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

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 PRO 101 Process Nitrogen Operators Manual 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 Boost pump loss of prime ..................................................................................................................................87 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 Boost pump loss of prime ..................................................................................................................................94 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 PRO 101 Process Nitrogen Operators Manual 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 PRO 101 Process Nitrogen Operators Manual APPENDIX 3 N2 PUMPER EDMONTON..........................................................................................................223 APPENDIX 4 N2 TRANSPORT EDMONTON ..................................................................................................224

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

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 PRO 101 Process Nitrogen Operators Manual

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.

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DETAILS OF AMENDMENT:

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Well Services Applications Included

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

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. A BJ SERVICES COMPANY Page 9 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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. A BJ SERVICES COMPANY Page 10 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 PRO 101 Process Nitrogen Operators Manual

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 PRO 101 Process Nitrogen Operators Manual 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 PRO 101 Process Nitrogen Operators Manual 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 PRO 101 Process Nitrogen Operators Manual 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 PRO 101 Process Nitrogen Operators Manual 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: Water line

Tailpipe Injector head Effluent bin Clearshot skid

Customer’s system Abrasive line Nitrogen line

Nitrogen Bulker Liquid nitrogen transfer hose Treating Iron Nitrogen Pumper Hard pipe

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Purge hose

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual PRODUCTION

GAS

GAS LIFT

COILED TUBING

COMPLETION

GAS LIFT THROUGH

GAS LIFT VALVES

NITROGEN GAS

COILED

CIRCULATED

TUBING

THROUGH 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

TO N2 CONVERTER TEST STRING

9 5/8" CASING

MUD

MUD

SEA WATER

D.S.T. STRING PRIOR TO N2 CUSHION

CIRCULATING VALVE CLOSED TEST VALVE RETRIEVABLE PACKER

CLOSED

T.C.P. GUNS

MUD

FORMATION

TO N2 CONVERTER

MUD

MUD

D.S.T. STRING

TO N2 CONVERTER TEST STRING

EFFECT OF D.S.T. STRING

N2 CUSHION

SEA WATER

N2 CUSHION

OIL

SEA WATER

SEA WATER

MUD

COMMENCEMENT OF

PRESSURIZED N2 GAS SEA WATER

PRESSURIZED

9 5/8" CASING

N2 GAS BLED DOWN SLOWLY

TEST STRING

9 5/8" CASING

MUD

MUD

FORMATION

CIRCULATING

CIRCULATING

VALVE OPEN

VALVE CLOSED

RETRIEVABLE PACKER

OIL

OPEN

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TEST VALVE

RETRIEVABLE PACKER

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CLOSED

MUD

TEST VALVE

T.C.P. GUNS

FORMATION

MUD

FORMATION MUD

FORMATION

PERFORATED JOINT

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T.C.P. GUNS ACTIVATED

FORMATION

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

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 Specific Gravity (relative to water) Gas density at 20oC (relative to air) Gas density at -196oC (relative to air) Expansion ratio (liquid to gas)

-196oC 0.81 0.97 3.8 696 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

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 subzero 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)

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual EFFECT OF TRAPPING LIQUID NITROGEN

1 Cubic Foot

1 Cubic Foot LIQUID NITROGEN AT o -196 C and 0 psig

THE SAME GASEOUS NITROGEN AT o 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%. A BJ SERVICES COMPANY Page 26 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

2.

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. 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 rewarm 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.

e) f)

Morphine or some potent analgesic is required to control the pain during thawing and should be administered under professional medical supervision. 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. Administer a tetanus booster after hospitalisation.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual Hoses -

1" R12 (rubber) 1/4" R13R (rubber) 1/2" R9R (rubber) 3/4" R9R (rubber) 1/2" POLYFLEX Stainless steel cryogenic hoses

Maximum working pressure 4,000 psig Maximum working pressure 10,000 psig Maximum working pressure 6,000 psig Maximum working pressure 6,000 psig Maximum working pressure 20,000 psig 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual Treating Iron One piece construction to eliminate all welds & threads

Wing union nut detaches for field removal Green Band H2S Service Circlip

Segments Uninterrupted bore

Available in lengths up to 10 ft

INTEGRAL JOINTS Cold Working End Pressure (PSI) Connect

Type of Size (ins.) Service

Weight Bore Size Wall Thickness (Ins) per Foot (Lbs) (Ins.)

