCF/Bbl = ______(7)SCF
(7)_____SCF / N2 Rate______SCFM = ______(8) Mins N2
Slug_____Bbls / FPR_____BPM = _____(9) Fluid Mins
(7)_______SCF / (4)_______SCF/Bbl = _______(10) Bbls N2
(Slug____Bbls+ (10)____Bbls) /((8)_____Mins+ (9)____Mins)=_____BPM

(11) Av. N2 & Fluid Rate
Well Vol.______Bbls / (11)______BPM = ______Mins (12) Bottoms-up Time
Page 200 of 224
TRAINING DEPARTMENT
EXPLANATION OF CALCULATIONS
1 GAS LIFT DESIGN. (EXAMPLE)
DATA :-
Inner String O.D.1.25", Wt 1.081 Lbs/Ft, Vol .00124 B/Ft, Disp .00152 B/Ft
Outer String O.D.4.5", Wt 16.6 Lbs/FT, Vol .0142 B/Ft
Inner String Depth 6000 Ft M.D. 5200 Ft T.V.D.
Fluid Depth 500 Ft M.D. 500 Ft T.V.D., Wt. 8.5 p.p.g. 0.441 psi/Ft
Temperature Gradient 1.6 Deg F per 100 Ft.
CALC :-
M.D. 6000 Ft / T.V.D. 5200 Ft = 1.154 (1) Deviation Factor
M.D. 6000 Ft - Fluid level 500 Ft M.D. = 5500 Ft(2) Fluid in Hole
O.S.Vol .0142 B/Ft - I.S.Disp .00152 B/Ft = .0127 B/Ft(3) Annular Vol.
( (3).0127 B/Ft + I.S.Vol .00124 B/Ft ) X (2) 5500 Ft = 76.56 Bbls(4)

Fluid Volume
(4) 76.56 Bbls / 2 = 38.28 Bbls(5) Overbalance Volume
(5) 38.28 Bbls / (3) .0127 B/Ft = 3,014 Ft(6) Height of fluid left in Annulus
(6) 3,014 Ft / (1)1.154 D.F. X Fluid Hyd .441 psi/Ft = 1,152 psi.(7)
Hydrostatic of Fluid in Annulus
( I.S.Depth 6000 Ft M.D./ 200 X T.G 1.6F/100ft ) + 60 = 108 Deg F(8)

Av. Temperature
TABLE SCF/Bbl Space using (7) 1,152psi & (8) 108 F = 400 SCF/Bbl(9)
(9) 400 SCF/Bbl X (5) 38.28 Bbls = 15,292 SCF(10) N2 Volume
TABLE WHP Multiplier using Tbg Depth 6000 Ft T.V.D. = 1.19 (11)
Wellhead Press. Multiplier
Page 201 of 224
TRAINING DEPARTMENT
1. GAS LIFT DESIGN EXAMPLE (Continued)
( Depth 6000 Ft. T.V.D. X H.G .441 psi/Ft ) / 1.19 (11) = 2,223 psi Max Tubing Head Press.
RESULTS :- N2 Volume required for Kickoff = 15,292 SCF Nitrogen
The N2 Vol. given in this result is the minimum amount of N2 required to displace a well to
Overbalance Point, the point at which the N2 Press. & Vol. is sufficient to displace the well to the
inner string depth. Allow for additional heavy fluid to be produced from the formation and add at
least 25% for slippage and losses
2 D.S.T. CUSHION DESIGN. (EXAMPLE)
DATA :-
Tubing String O.D. 4.5 ", Wt. 16.9 Lbs/Ft, Vol. 0.0137 B/Ft
Depth to Water-cushion 6800 Ft M.D., 5300 Ft T.V.D.
Pressure at Water-cushion 2,450 psi.
Temperature Gradient 1.5 deg F per 100 Ft
CALC :-
TABLE BHP at WHP using Temp. Grad. 1.5 F/100Ft,Depth 5300 Ft T.V.D.
& Press at Water-cushion 2,450 psi = 2,090 psi(1) Tubing Head Pressure
( THP(1) 2090psi + Cush.Press. 2450psi ) / 2 = 2270 psi(2) Av. Press.
M.D. 6800 Ft / 200 X T.G. 1.5 F/100Ft + 60 = 111 deg F(3) Av. Temp.
TABLE SCF/Bbl Space using (2) 2,270psi & (3) 111 F = 765 SCF/Bbl(4)
M.D. 6800 Ft X Tbg.Vol.0.0137 B/Ft = 93.1 Bbls(5) Vol. of empty Tbg.
(5) 93.1 Bbls X (4) 765 SCF/Bbl = 71,267 SCF(6) N2 Volume
Page 202 of 224
TRAINING DEPARTMENT
2. D.S.T. CUSHION DESIGN EXAMPLE (Continued)
RESULTS :-
Static Tubing Head Pressure Required = (1) 2090 psi.
Nitrogen Requirement for Cushion = (6) 71,267 SCF N2

3 DISPLACEMENT DESIGN. (EXAMPLE)
DATA :-
Tubing String O.D. 3.5", Wt.15.5 Lbs/Ft, Vol. 0.0066 B/Ft
Depth to Perforations 8600 Ft M.D., 7800 Ft T.V.D.
Injection Pressure required at Perforations 4600 psi.
Temperature Gradient 1.2 deg F per 100 Ft
Average Pump Rate required at Perfs. 2.0 BPM
CALC :-
TABLE BHP at WHP using Temp. Grad. 1.2 F/100Ft,Depth 7800 Ft T.V.D.
& Injection Press. 4600 psi = 3700 psi(1) Tubing Head Pressure
( THP(1) 3700psi + Inj.Press. 4600psi ) / 2 = 4150 psi(2) Av. Press.
M.D.8600 Ft / 200 X T.G.1.2 F/100Ft + 60 = 112 deg F(3) Av. Temp.
TABLE SCF/Bbl Space using (2) 4150 psi & (3) 112 F = 1275 SCF/Bbl(4)
M.D. 8600 Ft X Tbg.Vol. 0.0066 B/Ft = 56.8 Bbls(5) Vol. of Tubing
(5) 56.8 Bbls X (4) 1275 SCF/Bbl = 72,420 SCF(6) N2 Volume
Page 203 of 224
TRAINING DEPARTMENT
3. DISPLACEMENT DESIGN EXAMPLE (Continued)
Av. Pump Rate 2.0 BPM X (4) 1,275 SCF/Bbl = 2,550 (7) SCFM
RESULTS :-
Static Tubing Head Pressure Required = (1) 3,700 psi. at end of Displacement.
Nitrogen Requirement for Displacement = (6) 72,420 SCF N2
N2 Rate Required for Displacement = (7) 2,550 SCFM

4 NITRIFIED TREATMENT DESIGN. (EXAMPLE)
DATA :-
Depth to Perforations 8000 Ft. T.V.D.
Fluid Hydrostatic Gradient 0.441 psi. / Ft.
Bottom Hole Injection Pressure 4950 psi.
Bottom Hole Temperature 200 deg.F and Gradient 1.7 F / 100Ft
Nitrogen Pump Rate 500 SCFM
CALC :-
N2 rate 500 / TABLE SCF/Bbl @ BH T & P 1250 SCF = 0.40 Bbls (1) N2
1 / ( 1 + (1) 0.4 Bbls ) = 0.71 (2) Fluid Fraction
Depth 8000 Ft X F.G. 0.441psi/Ft X (2) 0.71F.F. = 2520 (3) Fluid Hyd
TABLE WHP Multipliers at 8000 Ft TVD = 1.252(4) Wellhead Press Mult
Page 204 of 224
TRAINING DEPARTMENT
4. NITRIFIED TREATMENT DESIGN EXAMPLE (Continued)
(BHIP 4950psi -(BHIP 4950psi / (4)1.252WHPM)) X (1-(2)0.71FF) =289 (5)