2

Standard

15000

Fig. 1502 1.75

0.375

8.5

2

Sour Gas 10000

Fig. 1502 1.75

0.375

8.5

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 Working Pressure

15,000 psi Working Pressure

White

Blue

Orange

PN 135196

PN 135195

PN 136756

6,000 psi Working Pressure

4,000 psi Working Pressure

2,000 psi Working Pressure

10,000 psi Working Pressure

SPECIALIZED TREATING LINE SYSTEMS Flourescent Green

Black

Red

PN 135200

PN 135201

PN 135197

H2S Sour Gas Service*

N2 Nitrogen Service*

CO2 Carbon Dioxide 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

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

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 A BJ SERVICES COMPANY Page 36 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual Plug Valve

2" INTEGRAL PLUG VALVE FEMALE UNION

MALE 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 5. 2" 2-way swivel joint 6. pup or long joint as required 7. 2" 2-way swivel joint 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

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual Typical Weco and Chiksan equipment recommended temperature ranges

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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. A BJ SERVICES COMPANY Page 42 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual Fittings

BS P NPT JIC

NPT

P arallel thread w ith internal cone seat. U sed for joining and connecting hoses. N o thread sealant should be used w ith these fittings.

Tapered thread, with thread and sealant form ing the seal. U sed for connecting injection 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. 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.

BSP

60O Thread angle. Pitch = 0.7143 (measured in inches) Truncation of root and crest are flat Taper angle 1 4O 7'

55O Thread angle. Pitch = 0.7142 (measured in inches) Truncation of root and crest are round Taper angle 1 4O 7'

NOTE THAT NPT AND BSP THREADS ARE SIMILAR AND CAN BE FORCED TO MATE RESULTING IN A FAULTY CONNECTION.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual Manifolds Injection Manifold Set Up

High Pressure, Nitrogen Gas Injection

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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:

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual Offshore Set up

Land Set up

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 . A BJ SERVICES COMPANY Page 51 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

AMBIENT HEAT TRANSFER TO LIQUID 1

1 VENT CLOSED

0 Barg

1 Barg 1 Barg

0 Barg

Venting to 0 Barg BOILING LIQUID NITROGEN o

SATURATED LIQUID NITROGEN 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 Barg

0 Barg

VENT OPEN

0 Barg 0 Barg (Vap. Press.) SATURATED LIQUID NITROGEN o

-196 C

VENT PRESSURE TO ATMOSPHERE

VENT CLOSED

1 Barg PRESSURE GENERATED BY 0 Barg (Vap. Press.) ARTIFICIALLY VAPORISER COLD LIQUID NITROGEN o

-196 C

COLD LIQUID

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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual SATURATED VAPOUR PRESSURE OF NITROGEN Saturated Pressure (psig)

Temperature o 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 .

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 ¾ ¾ ¾ ¾ ¾ ¾

The unit consists of a blower, fuel pump, burner chamber, heat exchanger, and control system A hydraulically driven high speed blower provides combustion air to the burner A belt driven fuel pump supplies fuel Burner exhaust flows over a tube heat exchanger in which liquid N2 is vaporized The burner controls are mounted in two watertight enclosures 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:

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 ¾ ¾ ¾

Cryogenic pump

vaporizer (hydraulic back-pressure or water-brake technology) Hydraulics to drive the triplex and other pumps

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:

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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, comingling 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!

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 Zone 1 Zone 2

In which an explosive gas/air mixture is continuously present for long periods. In which an explosive gas/air mixture is likely to occur in normal operation. 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. 2. 3. 4. 5. 6.

High exhaust temperature Low oil pressure High water temperature Low coolant level Engine overspeed High discharge pressure

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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:

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

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

V=

D /4 x L o r V =

W h e re

2

R L

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 1ft 1m 1mm 1ft 1in 1m3 1ft3 =

= = = = = = =

3.28ft 0.305m 1000mm 0.001m 12in 0.083ft 35.31ft3 0.028m3

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual WORKED EXAMPLE π SET @ 75 BAR 4"

2"

16"

12"

4" 3"

ID=2750mm TT=4800mm

V =πD2 / 4xL or V =πR2L

Vessel ID = 2750mm ID = 2.75m Using:

TT = 4800mm (length)TT = 4.8m

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)

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 cooldown, and 1 cool-down in total for a purging operation. Total = 18126 + 10000 (2480 + 300) = 28126 scf (2780m3) NOTE :

eg

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.

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)

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

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. A BJ SERVICES COMPANY Page 70 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

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 MAXIMUM OPERATING PRESSURE

5330 M3 (188 K SCF) 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

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

19

SAFETY VALVES @ 3 BAR

CHECK VALVE

7

VENT VALVE

9

RETURN VALVE

6 OVERFILL VALVE

16

3 +14 5

BURST DISC

TANK PRESSURE

15

2 TANK LEVEL

1

VACUUM POINT

13

PRESSURE COIL

SAFETY VALVES @ 10 BAR

11 8

12

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). A BJ SERVICES COMPANY Page 73 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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. 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. 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]. A BJ SERVICES COMPANY Page 74 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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. 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. 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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. Supply Tank

Receiving Tank

14

3

9 8

6

10

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. 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. 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 to detect possible leaks.