N2 Hydrostatic
BHIP 4950 psi - (3)2520 FH. - (5) 289 N2 H.= 2141 psi (6) W.H.Press
N2 rate 500 / TABLE SCF/Bbl @ 70F & (6)psi 790 SCF = 0.63Bbls (7) N2
( (7)0.63Bbls N2 + (1)0.4 Bbls N2 ) / 2 = 0.52 (8) Av. N2 Vol.
1 / ( 1 + (8) 0.52 Bbls ) = 0.66 (9) Av. Fluid Fraction
Depth 8000Ft X F.G.0.441psi/Ft X (9)0.66 Av.FF = 2328 (10) Fluid Hyd
(BHIP 4950psi -(BHIP 4950psi/ (4)1.25WHPM)) X(1-(9)0.66FF) = 339(11) N2 Hydrostatic
BHIP 4950psi - (10)2328 FH - (11) 339 N2 H. = 2283 psi(12) W.H.Press
RESULTS :-
Wellhead Pressure = (12) 2283 psi.
The Projected WHP derived from this calculation does not take into account the Nitrogen / Fluid
Friction which will depend on Tubular size and pump rates.
DATA :-
Depth to Cleanout Depth 7800 Ft T.V.D.
Fluid Gradient Pressure 0.441 psi / Ft (FGP)
Formation Pressure 2300 psi (FP)
Bottomhole Temp 195 deg.F, Grad. Temp. 1.7 F / 100Ft
Foam Quality at Bottomhole Temp. & Press. 60% FQ
Fluid Pump Rate 0.5 Bbbls / Min. (FPR)
Page 205 of 224
TRAINING DEPARTMENT
RESULTS :-
Foam Rate at Bottom hole Temp. & Press. = (3) 1.25 B.P.M.
Nitrogen Pump Rate = (4) 495 S.C.F.M.
Choke Back Pressure = (15) 921 psi. WHP
Foam Rate at Choke = (18) 1.93 B.P.M.
Foam Quality at Choke = (19) 74% FQ
These figures do not take into account the effect of friction on the Choke Pressure during the job .
However the effect is minimal except where high pumprates and or high FQs are used. This is the
basic calculation used in the handheld computer form of the Foam Cleanout Programme with the
difference being the calculation steps to determine the FQ profile are greatly increased to improve
accuracy. The full Foam Cleanout Programme Utilises data for friction due to foam and further
increases the calculation steps to increase accuracy.
CALC :-
TABLE WHP Multipliers @ 7800 Ft. TVD = 1.245 (1)
TABLE SCF / Bbl Space @ BHT & Press. = 660 SCF / Bbl(2)
(FPR) 0.50 BPM / (1-0.60 FQ) = 1.25 (3) BPM Foam Rate
(2) 660 SCF/Bbl X (3) 1.25 BPM X 0.60 FQ = 1376 SCFM (4) N2 Rate
Depth 7800 Ft X FGP 0.441psi/Ft X (1-0.60 FQ) = 1376 psi(5) Fluid Hyd
FP 2300 psi - (FP 2300psi / (1)1.245WHPM) = 453 psi(6)
(6) 453 psi X 0.60 FQ = 272 psi (7) N2 Hyd
FP 2300 psi - (5) 1376 psi - (7) 272 psi = 652 psi (8) WHP
TABLES SCF / Bbl Space @ (8)psi & 70F = 245 SCF / Bbl (9)
Page 206 of 224
TRAINING DEPARTMENT
( (2) 660 SCF / Bbl + (9) 245 SCF / Bbl ) / 2 = 453 SCF/Bbl (10)Av
(4) 495 SCFM / (10) 453 SCF/Bbl Av. = 1.093 Bbls. N2 (11)
(11)1.093 Bbls N2 / (FPR 0.5 BPM + (11)1.093 Bbls N2) = 0.69 Av.FQ
Depth 7800FtX FGP 0.441 psi/Ft X (1-(12)0.69 FQ) = 1,066(13) F. Hyd
(6) 453 psi X (12) 0.69FQ = 313 psi (14) N2 Hyd
FP 2300 PSI - (13)1,066 psi - (14) 313 psi = 912 psi (15) WHP
TABLES SCF/Bbl Space @ (15) psi & 70F = 345 SCF / Bbl (16)
(4) 493 SCFM / (16) 345 SCF/Bbl = 1.43 Bbls N2 (17)
(17) 1.43 Bbls N2 + FPR 0.5 BPM = 1.93 BPM (18) Foam Rate @ WHP&T
(17) 1.43 Bbls N2 / (18) 1.93 BPM = 0.74 FQ (19) @ WHP&T
6 NITRIFIED CLEANOUT DESIGN. (EXAMPLE)
DATA :-
Well Volume to cleanout depth 180 Bbls
Cleanout Depth 8500 Ft. TVD
Fluid Gradient Pressure 0.441 psi / Ft (FGP)
Control Formation Pressure 3150 psi (FP)
Bottomhole Temp 215 deg F, Grad. Temp. 1.7 F / 100Ft
Nitrogen Pump Rate 800 SCFM
Fluid Pump Rate 0.8 BPM
Page 207 of 224
TRAINING DEPARTMENT
6. NITRIFIED CLEANOUT DESIGN EXAMPLE (Continued)
Fluid Slug Size 25 Bbls
RESULTS :-
Bottoms-up Time = (12) 204 mins.
N2 Vol. per Slug = (7) 3081 SCF.
N2 Pump Period per Slug = (8) 3.8 Mins.
Fluid Pump Period per Slug = (9) 31.25 Mins.
This equation as in the Foam Cleanout Calc. does not take into account the friction which may be
considerable depending on the size of tubulars and pump rate. Furthermore there has been no
allowance for the surface pressure required to flow the well through the choke, however in reality
the calculation is made using the formation control pressure which can be reduced by the pressure
required at surface.
CALC :-
TABLES WHP Multipliers @ 8500 Ft TVD & 1.7 F/100ft = 1.267 WHPM(1)
FP 3150 psi - ( FP 3150 psi / (1) 1.27 WHPM ) = 664 psi (2) N2 Hyd
FGP 0.44 psi/ft X Depth 8500 ft = 3748 psi (3) Fluid Hyd.
TABLES SCF/Bbl Space@Av.P.(FP/2) &Av.T.(BHT+70/2)= 512 (4)SCF/Bbl
(FP 3150 psi - (2) 664 psi) / ( (3) 3748 psi - (2) 664psi) = 0.806(5)
Fluid Component
( 1 - (5)0.806) = 0.194(6) N2 Component
(Slug 25 Bbls / (5)0.806) X (6)0.194 X (4) 512 SCF/Bbl = 3081 (7)SCF
(7) 3081 SCF / N2 Rate 800 SCFM = 3.85 (8) Mins N2
Slug 25 Bbls / FPR 0.8 BPM = 31.25 (9) Fluid Mins
(7) 3081 SCF / (4) 512 SCF/Bbl = 6.02 (10) Bbls N2
Page 208 of 224
TRAINING DEPARTMENT
6. NITRIFIED CLEANOUT DESIGN EXAMPLE (Continued)
(Slug 25 Bbls+ (10)6.02Bbls) /((8)3.85 Mins+ (9)31.2mins)= 0.88BPM

(11) Av. N2 & Fluid Rate
Well Vol. 180 Bbls / (11) 0.88 BPM = 204 Mins (12) Bottoms-up Time
Page 209 of 224
TRAINING DEPARTMENT
NITROGEN EQUATIONS
This section has been included to provide the manual user with an understanding of the
Mathematical basis for the charts, tables and computer programmes that we use in normal job
design and calculation.
1 GAS EQUATIONS
(1) P V = n R T
The Equation of State for an Ideal Gas
(2) P V = Z n R T
The Equation of State for a Real Gas.
Where :- P = Pressure in psi.

V = Volume in cu.ft. @ P & T
Z = Gas Deviation Factor @ P & T
n = Number of Moles in Volume , V
R = The Universal Gas Constant
T = Temperature in deg. R ( deg. F + 460 R )
Equation (1) "The Ideal Gas Equation" shows a linear relationship between P, T, & V. i.e. we can
state :-
P1 V1 / T1 = P2 V2 / T2
Unfortunately for Real Gases we have to use equation (2)
Page 210 of 224
TRAINING DEPARTMENT
2 COMPRESSIBILITY FACTOR (Z) FOR NITROGEN GAS
In Equation (2) we have used Z, The Compressibility Factor for Nitrogen Gas. This Factor varies
so greatly with Temperature and pressure that a single best fit equation is not sufficient to cover the
full range of temperature and pressure. In fact there are four pressure ranges with three groups of
equations used to define these ranges. These equations can be used on computer to best fit Z to + or
- 1%. The results for A, B, and C can then be used in the equation :-
Z=APP+BP+C
Where Pressure is < 500 psi then Z = 1
Above 500 psi. the following equations will apply to derive Z
Where 500 psi. < Pressure < 4000 psi.
A = 1.679393x10-7 - 6.2243x10-10T + 8.0385x10-13T - 3.5472x10-16T
B = -3.122x10-4 + 8.488x10-7T - 5.37x10-10T
C = 1.0
Where 4000 psi. < Pressure < 8000 psi.
A=0
B = 2.2817x10-4 - 4.066x10-7T + 2.3x10-10T
C = -0.0956 + 2.5x10-3T - 1.5x10-6T
Where Pressure > 8000 psi.
A=0
B = 2.2042x10-4 - 3.515x10-7T + 1.815x10-10T
C = -0.1573 + 2.438x10-3T - 1.4x10-6T
These Calculations for the derivation of Z Factors are to be found in :- API Research Project
No. 37 : "Thermodynamic Properties of the Lighter Paraffin Hydrocarbons and Nitrogen." By
B.H.Sage and W.N.Lacey API.
Page 211 of 224
TRAINING DEPARTMENT
3 NITROGEN VOLUME FACTORS
The Z Factor as derived above can now be applied to the Equation of State for a Real Gas to give
us the volume of gas occupying a given space at various Temperatures and Pressures.
Vs Zs n R Ts P
The Gas Volume Factor B = --- = ----------- ---
V Z n R T Ps
Where s is at 520 deg.R and 14.65 psia.
This equation may now be stated with n and R removed to give:-
Zs Ts P Ts
B = ---- ---- ---- where Zs = 1 , ---- = 35.495
Z T Ps Ps (a Constant)
Thus :- B = ----- 35.495 SCF / Cu.Ft.