Every time the equipment is used.

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 superinsulated 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. A BJ SERVICES COMPANY Page 78 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

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 8

7 10 11

12

16

17

12

Side view of the tank.

LIQUID NITROGEN

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual Front view of the cryolor cnt 8000 - 2.5 tank.

Side view of the tank.

LIQUID NITROGEN

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

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: Hydraulic oil: Diesel: Engine coolant: Funk gear box oil: Cryopumps g'box oil: Air pressure:

Between max and min on dipstick. Must be on scale of tank level indicator. Sufficient for the job - normally full. Visible through radiator fill cap. Between max and min on dipstick. Oil level to be visible in the circular sight glass on the 'warm end' of the pumps(1/4"). Pressure at 110 - 120 psi . If too low for starting, repressurise 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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. A BJ SERVICES COMPANY Page 83 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

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 Water Temperature Engine Tachometer Hydraulic Pressure Hydraulic Temperature Charge Pump Pressure Coolant Pressure Hydraulic Filter Pressure GN2 line temperature Fuel pressure

60 psi 190 oF 1800 - 2100 rpm 3200 - 4200 psi 100 - 165 oF (Usually 10 oF than engine water) 225 - 300 psi 250 psi < 30 psi 100 oF (hand hot) 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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. 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.

Water brake tank:

Must be on scale of tank level indicator.

Cryopumps oil:

Must be on scale of tank level indicator.

Air pressure:

Pressure at 110 - 120 psi . If too low for starting, repressurise from truck system by jumper hose or from customer supply.

ENGINE WARM-UP Ensure large water brake valve is closed. 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; 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 Water temperature Coolant pressure Hydraulic charge pressure

20 - 40 psi. 150 oF 50 psi. 225 - 300 psi.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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: The cryogenic seals in the boost pump are designed to operate at temperatures equal to the 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. Condition the nitrogen in the tank as described in the liquid nitrogen good housekeeping section prior to commencing cool-down. 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 Water Temperature Engine Tachometer Hydraulic Temperature Charge Pump Pressure Coolant Pressure Hydraulic Filter Pressure GN2 line temperature

60 psi 150 oF 1500 - 2100 rpm Max. 100 - 165 oF 225 - 300 psi 50 - 80 psi < 30 psi 100 oF

Boost pump loss of prime 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: Nitrogen Tank pressure Condition of nitrogen according to the good house keeping section Liquid nitrogen level in the tank.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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. 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, repressurise from truck system by jumper hose or from customer supply.

ENGINE WARM-UP Ensure that the large water brake valve is fully open and the small water brake valve is fully closed. 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; 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)

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual Prior to commencing cool-down with nitrogen the following engine conditions must apply, during idling at 1800 rpm: Engine oil pressure Water brake pressure Water temperature Coolant pressure Hydraulic charge pressure

20 - 40 psi. 35 psi. 170 oF 50 - 80 psi. 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: The cryogenic seals in the boost pump are designed to operate at temperatures equal to the liquid nitrogen (-196 Co). 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 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 following figures should be used as a guideline: Oil Pressure Water Temperature Water Brake Pressure Engine Tachometer Hydraulic Pressure Hydraulic Temperature Charge Pump Pressure Coolant Pressure Hydraulic Filter Pressure GN2 line temperature

60 psi 170 oF 35 psi 1800 - 2100 rpm 3500 - 4200 psi 100 - 165 oF 225 - 300 psi 50 - 80 psi < 30 psi 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. 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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. 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.

Triplex gearbox oil:

Oil level to be visible in the circular sight glass on the 'warm end' of the pumps.

Air pressure:

Pressure at 110 - 120 psi . If too low for starting, repressurise from supply.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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. 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual At all times during pumping all temperatures and pressures must be monitored. The following figures should be used as a guideline: Oil Pressure Water Temperature Engine Tachometer Hydraulic Pressure Hydraulic Temperature Charge Pump Pressure Coolant Pressure Hydraulic Filter Pressure GN2 line temperature Fuel pressure

60 psi 90oC (≈190 oF) 1800 - 2100 rpm 3200 - 4200 psi 40 – 75oC or ≈100 - 165 oF (Usually 10 oF than engine water) 225 - 300 psi 250 psi < 30 psi 40oC or ≈100 oF (hand hot) 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. 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 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. 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

FIRED UNITS ZWICK 240K (UNIT 110) OPERATING GUIDELINE WARNING: All pre-job check lists should be satisfactorily completed in accordance with 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 just below nut for cable drive.

Air pressure:

Pressure at 110 - 120 psi . If too low for starting, repressurise from truck system by jumper hose or from 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: Coolant temperature: Coolant pressure: Hydraulic pressure: Fuel pressure: Hydraulic charge pressure

40 - 60 psi 170/180 oF 30 - 60 psi 3200 psi (both circuits) 2 - 5 bar (if less, check filters) 225 - 300 psi

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 overpressure 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 following figures should be used as a guideline: Oil pressure: Fuel pressure: Coolant temperature: Coolant pressure: Engine tachometer: Hydraulic pressure: Hydraulic temperature: Hydraulic charge pressure: HP hydraulic filter Pressure monitors (2): GN2 line temperature:

20 - 40 psi (20 on idle) 2 - 5 bar 170/180 oF 250-290 psi 1800-2100 rpm 3000-3500 psi (both circuits) 120-180 oF 225-300 psi 0 psi (change at 30 psi) 100 o F (hand hot)

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual FIRED HP UNITS 90K (UNIT 101) OPERATING GUIDELINE WARNING: All pre-job check lists should be satisfactorily completed in accordance with 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:

Also between max and min on dipstick.

Diesel:

Sufficient for the job - normally full.

Engine coolant:

Visible through radiator fill cap.

Heater header tank:

Level inside sight glass.

Cryopumps g'box oil:

Oil level to be visible in the circular sight glass on the '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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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: Engine oil pressure: Air pressure: Heater hydraulic pressure: Heater water temperature: Heater water pressure: Atomising air pressure:

14 - 60 psi 100-120psi 1000 psi (drops to 500 psi when oil is warm) 170 oF 20-40 psi 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 overpressure the boost pump as rapid and permanent damage will occur. Condition the nitrogen in the tank as described in the liquid nitrogen good housekeeping section 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. Once liquid nitrogen issues from the vent, close vent and increase centrifugal pump hydraulic 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 following figures should be used as a guideline: Engine oil pressure: Air pressure: Heater hydraulic pressure: Boost pump hyd pressure: Heater water temperature: Heater water pressure: Atomising air pressure: Boost pump discharge: GN2 line temperature: Rig tank pressure:

14 - 60 psi 100-120 psi 1000 psi (drops to 500 psi when oil is warm) 500 psi 170 oF 30-40 psi 20-40 psi 1 bar above tank pressure 10 oC 1.5-2 bar

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 tank pressure Nitrogen contents indicator Nitrogen condition Once boost pump prime is regained, check for GMPD prime.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual UNIT 103 (OPEN FIRED) WARNING: All pre-job check lists should be satisfactorily completed in accordance with Base procedures prior to commencing operation with this unit. In particular - check all fluid levels and switches are in accordance with the following list: Engine oil:

Between max and min on dipstick.

Engine manual stop:

Set in the run position.

Hydraulic oil:

Must be on scale of tank level indicator.

Diesel:

Sufficient for the job - normally full.

Engine coolant:

Visible through radiator fill cap.

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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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: Coolant temperature: Engine RPM: Air pressure: Heater hydraulic pressure: Heater water temperature: Heater water pump pressure: Aux water pump pressure: Atomizing air pressure:

Green 'eye' showing Green 'eye' showing 1500 100-120 psi 500 psi 180 oF 60-80 psi 60-80 psi 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

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. Once liquid nitrogen issues from the vent, close vent and increase centrifugal pump hydraulic 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual The following figures should be used as a guideline: Engine oil pressure Coolant temperature Engine RPM Air Pressure Heater hydraulic pressure Heater water temperature Heater water pump pressure Aux water pump pressure Burner fuel pressure Atomising air pressure GN2 line temperature

Green 'eye' showing Green 'eye' showing 1500-2000 100-120 psi 500-1000 psi 200 oF 60-80 psi 60-80 psi 0-20 psi depending on the job 20-40 psi > 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: Nitrogen tank pressure Nitrogen contents indicator 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 PRO 101 Process Nitrogen Operators Manual 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 PRO 101 Process Nitrogen Operators Manual 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 PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 PRO 101 Process Nitrogen Operators Manual

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 75 450 850 2200 5400

-- 125 psig -- 550 psig -- 850 psig -- 2200 psig -- 5400 psig -- 10000 psig

Axelson Axelson Brisco Brisco Brisco 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 PRO 101 Process Nitrogen Operators Manual 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 PRO 101 Process Nitrogen Operators Manual 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. A BJ SERVICES COMPANY Page 119 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 crossover 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

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 PRO 101 Process Nitrogen Operators Manual 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 PRO 101 Process Nitrogen Operators Manual 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 PRO 101 Process Nitrogen Operators Manual 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 PRO 101 Process Nitrogen Operators Manual 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 PRO 101 Process Nitrogen Operators Manual OPPS SCHEMATICS