TZ
To get Scf per Barrel we use 5.6146 Cu.Ft. per Barrel
Thus :- B = 199.3 ----- SCF / Bbl

TZ
This equation is the one used to calculate the tables for SCF per Barrel of Space. It is also used to
provide these results for the hand held computer and in Programmes.
Page 212 of 224
TRAINING DEPARTMENT
4 HYDROSTATIC PRESSURE OF A STATIC COLUMN OF NITROGEN GAS
The Pressure due to a column of fluid may be expressed by :-

p D p
Pbh = ------ or dP = ------ x dD
144 144
However we are dealing in this instance with a Real Gas the density of which will vary with
Temperature and Pressure.
Thus we have to define p (density) in terms of the equation of state for a real gas in (1) , and insert
the Molecular Weight for Nitrogen 28.02 into the equation.
P (28.02)
Thus :- p = ---------
ZRT
Density can now be inserted thus :-
P (28.02) dD
dP = --------------
Z R T (144)
By introducing Wellhead and Bottomhole depth, Pressure and average Temperature, we can
integrate the equation thus :
Pbh D
dP 28.02 1
---- = ------- ----- dD
P 144 Z R T
Pw 0
This integrates as follows :-
Pbh 28.02 L
Log e ----- = -----------
Pw 144 Z R T
By substituting the universal gas constant R for 10.73 we get :
L 1
--- x -----
Z T 55.1
Pbh = Pw e
This equation is used for the calculation of BHP due to a column of Nitrogen at various WHPs and
Temperature Gradients, as well as hand held computers and Foam Programmes etc.
Wellhead Pressure Multipliers are also determined using this method.
Page 213 of 224
TRAINING DEPARTMENT
NITROGEN FLOW BACK RATIOS
The Nitrogen Flowback Ratios have been calculated using volume factors for commingled fluids
and Nitrogen gas. This is derived from the volume of gas per barrel of space and calculated every
100 ft. A nominal backpressure of 100 psi. at the Wellhead choke and a friction loss of 30 psi /
1000 ft. has been utilised. Wellhead Temperature of 70 deg. F and 1.1 deg. F / 100,ft. Grad.
The equation is expressed here in a basic form as used on computer to calculate the SCF N2 per
Barrel of fluid of varying S.G. produced.
dP = Hyd. N2 + Hyd. Fluid @ P1 & T1 and Gas Fluid Ratio
--> P1 = P1 - dP
T1 = T1 - dT --->Return
Page 214 of 224
TRAINING DEPARTMENT
BOC SITING OF MSV’S
Page 215 of 224
TRAINING DEPARTMENT
Page 216 of 224
TRAINING DEPARTMENT
Page 217 of 224
TRAINING DEPARTMENT
Page 218 of 224
TRAINING DEPARTMENT
APPENDIX 1 FLANGE RATINGS
Page 219 of 224
TRAINING DEPARTMENT
Page 220 of 224
TRAINING DEPARTMENT
Page 221 of 224
TRAINING DEPARTMENT
APPENDIX 2 COLDER PRODUCTS FITTINGS INFORMATION
Page 222 of 224
Pipe Thread Types and Designations
Overview: Different types of screw threads have evolved for fastening,

and hydraulic systems. Of special concern are plastic-to-metal,
taper/parallel threaded joints in hydraulic circuits. A discussion and
recommendations are provided to create an awareness of different types
of threads and how they are used.
Over time many different types of screw threads have been developed. Applications
include fastening components, and hydraulic and pneumatic circuits. In the
nineteenth century, manufacturers needing fasteners would devise their own
systems. This resulted in compatibility problems. The English mechanical engineer
and inventor, Sir Joseph Whitworth devised a uniform threading system in 1841 to
deal with these difficulties. The Whitworth thread form is based on a 55 degree
thread angle with rounded roots and crests.
In America, William Sellers set the standard for nuts, bolts, and screws which became
the National Pipe Tapered Thread (NPT) in 1864. His 60 degree thread angle, in
common use by early American clockmakers, enabled the American Industrial
Revolution. These thread forms later became the American National Standard.
The Whitworth thread form was selected as a connecting thread for pipes, which was
made self sealing by cutting at least one of the threads on a taper. This became known
as the British Standard Pipe thread (BSP Taper or BSP Parallel thread). The Whitworth
thread is now used internationally as a standard thread for jointing low carbon steel
pipes.
The best known and most widely used connection where the pipe thread provides
both the mechanical joint and the hydraulic seal is the American National Pipe
Tapered Thread, or NPT. NPT has a tapered male and female thread which seals with
Teflon tape or jointing compound.
Pipe threads used in hydraulic circuits can be divided into two types:
a) Jointing threads – are pipe threads for joints made pressure tight by sealing on
the threads and are taper external and parallel or taper internal threads. The
sealing effect is improved by using a jointing compound.
b) Fastening threads – are pipe threads where pressure tight joints are not made on
the threads. Both threads are parallel and sealing is affected by compression of a
soft material onto the external thread, or a flat gasket.
Sizes
Pipe thread sizes are based on an inside diameter (ID) or flow size. For example, “1/2–14 NPT” identifies a pipe
thread with a nominal inside diameter of 1/2 inch and 14 threads to the inch, made according to the NPT
standard. If “LH” is added, the pipe has a left hand thread. The most common global pipe thread forms are:
NPT American Standard Pipe Taper Thread

NPSC American Standard Straight Coupling Pipe Thread
NPTR American Standard Taper Railing Pipe Thread
NPSM American Standard Straight Mechanical Pipe Thread
NPSL American Standard Straight Locknut Pipe Thread
NPTF American Standard Pipe Thread Tapered (Dryseal)
BSPP British Standard Pipe Thread Parallel
BSPT British Standard Pipe Thread Tapered
Plastic injection molded thread forms are manufactured to ANSI B2.1 and SAE J476 standards.
The word “tapered” in several of the above names points to the big difference between many pipe threads and
those on bolts and screws. Many pipe threads must make not only a mechanical joint but also a leakproof
hydraulic seal. This is accomplished by the tapered thread form of the male matching the thread form of the
female tapered thread and the use of pipe sealant to fill any voids between the two threads which could cause a
spiral leak. The bottoms of the threads aren't on a cylinder, but a cone; they taper. The taper is 1⁄16 inch in an
inch, which is the same as 3/4 inch in a foot.
Because of the taper, a pipe thread can only screw into a fitting a certain distance before it jams. The standard
specifies this distance as the length of hand tight engagement, the distance the pipe thread can be screwed in by
hand. It also specifies another distance – the effective thread, this is the length of the thread which makes the seal
on a conventional machined pipe thread. For workers, instead of these distances, it is more convenient to know
how many turns to make by hand and how many with a wrench. A simple rule of thumb for installing tapered
pipe threads, both metal and plastic, is finger tight plus one to two turns with a wrench. Torque installation values
can be determined per application, but due to the variations involved in pipe joints such as disimiliar materials of
male and female threads, type of sealants used, and internal variations in product wall thickness, a standard torque
specification cannot be generically applied .
This table shows the distances and number of turns called for in the standard. A tolerance of plus or minus one
turn is allowed, and in practice threads are often routinely cut shorter than the standard specifies. All dimensions
are in inches.
American Standard Taper Pipe External Thread