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 1 2 3 4 5 6 7 8 9 10

Type Earth Terminal Through Terminal Fused Terminal I.S. Terminal I.S. Terminal Diode Terminal Through Terminal Through Terminal Diode Terminal Through Terminal

Connected to 110v Mains Earth 110v Mains Neutral 110v Mains Live

24v Battery Ov Battery 24v Solenoid Ov Solenoid

Terminal 3 has a 2A antisurge 20 x 5mm fuse and terminals 6 and 9 have IN4001 diode.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 1 2 3 4 5 6 7 8

Type MTL 708+ MTL 787S+ MTL 779+ MTL 779+ MTL 3013 MTL 3013 MTL 3041 MTL 3041

Connected to Alarm Horn Display Alarm LED Solenoid LED Battery LED Mains LED Power Switch Solenoid Switch Alarm Test Switch Alarm Mute Switch Pressure Transducer 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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"

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 prealarm 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". A BJ SERVICES COMPANY Page 137 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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. A BJ SERVICES COMPANY Page 138 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 RELAY B

-

below this set temperature, the solenoid will operate. 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) ii) iii) iv) v)

All external cables are free from kinks and there is no damage to their outer sheaths. The door seal is intact. The display and LED's are kept clean. The EExd box is checked. 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual EMOS SYSTEM - OPERATIONAL PRESSURE TRANSDUCER

7 1 7 5 3 3

AIR "IN"

AIR "OUT"

7 1 7 5 3 3

TEMPERATURE TRANSDUCER .

PROTECTIVE BARS DO NOT USE FOR LIFTING

PRESSURE

TEMPERATURE

WARNING 110v SUPPLY ONLY

.

I.SCOMTEC OVERPRESSURE DISPLAY oech mm ss o ng SYSTEMAND ALARM iiClTn g o y no

AIR "EXHAUST"

I.S EARTH

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

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual EMOS UNIT - FRONT VIEW

.

PROTECTIVE BARS DO NOT USE FOR LIFTING

PRESSURE PRESSURE

TEMPERATURE

TEMPERATURE

PSI / BAR

..

..

oC / oF

WARNING 110v SUPPLY ONLY

.

COMTEC I.S OVERPRESSURE DISPLAY AND ALARM SYSTEM

ON / OFF

MAINS

BATTERY

VALVE ON / OFF

VALVE

ALARM MUTE

ALARM

ALARM TEST

EMOS UNIT - SIDE VIEW

.. .. PRESSURE TRANSDUCER

.

110v SUPPLY

AIR "OUT"

I.S EARTH

AIR "EXHAUST"

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TEMPERATURE TRANSDUCER

AIR "IN"

EARTH STUD

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual EMOS UNIT - CONNECTIONS .

TRANSDUCE PROTECTIVE BARS DO NOT USE FOR LI FTING

PRESSUR

.

TEMPERATU TRANSDUCE

TEMPERATU

WARNING 110v SUPPLY ONLY

110v SUPPL

COMTE I.S C DISP LAY AND OVERPR ESSUR E SYSTE ALARM M

I.S

EARTH AIR AIR "EXHAUST AIR

EMOS - INSIDE UNIT

VENTILATION FILTER

BATTERIES

ALARM

VENTILATION FILTER

SOLENOID

Eex-d BOX CABLES

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual EMOS - Exe-d BOX

ALARM POINT B

. . . . . . . .

ALARM POINT A

POWER ISOLATOR ON / OFF

ALARM SET ON / OFF

ALARM DISPLAY

BAR 8 TEMP TRANS

BAR 7 PRES TRANS

RELAY 1

BAR 6 SWITH ISOL

RELAY 2

TEMP T R IP A M P

MATRIX LB

MOUNT BLOCK

BAR 5 SWITH ISOL

MTL 700 SERIES

END STOP

BAR 3 LED

BAR 2 4 - 20 mA LOOP

MOUNT BLOCK

BAR 1 - ALARM

PR ESSU R E T R IP A M P

4 - 20 mA PCB

END STOP

MTL 700 SERIES

EMOS - Exe-d BOX ASSEMBLY

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PSU

. . . .

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual EMOS - LOOP POWERED I.S. INDICATORS

I.S INDICATOR

MTL 684

1000. WARNING CLEAN WITH NON ABRASIVE LIQUIDS

CONFIG

mA

MTL

0%

100%

LKLFJWEROIHOHOIPIEJHIG VJNWKJHOIHGOIWHGIHOI

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ENTER

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

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 offshore 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

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual TYPICAL SINGLE ENGINE INTERCONNECTIONS

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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:

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 cutoff.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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:

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 nonhazardous. 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

ENGINE TROUBLESHOOTING GUIDE

#

TROUBLE

A.