Nominal size Actual OD Threads Length of engagement Length of
per inch (tightened by hand) effective thread
1/8 0.407 27 0.124 3.3 turns 0.260
1⁄4 0.546 18 0.172 3.1 turns 0.401
3/8 0.681 18 0.184 3.3 turns 0.408
1/2 0.850 14 0.248 3.4 turns 0.534
3/4 1.060 14 0.267 3.7 turns 0.546
1 1.327 11.5 0.313 3.6 turns 0.682
2
Taper/Parallel Threaded Joints
BSPP Female Thread Despite the standards created to maintain uniform
fittings, tapered pipe threads are inexact and
during the course of use and repair the threads can
become damaged and susceptible to leakage. The
BSPT Male Thread area where the crest and the root of the thread
meet can form a spiral leak path no amount of
tightening will eliminate.
A pressure tight joint is achieved by the compression
in the threads resulting from tightening. This
compression and sealing occurs in the first few turns
of the internal thread. As wrenching takes place,
material from both the male and female threads
deform into each other. This ensures full thread
contact which minimizes spiral leakages. Variations
between injection-molded plastic and machined
metal thread forms can occur due to different
Figure 1 – BSPT Male with BSPP Female manufacturing processes.
Pipe threads were originally designed as machined
thread forms. With the use of thermoplastics and
plastic injection molding in the manufacture of
BSPT Female Thread plastic pipe thread forms, mold shrinkage and
plastic sink make it difficult to insure leak free
joints. For this reason, the use of a Teflon based
sealant is recommended on all plastic pipe threads.
The most common form of sealant is Teflon tape
BSPT Male Thread
wrapped 2 to 3 turns around the male thread
before assembly. Liquid Teflon based sealants are
also used successfully to ensure a pressure tight
seal. It is always important to use care when
applying sealants to avoid introducing the sealant
material into the system flow path.
The following sections show examples of how
different threads are used and issues that can arise
in attempting to create a leak free connection.
When a BSPT tapered male thread is tightened into
a straight female thread (BSPP) the seal can only be
made at the base of the female port with 1 or 2
threads. See figure 1. Sealing is compromised by
Figure 2 – BSPT Male with BSPT Female the lack of thread form control in BSP specifications.
Variation in crests and roots may cause a mismatch
in the thread and create a spiral leak. Thread sealant
is required to seal this combination.
Using both tapered male and female BSPT threads
would offer a better chance of sealing since you are
now matching the taper of the male and female
thread. See figure 2. This offers more threads a
3
chance of sealing against spiral leakage. Crest
Female NPTF
and root control is still missing, but with thread
sealant, a pressure tight joint would be easier to
accomplish.
A number of variations of the NPT thread have
been introduced to overcome the problem of
Male NPTF spiral leakage and are known as Dryseal threads
(See SAE standard J476). The best known is the
NPTF (F for Fuel). With this thread design, there
are controls on the crests and roots of both the
male and the female threads to ensure the crest
crushes or displaces material into the root of the
mating thread. The interference fit between the
crest of one thread and the root of the other,
along with the thread flanks matching, seals
against spiral leakage.
Figure 3 – NPTF, Hand Tight Figure 3 shows an NPTF male tightened into
an NPTF female hand tight. You can see the
crests of both the male and female thread come
into contact with the root before the thread
flanks meet.
Female NPTF
Figure 4 shows the NPTF male and female
threads tightened approximately 1 turn past
hand tight, and you can see the flanks meet and
the crests are displaced into the roots. Although
Male NPTF these threads are considered Dryseal, a Teflon
Displaced tape or liquid is still recommended to aid in the
Material
assembly process. The Teflon works as a lubricant
to avoid galling of the material when tightening
the two threads together and also fills any voids
that may cause leakage.
A variation of the Dryseal thread is the NPSF
(National Pipe Straight Fuel). It is used for
internal threads and a NPTF external thread can
be screwed into it to provide a satisfactory
mechanical connection and a hydraulic seal. The
Figure 4 – NPTF, Fully Engaged (hand tight plus 1 turn)
combination of a parallel and tapered thread is
not regarded as ideal but is widely used. High-
quality plastic quick disconnect couplings
typically use NPT threads.
4
Another tapered thread is the British Standard
Female BSPP Pipe taper, or BSP, covered by British Standard 21.
BSP thread is commonly used for low pressure
plumbing, but is not recommended for medium
and high pressure hydraulic systems. This form
Male NPT
uses the Whitworth thread with an angle of 55°
and a 1 in 16 taper. It is not interchangeable with
the American NPT thread, though at the 1/2" and
3/4" size, they both have 14 threads per inch.
Problems arise when threading a NPT male thread
form into a BSP female straight thread form. The
1/16”, 1/8”, 1/4”, and 3/8” sizes have a dissimilar
pitch, which causes a misalignment of the
threads. The flank angles of the threads are also
Figure 5 – Male NPT in a Female BSPP with Different Pitch
different between NPT and BSP. NPT has a 60°
thread where the BSP has a 55° thread.
Figure 5 shows a male NPT tightened into a BSPP.
Because of the smaller size of the BSPP and the
Female BSPT pitch difference, the NPT tightens with only a
few turns.
Figure 6 shows an NPT tightened into a BSPT. The
BSPT being wider at the opening will allow the
Male NPT NPT thread to engage further, but pitch
difference eventually causes a binding of the
threads. Pitch and thread angle differences will
Binding
Threads allow spiral leakage.
The 1/2” and 3/4” sizes in the NPT and BSP are
all 14 threads per inch, and the NPT will engage
the BSP fairly well.
Although these threads are the same pitch and
engage well there are still issues with the thread
form. The thread angles and the crest and root
tolerances being different will allow spiral leakage
as shown in figure 7. These threads might be used
Figure 6 – Male NPT in a Female BSPT with Different Pitch
effectively together if an appropriate thread
sealant is incorporated.
Many issues arise when plastic quick disconnect
couplings, with their corresponding injection-
molded pipe thread forms are plumbed into
metal-piped hydraulic systems. Leaks and plastic
thread form failures may occur if care is not taken.
When investigating a metal-to-plastic pipe joint
failure, two factors, chemical attack and over
tightening, need to be considered.
5
Chemical attack can occur when improper thread
Female BSPT sealants are used. Thread sealing is an attempt to
block the spiral leak path which occurs when the
crests and roots of the thread forms do not match.
Male NPT Anaerobic thread sealants should be avoided
when sealing plastic thread forms. These sealants
contain chemicals which may attack plastics. Use
of a Teflon-based pipe thread sealant is a better
choice for plastic threads.
Over tightening of any plastic pipe thread will
have adverse affects on the function of the joint.
The major difference between plastics and
metals is the behavior of polymers. Injection-
Gaps Causing
Spiral Leakage molded plastic parts continue to deform if they
are held under a constant load e.g. creep. Creep
is the continued extension or deformation of a
Figure 7 – Male NPT in a female BSPT of the Same Pitch
plastic part under continuous load. Typically the
plastic material in an injection-molded plastic
pipe thread form will creep from being over
tightened into a female tapered port. The
deformation of the part’s internal features can
lead to part failure.
Standard Pipe Thread forms Colder Products Company produces

NPT (National Pipe Taper) BSPT (British Standard Pipe Taper)
Sizes: Sizes:
1/16 – 27NPT
1/8 – 27NPT 1/8 – 28BSPT
1/4 – 18NPT 1/4 – 19BSPT
3/8 – 18NPT 3/8 – 19BSPT
1/2 – 14NPT 1/2 – 14BSPT
3/4 – 14NPT 3/4 – 14BSPT
1 – 11-1/2 NPT
Virtually any thread configuration can be incorporated into a CPC coupler on a custom basis. Some examples of
custom applications are NPSM (National Pipe Straight Mechanical), BSPP (British Standard Pipe Parallel), SAE flare
fittings, and a variety of ISO (Metric) and American Unified screw threads.
With over 20 years experience in the design and manufacture of injection-molded plastic quick disconnect
couplings, Colder Products Company knows about the shrink and sink of molded plastic parts and how they can
affect the seal ability of pipe threads. Our NPT thread has been engineered to add more control to the plastic
thread form to ensure a leak-proof seal.
This paper was researched, organized and written by Mark Schmidt, CPC Product Control Engineering.
Mark works at Colder Products Company in St. Paul, MN. He can be contacted at askourengineers@colder.com.
6
TRAINING DEPARTMENT
APPENDIX 3 N2 PUMPER EDMONTON
Page 223 of 224
BJPPS MODEL SP6000
NITROGEN PUMPER
TABLE of CONTENTS
Unit Information Page 3
Related N2 Equipment Page 4
Introduction Page 5
Unit Operation page 6 – 19
Trouble Shooting
Heater Operation Page 20
Trouble Shooting
Pumps Page 21
Rigup Page 22
Calibration Chart
9.5 m3 Tank Page 23
Calibration Chart
15.9 m3 Mini Page 24
Pump Chart Page 25

BJPPS SP6000 NITROGEN PUMPER UNIT
BJ Nitrogen Pumper Units are designed to transport and Specifications: Dimensions:

pump nitrogen for the use in stimulation treatments (acid Nitrogen Pump Flow Height: 12 ft. 6 in.
& fracturing), completions, clean outs, pressure testing, Rates: 955 m3/min Width: 8 ft.
and other well servicing operations. to 5000 psi / Length: 36 ft.
The high-efficiency nitrogen pump is powered by the with 2 7/8in Cold Ends Gross Vehicle Weight:
chassis engine, with controls located for maximum 154 m3/min 22,400 kg.
operator visibility of all equipment during operations. to 10000 psi /
The Unit illustrated here incorporates the heater, pump, with 2 in Cold Ends
and a 9.5 m3 nitrogen tank mounted on a single chassis.
9.5 m3 tank with
5000 m3 pumpable
OTHER NITROGEN RELATED EQUIPMENT
Nitrogen Mini – Capacity-4200 gallon (350,000 scf pumpable)
Nitrogen Transport – Capacity-7200 gallons (600,000 scf pumpable)
Two-12,000 gallon Nitrogen Storage Vessels

(1,100,000 scf/vessel)
INTRODUCTION
Liquid nitrogen is colorless, odorless, non-corrosive, extremely cold (-1960C) and nonflammable.
Nitrogen is a gaseous chemical element forming nearly four-fifths of the atmosphere. Nitrogen, although
used chiefly in a gaseous state, is often stored and transported as a liquid because liquid nitrogen
requires less space to store than gas. Liquid nitrogen storage systems are insulated or vacuum insulated
to minimize product loss through vaporization. The molecular symbol for liquid nitrogen is N2.
Nitrogen is nontoxic, but can act as an asphyxiant (can cause suffocation) by displacing the amount of
oxygen in the air necessary to sustain life. In the liquid state it may cause frostbite. Frostbite effects are
a change in color of the skin to gray or white possibly followed by blistering. Loading of nitrogen is to
be done in a well-ventilated area. The use of loose fitting insulated gloves and goggles are required
when loading liquid nitrogen and handling load lines.
BJ Services utilizes nitrogen primarily in the stimulation (enhancing the production) of oil and gas wells.
It is transported to the well site in a liquid state then changed to a gaseous state before going into the
well. Caution must be exercised when pumping nitrogen. Nitrogen is being changed from a liquid
to a gaseous state. Rapid expansion is taking place under pressure from the pumps. DO NOT
PUMP IN A CLOSED SYSTEM i.e. against a closed valve.
In cab of unit, place shifter in neutral, start
engine. Make sure engine has at least 90
psi air pressure. At this time depress
clutch, place pump gear selector from
road gear to pump gear. This will also
engage hydraulics and lube pump PTO’s.
Then locate the throttle control switch.

Place switch in control panel mode, then
release clutch slowly.
Open the control panel lid. Be sure to use
the support bar!
Locate the clutch and pump controls.

These are two black Knobs on the left side
of the panel. They are both identified with
nameplates. Labels will tell you which
position is required to engage and
disengage. These are push-pull controls.
Both the pump and the clutch should be
disengaged at this time.
Now, find the remote Discharge Control

Valve. This is also a black knob located on
the left side of the control panel. Its
positions should be labeled.
At this time, Remote Discharge Valve

should be closed. Make sure the pump and
clutch are disengaged and the Remote
Discharge Valve is closed at this time.
Next, check the Hydraulic Pressure. It
should read 2000 psi.
Now, the power must be turned on. The power

switch is on the upper right of the panel. It is
marked “CONTROL.”
When the power’s on, adjust the throttle to

1000 rpm. You should see this on the road
engine tach.
To review. Here’s where you should be. You

should be standing in front of the control
panel, the truck engine should be running. All
instruments should be in the operating range.
Let’s talk a little now about the “cool-down”

procedure. “Cooling-down” introduces the
nitrogen, which is extremely cold (-1960C),
into the working parts of the pumps gradually
before they’re operating. If you attempted to
start the pumps without cooling down, you
could seriously damage them.
Before “cooling-down,” the truck engine must

be running. If you’re having a problem with
the engine at this point, stop and report to your
supervisor. If the engine is running, proceed to
next step.
At the control panel, check the tank
pressure gauge. It should be reading a
maximum of 10 psi.
Now, check the bypass valve to insure that

it is open. It is just left of the control box.
To open the bypass valve, turn the handle

counterclockwise.
Now, you must locate the ROAD valve.
This is the smaller of the two valves
located up high between the tank and
heater box. The ROAD valve is to be kept
open at all times until you begin the
nitrogen cool-down. It keeps the tank from
building up too much pressure.
It should be closed at this time. The

MAIN VENT VALVE – the larger of the
two- should be closed also.
Next, you will open five nitrogen control

valves.
In opening these valves, turn them

counterclockwise to the stop, then back off
one turn. This will prevent their freezing
open.
As you open them, you will notice an

immediate release of nitrogen vapor, which
will shoot out of the Booster Pump
Primer Valve.
Now, locate and open these five valves.

Open them in this order:
1. Re-circulation Valve
2. Booster Pump Primer Valve
3. Main Nitrogen Valve
4. Loading Valve
5. Cold End Re-circulation Valve
First, the Re-circulation Valve. Second, the

Booster Pump Valve. Third, the Main
Nitrogen Valve. Fourth, the Load Valve
and fifth, the Cold End Re-circulation
Valve.
Nitrogen is now flowing into the Booster
Pump. You should be noticing frost
building up on the outside of the pump.
This build-up will take several minutes.

Wait until you are able to wipe frost away
from the outside of the Booster Pump.
When it’s frosted over that much, you’re
ready to go on.
Wait 20 minutes for the Booster Pump

to frost over.
Next, check the Hydraulic Pump
pressure. It’s located at the right of the
panel.
Check hydraulic pressure gauge, which

should be reading 2000 psi. If it isn’t, tell
your supervisor immediately.
Turn on the vaporizer fan by pulling the
large lever control toward you. The
vaporizer fan indicator should show 2100
rpm. This gauge is on the right of the
control panel.
Now you are ready to turn on the Booster

Pump.
To turn the Booster Pump on, pull the lever
marked BOOSTER PUMP toward you.
This is the lever to the left of the vaporizer
fan control.
Locate the Booster Pump Control Valve.

This is a small valve on the floor of the
control box on the right side. Turn it 4 or 5
turns counterclockwise. Notice LIQUID
NITROGEN instead of vapor escaping
from the Booster Pump Primer Valve.
Now, close the Booster Pump Primer Valve

and slowly close the Booster Pump Re-
circulation Valve clockwise.
Keep an eye on the Booster Pump

Discharge Pressure Gauge. Note the rise
in pressure. When closed, the gauge
should read 50 to 60 psi.
Return to the Booster Pump Control Valve.

Continue turning it clockwise until the
“discharge” pressure is 60 to 80 psi.
Now the Booster Pump is operating. The

next step is to turn on the MAIN pump.
But before you turn it on, you must wait. It
must be cooled down.
Nitrogen is now flowing out of the Booster
Pump to the cold ends. They will frost
over.
Take your time. Wait for a complete

frosting; that is completely covered with a
thick layer of frost.
It is very important that this procedure be

done correctly before taking the next step.
So, if you have any doubts, check with
your supervisor.
With the cold ends frosted over past the lock

nut, you can turn on the MAIN pump.
First, a word of caution. Pay very close
attention to the Lube Oil Pressure Gauge.
It should never read below 60 psi. If it
does, disengage the Main Pump
immediately.
Note Lube Oil Warning Indicator

Light—it should go out once lube oil
pressure exceeds 60 psi. If it does not go
out disengage Main Pump.
Now, you put the clutch control in the

ENGAGE position. Check the clutch pedal
in the cab: it should go all the way to the
floor.
Wait 30 seconds to allow the equipment

time to properly engage. This is very
important.
Then, engage the Main Pump. Set the