Engine Starter not turning over

PROBABLE CAUSE 1. No Air Pressure.

REMEDY 1. Check system air pressure.

2. Faulty Start Button. 2. Ensure start valve is pressurising diaphragm valve. 3. Check Diaphragm Valve (Dump Valve to Starter) to be sure it is opening and delivering air supply to starter.

4. Check the Emergency Kill "Flapper" to see if it is in closed position.

3. Remove air pilot line and push start button. If good air pressure and 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. Reset Emergency Kill 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual ENGINE TROUBLESHOOTING GUIDE # B.

TROUBLE Engine Cranks but will not start

PROBABLE CAUSE

REMEDY

1. Slow cranking speed.

1. Refer to A.

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 cylinder to see if it is stuck in kill position.

4. Repair or remove and replace normal kill cylinder.

5. Throttle linkage binding.

5. Check linkage and make adjustments as necessary.

6. Poor quality fuel, incorrect fuel or water in fuel.

6. Drain fuel, change filters and replace fuel.

7. Improper oil viscosity.

7. Drain oil, change filters and replace oil.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual ENGINE TROUBLESHOOTING GUIDE #

TROUBLE

C.

Engine Misfiring

PROBABLE CAUSE

REMEDY

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 lines.

3. Check for fuel leaks and 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 or pump.

6. Contact authorised engine repair representative

.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual ENGINE TROUBLESHOOTING GUIDE # D.

E.

F.

TROUBLE Engine Stalls

Erratic Engine Speed

Low Power

PROBABLE CAUSE

REMEDY

1. Manicoolers or Flame traps choked up.

1. Remove & clean.

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 (eg. LN2 pump hydraulic pump speed control).

4. Check for engine loading during starting.

1. Air leaks in fuel section line.

1. Check for air leaks and repair as necessary.

2. Throttle linkage loose.

2. Check throttle linkage.

3. Engine governor problems.

3. Contact authorised repair representative.

1. Restrictions in air intake system, clogged filter.

1. Check air pressure in air inlet manifold. Replace air filter and make necessary repairs to air system.

air

2. Poor fuel quality.

2. Refer to B, Item 6.

3. Damaged restrictions in throttle linkage.

3. Check linkage, adjust or replace if necessary.

4. Emergency kill flapper partially closed.

4. Check flapper, reset or repair as necessary.

5. Normal kill cylinder partially extended.

5. Reset cylinder or repair as required.

6. Manicooler flame traps blocked by carbon build up

6. Remove and clean flame traps or manicoolers (as appropriate).

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

# G.

TROUBLE Engine Overheating

PROBABLE CAUSE 1. Coolant level low.

1. Determine cause, replace defective parts and replace coolant.

2. Expansion tank cap defective.

2. Replace expansion cap.

3. Defective thermostat.

3. Replace thermostat.

4. Defective coolant pump.

4. Replace coolant pump.

5. Fan not engaging fully (full RPM) or turning. H.

I.

Low Engine Oil Pressure

Oil in Coolant

REMEDY

5. Inspect fan speed. Repair as necessary

1. Oil leakage, low level.

1. Check for leaks and 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.

1. Defective oil cooler or seals.

1. Contact authorised repair representative.

2. Blown head gasket.

2. Contact authorised repair representative.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual ENGINE TROUBLESHOOTING GUIDE # J.

TROUBLE Coolant in Oil

PROBABLE CAUSE

REMEDY

1. Defective oil coolant core or seals.

1. Contact authorised repair 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual NITROGEN PUMPING SYSTEM TROUBLESHOOTING GUIDE # A.

TROUBLE Low flow rate to unit from LN2 Tank

PROBABLE CAUSE

REMEDY

1. Low tank pressure.

1. Increase tank pressure.

2. Supply valve not fully open.

2. Open valve fully on LN2 tank and skid.

3. Return valve closed or partially closed.

3. Open valve fully on LN2 tank and skid.

4. Suction strainer on LN2 tank clogged.

4. Clean or replace strainer.

5. Suction strainer on skid clogged.

5. Clean or replace strainer.

6. Clogged piping or transfer hoses.

6. Inspect piping and hoses to ensure free flow. 1. Thaw valve and dry out packing.

B.

Frozen Valve

1. Moisture in stem packing

C.

Boost pump will not turn

1. Hydraulic valve closed boost pump.

at

1. Open valve.

2. Locked up from ice formation.

2. Turn the shaft coupling with a pipe wrench. Do not use excessive force. If pump will not turn, thaw out, and dry out pump.

3. Suction valve to hydraulic pump closed.

3. Open valve.

4. Defective hydraulic pump.

4. Disconnect motor supply 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual NITROGEN PUMPING SYSTEM TROUBLESHOOTING GUIDE #

TROUBLE

D.

Triplex pump will not rotate

PROBABLE CAUSE

REMEDY

1. Overpressure shutdown is active or tripped.

1. Reset to operating position.

2. No hydraulic charge pump pressure.

2. Check flushing valve by plugging off outlet flushing valve. If pressure is good remove flushing valve and repair or replace as required.

3. Check pump drive coupling to ensure drive components are not slipping of input shaft.

3. Replace damaged or broken drive coupling.

4. Check main system pressure. If pressure rises above required to drive triples one of the following is locked up : (a) Hydraulic drive motor, (b) reduction gear box or (c) Triplex pump.

4. Remove triplex dump drive coupling. Attempt to rotate triplex. If hydraulic motor and reduction gear box rotate, the triplex is locked-up. If the motor 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.

NITROGEN PUMPING SYSTEM TROUBLESHOOTING GUIDE #

TROUBLE

PROBABLE CAUSE A BJ SERVICES COMPANY Page 170 of 224

REMEDY

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual E.

Dyno will not build heat in the coolant circuit.

1. Check hydraulic drive system. If hydraulic 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual TANK TROUBLESHOOTING GUIDE # A.

TROUBLE Low rate to pumping skid

PROBABLE CAUSE

REMEDY

1. Low tank pressure.

1. Build pressure on LN2 Tank.

2. One or more valves required for liquid supply not fully open.

2. Check supply and return valves to make sure they are fully open.

3. Ice or contamination in supply line filters.

3. Check for ice or contamination in LN2 supply filters/strainers.

B.

Frozen valve stem

1. Moisture in stem packing.

1. Thaw and dry valve packing and packing gland with dry nitrogen gas.

C.

Valve leaking vapour and liquid

1. Foreign material or ice on valve seat.

1. Disassemble valve and repair or replace as required.

D.

Tank will not build or maintain pressure.

1. Line to pressure building coil obstruction. Ice or valve closed.

1. Clear obstruction and/or open valve.

2. Low liquid level.

2. Fill Tank.

3. Leak to atmosphere.

3. Locate leak and repair.

1. Defective pressure gauge.

1. Check indicator, replace if necessary.

2. Road relief not functioning.

2. Repair or replace road relief as required.

3. Pressure building valve open.

3. Close valve.

E.

Excessive tank pressure

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

NITROGEN EQUIPMENT SCHEMATICS

PLUMBING FOR CRYLOOR LN2 TANK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

-

LIQUID LEVEL GAUGE. PRESSURE GAUGE. FILL VALVE [95%]. RELIEF VALVES. TRANSPORT VALVE. VENT VALVE. CHECK VALVE. OUTBOARD SHUT OF VALVE. PUMP RETURN VALVE. INBOARD SHUT OFF VALVE. PRESSURE BUILDING VALVE. PRESSURE BUILDING COIL. VACUUM SYSTEM. FILL VALVE AT 85%. BURSTING DISC. IN-FILL NOZZLE. DISCHARGE NOZZLE. BACKFILL (REAR FILL).

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 5 +14 NOT PRESENT ON THIS TYPE OF TANK

15

1

4

2 13

6

3 9

18

8

10 11

12

7 16

17

12

PLUMBING FOR L’AIR LIQUIDE LN2 TANK 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

-

LIQUID LEVEL GAUGE. PRESSURE GAUGE. FILL VALVE [95%]. RELIEF VALVES. TRANSPORT VALVE. VENT VALVE. CHECK VALVE. OUTBOARD SHUT OF VALVE. PUMP RETURN VALVE. INBOARD SHUT OFF VALVE. PRESSURE BUILDING VALVE. PRESSURE BUILDING COIL. VACUUM SYSTEM. FILL VALVE AT 85%. BURSTING DISC. IN-FILL NOZZLE. DISCHARGE NOZZLE. BACKFILL (REAR FILL).

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual NITROGEN TANK - SCHEMATIC 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 DISCHARGE VALVE: 9 - PUMP RETURN VALVE:

10 - INBOARD DISCHARGE 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 NOZZLE : 19 - GAS WITHDRAWL VALVE:

NITROGEN TANK - SCHEMATIC GAS WITHDRAWL

19 VENT VALVE

SAFETY VALVES @ 3 BAR

6

4

RETURN VALVE CHECK VALVE

9

7

OVERFILL VALVE

3 +14

16

BURST DISC

TANK PRESSURE

15

2 TANK LEVEL

VACUUM POINT

13

1 PRESSURE COIL

12

SAFETY VALVES @ 10 BAR

11 10 18

BACK FILL LINE AMBIENT HEAT

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17 8 OUTBOARD DISCHARGE VALVE