Main Pump Control to the ENGAGE
position.
Wait another 30 seconds, then put the

clutch control in the DISENGAGE
position. The clutch pedal in the cab
should be all the way up.
The next step is to make sure the Main
Pump is working properly. Close the
bypass valve by turning it clockwise.
Check the gas discharge pressure gauge
in the center of the control panel. When
the pressure reads 2000 pounds, open the
bypass valve again. Open it all the way
and back off one-half turn (1/2).
Check the gas discharge pressure again. It

should stabilize at 2000 pounds. Then,
open the Remote Discharge valve located
on the panel. The gas discharge pressure
should decrease. When it reaches ZERO,
close the Remote Discharge valve.
You now know the Main Pump is working

properly.
You are going to put the heater into
operation in 3 stages, LOW,
INTERMEDIATE, and HIGH. These
settings must be made gradually – YOU
MUST GO THROUGH ALL THREE
STAGES IN ORDER.
You will not actually pump in this exercise;

the nitrogen will still be circulating. You
must keep up with the temperature at all
times and not exceed the maximum. When
you are pumping, the combustion
temperature should not exceed 8000F. The
absolute maximum is 12000F – never go
above that. When you are going through
the lighting operation; that is, not pumping
nitrogen, the temperatures should not go
above 4000F.
HEATER START-UP
1. Engage the fuel pump lever--pull it
towards you.
2. Regulate the fuel pump pressure to
150 psi-turn regulator clockwise.
3. Turn electronic ignition switch to on.
4. Start LOW setting—press LOW ON
button.
5. Check the heater sight gauge for
flame—this is on the underside of the
heater box. The sight gauge should be
cleaned after every job.
6. Watch the combustion temperature
gauge for a rise in temperature to over
2500F.
7. Turn electronic ignition switch to OFF.
8. Increase the fuel pressure to 225
pounds.
9. Turn on the INTERMEDIATE burner.
10. Watch the combustion temperature—do
not exceed 4000F.
11. Increase the fuel pressure to 300
pounds.
12. Turn on the HIGH burner. The
temperature will rise quickly—do not
exceed 400 0F.
13. Turn off all three burners—push all
three buttons.
Now you are going to do the heater
shutdown. Actually, you have already
done the first step—turning off the burners.
Again, you are going to keep a watchful
eye on the combustion temperature. DO
NOT turn off the vaporizer fan until the
combustion temperature drops to 250 0F.
At 2500F, the Low Flame light should go
off but watch both—the temperature gauge
and the light. Shut down is basically the
reverse of all the steps you’ve done before.
HEATER SHUT-DOWN
1. Push all three heater off buttons—you
have already done this.
2. Turn the fuel pump OFF—push it
forward.
3. Put the clutch in the ENGAGE position
and wait 30 seconds.
4. Put the Main Pump in the
DISENGAGE position and wait 30
seconds.
5. Put the clutch in the DISENGAGE
position.
6. Turn off the Booster Pump—push the
lever forward.
7. Turn off the Booster Pump Regulator
Valve—clockwise.
8. Close all valves.
9. Open the ROAD valve.
10. If the combustion temperature is less
than 250 0F, turn off the vaporizer fan.
If not, wait for the temperature to drop
below 250 0F.
11. Bring the engine to IDLE, then turn it
OFF.
12. Turn off the truck engine.
13. Turn off the main power to the control
panel.
14. In the cab, press the clutch in, put the
transmission in NEUTRAL. Place the
PTO in ROAD position and put the
Local/Remote to LOCAL.
TROUBLE SHOOTING
Heater to Model SP6000 Unit
A. NO POWER to CONTROL BOX
After Turning Power Power cable not plugged in.
Switch On. Battery leads not connected.
Low battery voltage.
B. NO POWER TO IGNITOR or
ELECTRODES Faulty switch.
Bad permatune.
Faulty ground wire.
Faulty spark electrode.
C. WATLOW PYROMETER
Indicator not working Thermocoupler broken.
No power to Walton.
D. FUEL PRESSURE
No fuel pressure or low fuel pressure No hydraulic pressure to fan and fuel
pump motor.
Pump not primed.
No fuel.
Clogged fuel filter.
E.. START UP
Heater will not light with LOW ON Faulty fuel solenoid.
button activated. Clogged fuel orifice.
No power to button.
F. INTERMEDIATE BURNER
BUTTON
Fails to Ignite No power to button.
Faulty intermediate fuel solenoid.
Faulty power relay.
Clogged fuel orifice.
G. HIGH BURNER BUTTON
Fails to Ignite No power to button.
Faulty intermediate fuel solenoid.
Faulty power relay.
Clogged fuel orifice
IF BURNER FAILS TO SHUT OFF POWER AND
SHUT OFF FUEL PUMP –
LIGHT HEATER WILL LOAD UP
WITH FUEL. Notify Supervisor
Immediately
TROUBLE SHOOTING
Booster Pump
Pump Will Not Prime Main vent open.
Low hydraulic pressure.
Pump iced up.
Pump Boost Pressure Erratic Leaking seal.

Liquid leaking back through re-circulation valve.
Tank pressure low.
Pump Boost Pressure Erratic During Bad suction valve on cold end.
Pumping Main pump
Minimum Boost Prime Pressure

Model 600 60 – 70 psi
Model 540 A & B 70 – 80 psi
Main Power End (LMPD) Pump

Failure to Prime Cold Ends Low boost pressure.
Foreign material in pump (i.e. ice).
Nitrogen (liquid) Leaking from Back of Worn packing.

Cold End
Cross Head Oil Seal Leaking Worn seal.
Low Lube Pressure

Model 600 below 60 psi Lube oil tank low.
Model 540 A & B below 100 psi Lube pump failure.
Lube pump not engaged.
Pump Rate Meter Erratic or Not Broken pump gear.

Working Notify supervisor immediately.
Main Pump Making Hammering Sound Bad cold end.

Bad bearings in LMPD drive unit.
Main Pump Temperature Above 1300F Bad bearings in LMPD drive unit.
Bad cold end.
IF ANY OF THE ABOVE OCCUR –
NOTIFY SUPERVISOR
IMMEDIATELY.
RIGUP
Calibration Chart For 9.46 m3 Nitrogen Tank
Inches of Gallons Inches of Gallons
Liquid N2 m3 Gas Liquid N2 m3 Gas
1 6 15.80 34 1158 3053.15
2 17 44.83 35 1204 3174.43
3 32 84.38 36 1249 3293.08
4 49 129.18 37 1295 3414.36
5 69 181.94 38 1340 3533.00
6 91 239.93 39 1386 3654.29
7 115 303.19 40 1431 3772.94
8 141 371.77 41 1476 3891.58
9 168 442.93 42 1521 4010.23
10 197 519.39 43 1565 4126.25
11 227 598.50 44 1610 4244.92
12 259 682.86 45 1654 4360.91
13 292 769.88 46 1679 4474.29
14 326 859.53 47 1741 4590.30
15 361 951.81 48 1783 4701.02
16 397 1046.73 49 1825 4811.79
17 434 1144.25 50 1867 4922.49
18 472 1244.47 51 1908 5030.60
19 511 1347.29 52 1948 5136.05
20 550 1450.13 53 1988 5241.53
21 591 1558.22 54 2027 5344.35
22 632 1666.33 55 2065 5444.54
23 673 1774.42 56 2102 5542.08
24 715 1885.16 57 2138 5637.01
25 758 1998.52 58 2173 5729.29
26 801 2111.90 59 2207 5818.94
27 845 2227.91 60 2240 5905.93
28 889 2343.93 61 2271 5987.65
29 933 2459.94 62 2302 6069.43
30 978 2578.60 63 2331 6145.86
31 1023 2697.24 64 2358 6217.05
32 1068 2815.86 65 2384 6286.60
33 1113 2934.50
Calibration Chart For 15.9 m3 Nitrogen Mini
Inches of Inches of
Liquid m3 Gas Liquid m3 Gas
1 42.41 31 5706.72
2 110.60 32 5943.73
3 197.51 33 6180.75
4 302.85 34 6415.12
5 421.35 35 6649.50
6 550.40 36 6881.25
7 690.00 37 7110.36
8 840.08 38 7339.47
9 998.08 39 7565.95
10 1166.62 40 7789.80
11 1340.44 41 8011.06
12 1519.51 42 8226.95
13 1705.98 43 8440.26
14 1901.36 44 8650.94
15 2098.87 45 8916.92
16 2301.65 46 9056.29
17 2509.69 47 9251.11
18 2723.00 48 9440.84
19 2936.32 49 9622.63
20 3157.53 50 9801.59
21 3378.74 51 9970.08
22 3605.22 52 10130.92
23 3831.69 53 10286.09
24 4063.44 54 10428.53
25 4295.18 55 10562.75
26 4526.93 56 10686.49
27 4761.31 57 10797.21
28 4998.32 58 10891.79
29 5232.69 59 10968.25
30 5469.71 60 11020.92
Pump Chart For 2 7/8" Cold Ends
1st Gear Pumping 2nd Gear Pumping
RPM RATE m3 RPM RATE m3
1000 42.48 1000 53.80
1200 50.97 1200 65.13
1400 59.46 1400 76.45
1600 69.97 1600 87.78
1800 76.46 1800 99.11
2000 84.95 2000 110.44
3rd Gear Pumping 4th Gear Pumping

RPM RATE m3 RPM RATE m3
1000 72.21 1000 96.28
1200 84.95 1200 110.44
1400 101.94 1400 131.67
1600 114.68 1600 148.66
1800 127.43 1800 169.10
2000 144.42 2000 186.89
5th Gear Pumping

RPM RATE m3
1000 118.93
1200 138.75
1400 165.65
1600 191.14
1800 212.38
2000 237.86
TRAINING DEPARTMENT
APPENDIX 4 N2 TRANSPORT EDMONTON
Page 224 of 224
BJ PPS
Nitrogen
Trailer Transport
TABLE of CONTENTS
Unit Information Page 3
Related N2 Equipment Page 4
Introduction Page 5
Unit Operation Page 6 – 17
Trouble Shooting
Operation Page 18
Rigup Page 23
Calibration Chart
7500litre Tank Page 20
Calibration Chart
2725litre Tank Page 21
Calibration Chart
1590litre Mini Page 22
Pump Chart Page 26

BJ TRANSPORT NITROGEN PUMPER UNIT
BJ Nitrogen Pumper Units are designed to transport and Specifications : Dimensions:

pump nitrogen for the use in stimulation treatments (acid Nitrogen Pump Flow Height: 11 ft. 6 in.
& fracturing), completions, clean outs, pressure testing, Rates: 568 litres/min Width: 8 ft.
and other well servicing operations. Length:
The high- efficiency nitrogen pump is powered by an air Trailer 42’.3” ft.
cooled auxiliary engine, with controls located by the pump Tractor Trailer 62’ ft.
for operator visibility. Gross Vehicle Weight:
The Unit illustrated here incorporates the pump, 17,460 kgs. Empty
auxiliary engine and a 2725 litre nitrogen tank. 2725 litre tank with 43 inches on unit
15,570 m3 pumpable 35,607 kgs.
OTHER NITROGEN RELATED EQUIPMENT
Nitrogen Mini – Capacity-15.9 m3 (9910 m3 pumpable )
Nitrogen Pump Truck – Capacity-7.5 m3 (150,000 m3 pumpable )
Two -45.5 m3 Nitrogen Storage Vessels

INTRODUCTION
Liquid nitrogen is colorless, odorless, non- corrosive, extremely cold (-196 0 C ) and nonflammable.
19
Nitrogen is a gaseous chemical element forming nearly four-fifths of the atmosphere. Nitrogen,
although used chiefly in a gaseous state, is often stored and transported as a liquid because liquid
nitrogen requires less space to store than gas. Liquid nitrogen storage systems are insulated or
vacuum insulated to minimize product loss through vaporization. The molecular symbol for liquid
nitrogen is N2 .
Nitrogen is nontoxic, but can act as an asphyxiant (can cause suffocation) by displacing the amount of
oxygen in the air necessary to sustain life. In the liquid state it may cause frostbite. Frostbite effects
are a change in color of the skin to gray or white possibly followed by blistering. Loading of nitrogen
is to be done in a well-ventilated area. The use of loose fitting insulated gloves and goggles are
required when loading liquid nitrogen and handling load lines.
BJ Services utilizes nitrogen primarily in the stimulation (enhancing the production) of oil and gas
wells. It is transported to the well site in a liquid state then changed to a gaseous state before going
into the well. Caution must be exercised when pumping nitrogen. Nitrogen is being changed
from a liquid to a gaseous state. Rapid expansion is taking place under pressure from the
pumps. DO NOT PUMP IN A CLOSED SYSTEM i.e. against a closed valve.
The first thing to check before Transporting
the Nitrogen Tanker unit is the Pressure
Gauge and Liquid Product Gauge, also
check the Discharge Pressure Gauge.
Caution With unit Loaded the Pressure

Gauge should be between 10 and 20 psig.
The Liquid Gauge should be 50 inches.
The Discharge Gauge should read zero.
Caution: The pressure on the unit should
never go over 35 to 40 psi, the unit is
equipped with a 2 inch 45 psig Relief Valve
,
and a Rupture Disk is set at 61 psi
To control the pressure on the vessel you

must use the Vent Control Valves.
The first valve is the Main Vent Valve

This is a 2 inch Valve which is used to
bring pressure down quickly.
The second valve is the Road Relief Valve

This is a ¾ inch valve used to control
pressure while unit is in transit. It goes through
a pressure relief set between 13 and 15 psig.
When in transit the Main vent should be

closed, and Road Vent should be open.
If loading the unit at a plant or site location,
and the location has scales, you should first
weight the unit. Make sure pressure on
vessel is below 15 psig before weighing
unit. Next pull unit to loading area.
First connect the loading hose on to the fill

union located on the Loading Valve.When
loading at a plant there will be a 10 to 20
min wait while there pump cools down to
prevent damage to the pump seals. Once
ready, open the Recirculation Valve and
Load Valve to the full open position,
(counter clockwise).Then turn the valve a
¼ turn back, (clockwise), to the closed
position to prevent the valve from freezing
open.
Once the liquid starts to enter the vessel, the

pressure on the vessel will increase rapidly
At this time both the Main Vent, and the
Road Vent, should be open to control
pressure on the vessel. Do not allow
pressure to go over 35 to 40 psig.
Once liquid temperature in vessel equalizes

the pressure will stabilize.
Once the unit is loaded to the desired liquid
level, around 48 to 50 inches on the Liquid
Gauge. For a legal load this level may vary.
You need to make sure that the plant or

location pump is shut down. Then you can
shut off the Recirculation Valve , and
Load Valve on the unit.
Next knock The Load Union loose on the

loading line. Let the pressure bleed off the
hose before you disconnect the hose. Then
release the pressure on the pump by
opening the Load Valve a ¼ turn. The
trapped Nitrogen between the pump and
valve will vaporize and build pressure if it
is not released and cause damage to the
pump seal.
Now we can close the Main Vent Valve,
and leave the Road Valve open.
Next close up the loading compartment on

rear of unit.
You are now ready to weight the unit out,

and sign load slip before leaving plant.
For off loading at plant and site delivery.
Always check Fuel Tank on trailer unit,
and make sure tank is full of gasoline.
Open up Engine Compartment doors on

both sides, So engine will stay cool during
operation.
Next make sure engine Clutch is in the

disengaged position.
Also make sure to Check Engine Oil on

unit.
Next turn the Ignition Switch to the on
position .
.
Next go to the engine compartment turn the

Power Switch to the on position, and push
the engine Starter Button. Once engine
has started let engine run till it has warmed
up, you my have to trottle engine rpms up
with pull throttle located on rear control
panel on back of unit, to keep engine
running.
Next open the Product Main Supply
Valve. Located on the drivers side of the
unit.
We can now close the Main vent and

Road Vent so we can build tank pressure.
Now we are ready to cool down unit to
unload vessel. Start by opening the Pump
Product Valve.
Then open the Recirculation Valve so
nitrogen can circulate through the pump
back into the tank to cool down the pump.
This will take 10 to 15 min.
Caution:
Check on the Pressure Gauge during cool
down as thetank will build pressure quickly.
You will need to open the main vent valve to
keep pressure below 35 psig.
Once the pump has cooled down and
frosted completely over, it is ready to
pump off product.
Open the Pump Discharge Valve, make

sure the load valve on the unit you are
going to pump into is also open.
Next close the Recircalation Valve, this
will let product discharge through the
Discharge Valve Outlet.
Next go to the Engine compartment and

place the Clutch in the engage position,
this will start the pump.
Once you have engaged the pump you will
see pressure on the Discharge Pressure
Gauge. You will now use the Trottle
Control to increase engine rpm and pump
speed. Watch the discharge pressure
making sure pressure does not go over 150
psig.
Once discharge pressure is established you
will have to use the Tank Pressure Build
Valve to build pressure during pump
discharge. Try to maintain Tank Pressure
at 25 to 30psig.
The tank pressure valve lets nitrogen flow

through the Vaporizer turning it into gas,
creating pressure in the tank to help keep
prime to the pump.
Shut Down And Review:
To shut down after vessel is empty

1. Throttle Engine Down.
2. Shut Engine Switch Off.
3. Open Main Vent Valve.
4. Open Road Valve.
5. Close Main Pump Valve.
6. Close Discharge Valve.
7. Disengage clutch on engine.
8. Close up engine compartment.
9. Disconnect loading hose place back
on unit.
10. Release pressure on pump by
cracking open pump discharge valve.
11. Once pressure is below 10 to 15 PSI
shut Main Pressure Vent Valve.
12. Leave road valve open.
13. Secure rear control compartment
and Vessel.
14. Close the Main Product Valve
located on the side of the re ar
compartment.
TROUBLE SHOOTING
Booster Pump
Pump Will Not Prime Pump maybe iced up due to condensation.
Pump Boost Pressure Erratic Leaking boost pump seal.
Leaking boost pump seal causes 1.Pumping pump before adequate cool down is
allowed on pump..
2.Pressure build up from closed valves with product
trapped between them.
3.Always-bleed pressure off valves after liquid
nitrogen is shut off.
Product valves frozen open. Condensation builds up on valve stems.

Always open valves all the way open then turn
closed ¼ turn to prevent freeze up.
Auxiliary engine will not crank. 1.Ignition switch turned off

2.Low battery.
Engine cranks but will not start. 1.Ignition switch turned off
2.Check fuel
3.Make sure the clutch is not engaged.
Calibration Chart For 56.6 m3 Nitrogen Tank
Inches m3 Gas Inches m3 Gas
1632 1 46.21 97261 31 2754.13
3174 2 89.88 101320 32 2869.06
4176 3 118.25 105344 33 2983.01
6744 4 190.97 109368 34 3096.96
8772 5 248.40 113333 35 3209.23
11188 6 316.81 117299 36 3321.54
13604 7 385.22 121180 37 3431.44
16342 8 462.75 125062 38 3541.36
18081 9 512.00 128831 39 3648.09
22095 10 625.66 132600 40 3754.81
25109 11 711.01 136232 41 3857.66
28357 12 802.98 139865 42 3960.54
31606 13 894.98 143332 43 4058.71
35054 14 992.62 146799 44 4156.89
38503 15 1090.28 150069 45 4249.48
42121 16 1192.73 153340 46 4342.11
45739 17 1295.18 156378 47 4428.13
49496 18 1401.57 159417 48 4514.19
53254 19 1507.99 162186 49 4592.60
20 0.00 164955 50 4671.01
57124 21 1617.57 167405 51 4740.38
60995 22 1727.19 169855 52 4809.76
64952 23 1839.24 171000 53 4842.18
68910 24 1951.31 172900 54 4895.98
72929 25 2065.12
76949 26 2178.95
81005 27 2293.81
85062 28 2408.69
89132 29 2523.94
93202 30 2639.19
Calibration Chart For 204 m3 Nitrogen Tank
Inches m3 Gas Inches m3 Gas
1955 1 55.36 310336 33 8787.74
5400 2 152.91 322533 34 9133.12
9870 3 279.49 334824 35 9481.16
15177 4 429.76 347114 36 9829.18
21136 5 598.50 359405 37 10177.22
27654 6 783.07 371602 38 10522.60
34637 7 980.81 383893 39 10870.64
42179 8 1194.38 396090 40 11216.02
50093 9 1418.48 408287 41 11561.40
58380 10 1653.14 420392 42 11904.18
67039 11 1898.33 432496 43 12246.92
76071 12 2154.09 444507 44 12587.04
85382 13 2417.75 456425 45 12924.52
94972 14 2689.31 468250 46 13259.37
104749 15 2966.16 479982 47 13591.58
114898 16 3253.55 491621 48 13921.16
125140 17 3543.57 503166 49 14248.08
135754 18 3844.13 514526 50 14569.76
146462 19 4147.34 525792 51 14888.77
157356 20 4455.83 536872 52 15202.52
168436 21 4769.58 547766 53 15511.01
179702 22 5088.59 558474 54 15814.22
191062 23 5410.27 568995 55 16112.15
202514 24 5734.56 579330 56 16404.80
214153 25 6064.14 589386 57 16689.55
225978 26 6398.99 599256 58 16969.04
237803 27 6733.83 608846 59 17240.60
249721 28 7071.31 618157 60 17504.26
261732 29 7411.43 627096 61 17757.38
273743 30 7751.54 635755 62 18002.58
285138 31 8074.21 644135 63 18239.87
298138 32 8442.33 652049 64 18463.97
Calibration Chart For 15.9 m3 Nitrogen Mini
Inches of Inches of
Liquid m3 Gas Liquid m3 Gas
1 42.41 31 5706.72
2 110.60 32 5943.73
3 197.51 33 6180.75
4 302.85 34 6415.12
5 421.35 35 6649.50
6 550.40 36 6881.25
7 690.00 37 7110.36
8 840.08 38 7339.47
9 998.08 39 7565.95
10 1166.62 40 7789.80
11 1340.44 41 8011.06
12 1519.51 42 8226.95
13 1705.98 43 8440.26
14 1901.36 44 8650.94
15 2098.87 45 8916.92
16 2301.65 46 9056.29
17 2509.69 47 9251.11
18 2723.00 48 9440.84
19 2936.32 49 9622.63
20 3157.53 50 9801.59
21 3378.74 51 9970.08
22 3605.22 52 10130.92
23 3831.69 53 10286.09
24 4063.44 54 10428.53
25 4295.18 55 10562.75
26 4526.93 56 10686.49
27 4761.31 57 10797.21
28 4998.32 58 10891.79
29 5232.69 59 10968.25
30 5469.71 60 11020.92

N2 Training Manual

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NITROGEN OPERATORS COURSE

NITROGEN OPERATORS COURSE ....................................................................................................................1

DOCUMENT AMENDMENT PAGE .........................................................................................................................8

APPENDIX 1 FLANGE RATINGS......................................................................................................................219

APPENDIX 2 COLDER PRODUCTS FITTINGS INFORMATION...............................................................222

APPENDIX 4 N2 TRANSPORT EDMONTON ..................................................................................................224

The intention of this manual is to introduce the delegates to BJ PPS nitrogen

DOCUMENT AMENDMENT PAGE

Other Gases 0.1%

HISTORY OF N2 IN THE OIL INDUSTRY

BJ SERVICES NITROGEN APPLICATIONS

The following PROCESS services all utilise nitrogen:-

Vacuum Cycle Purging

Dilution (Pressure Cycle Purging)

Helium Leak Detection

Helium at a concentration of approximately 1% is mixed with the injection stream of nitrogen

Nitrogen Foam Inerting

Hot Gas Drying

Tailpipe Water line

The following WELL services all utilise nitrogen:-

This process is also known as a "Kick-Off" or "Fluid Lift".

GAS LIFT COILED

NITROGEN GAS COILED

9 5/8" CASING TEST STRING

9 5/8" CASING TEST STRING

D.S.T. STRING D.S.T. STRING

TEST VALVE TEST VALVE

CLOSED RETRIEVABLE OPEN RETRIEVABLE

T.C.P. GUNS PERFORATED JOINT

FORMATION FORMATION FORMATION FORMATION

In its normal state (at 20oC and 1013 mbA), it is a gas.

Physical properties of nitrogen

(at atmospheric pressure)

Boiling point -196oC

Critical temperature and pressure

NON-CRYOGENIC MATERIALS NON-CRYOGENIC COMPONENTS

1. Carbon Steels 1. High Press, Treating Iron

CRYOGENIC MATERIALS CRYOGENIC COMPONENTS

1. Stainless Steel 1. Inner Vessel of N2(Liquid)Tank

Liquid Nitrogen Gaseous Nitrogen

One Volume = 696 Volumes

EFFECT OF TRAPPING LIQUID NITROGEN

LIQUID NITROGEN AT THE SAME GASEOUS NITROGEN AT

TRAPPED LIQUID NITROGEN WILL EXERT A PRESSURE IN EXCESS

BREATHING A PURE NITROGEN ATMOSPHERE WILL PRODUCE IMMEDIATE LOSS

Symptoms of Oxygen Deficiency

% Oxygen at Ambient Pressure Signs and Symptoms of Oxygen

Effects of cold on lungs

Prolonged breathing of extremely cold atmospheres may damage the lungs.

Operations and maintenance

IF IT IS NECESSARY FOR A PERSON TO ENTER AN OXYGEN DEFICIENT

Treatment of cold burns and frostbite

Liquid Nitrogen Spillage

- Dangers of compressed gas

- 1" R12 (rubber) Maximum working pressure 4,000 psig

One piece construction to eliminate Wing union nut

Field Iron Colour Code Chart

HIGH PRESSURE STANDARD TREATING LINE SYSTEMS

Yellow Silver Dark Green

PN 135199 PN 135202 PN 135198

White Blue Orange

PN 135196 PN 135195 PN 136756

SPECIALIZED TREATING LINE SYSTEMS

PN 135200 PN 135201 PN 135197