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual BULKER SCHEMATIC

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual NITROGEN TRANSPORT SCHEMATIC LEGEND UNIT # 2724B & 2725B V-1 V-2 V-3 V-4 V-5 V-6 V-7 V-8 V-9 V-10 V-11 V-12 V-13 V-14 V-15 V-16 V-17 V-18 V-19 V-20 V-21 PI-1 PI-2 SV-1 SV-2 SV-3 BD-1 BD-2 R-1 HC-1 HC-2 CV-1 PB-1 P-1 S-1 VV-1 TV-1 TT-1 RF-1

Main supply valve to boost pump suction Return valve from boost pump to tank Bypass valve 95% full valve Isolation valve Vapour phase valve for level gauge Liquid phase valve for level gauge Equalising valve for level gauge Liquid valve for pressure build Isolation valve for road relief Main N2 tank pressure vent valve Main discharge valve from boost pump Vent valve for pressure build Main N2 fill valve Discharge line & fill line vent valve Isolation valve for boost pump pressure indicator 85% full valve Diverter valve to burst disks Top fill valve N/A N/A Tank Pressure Indicator Boost Pump Pressure Indicator N2 Tank PSV Hose PSV Boost Pump suction line PSV Burst Disk #1 Burst Disk #2 Road relief valve Hose Connection Hose Connection Check valve Pressure Build Coil Boost Pump Screen Vacuum valve Vacuum transmitter valve Vacuum transmitter connection Lost vacuum indicator cap

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual NITROGEN UNIT - MAIN COMPONENTS

D IE S E L T A NK (F A R S ID E ) A IR R E C E IVE R

HYD R A UL IC O IL T A NK

A IR INT A K E A ND E M E R G E NC Y BARBER S HUT D O W N ASSEMBLY

E NG INE E X HA US T L IQ UID VE NT

A IR INL E T F L A M E ARRESTER

C O NT R O L P A NE L

H IGH D ISC H AR G E PR ESSU R E

C H AR T R EC O R D ER

A IR L INE C O NNE C T IO N

R A D IA T O R EMOS C O NNE C T IO NS

CToe m c hmn iosl s o igoyn i

E NG INE BLOCK

T R IP L E X P UM P

R .P.M T R IPL EX PU M P SPEED

VA P O R IS ING POT C O O L A NT T A NK

M A IN HE A T E X C HA NG E R

W ATER BREAK

F O R K L IF T SLOTS

FLAMETRAP STORE

M A NIF O L D COOLER A ND FLAME TRAP

COOLDOW N VA L VE

BARBER R E S E T L E VE R

B O O S T P UM P IS O L A T IO N VA L VE

O IL HE A T E X C HA NG E R

T E M P E R ING VA L VE

L IQ UID IN

BOOST P UM P

D YNO VA L VE

NITROGEN UNIT - TYPICAL CONTROL PANEL SAFETY SHUT-DOWNS

HIGH EXH AU ST TEMPERATURE

HIGH WATER TEM PERATURE

LOSS OF COOLANT

LOW OIL PRESSU RE

NITROGEN DISCHARGE TEM PERATURE HIGH DISCHARGE PRESSURE

CHART RECORDER

NITROGEN DISCHARGE VALVE AND "OPEN / CLOSE" BUTTON

NITROGEN DISCHARGE

BOOST PU MP PRESSURE PU MP SAVER

COOLANT CIRC UIT TEM PERATURE

LUBE OIL

OIL PRESSU RE

PRESSURE R.P.M

TEMPER ATURE

LIQUID NITROGEN CHARGE PUMP

HYDRAULIC PRESSURE AND CONTROL VALVE

WATER TEMPERATURE TRIPLEX PUM P SPEED

M AIN HYDRAULIC PRESSURE

PUMP SPEED CONTROL

NITROGEN PUMP CONTROLS

CHARGE PRESSURE

AIR PRESSU RE PERMISSIVE "START"

EM ERGENCY AND ENGINE KILL

ENGINE SPEED ENGINE "START"

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THROTTLE VALVE

ENGINE CONTROLS

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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

.

TEMPERING VALVE

.

. .

ENGINE EXHAUST PIPE

. RAPID "COOL DOWN" VALVE

BOOST PUMP BY PASS VALVE

COLD END RECIRCULATION VALVE

.

SUCTION STRAINER

VENT VALVE SUCTION STRAINER HOT WATER "IN"

10 BAR LN2 RELIEF VALVES

COOLER WATER "OUT"

10K RELIEF VALVE DISCHARGE VALVE

.

LN2 BLEED VALVE

. .

. .

.

.

.

.

.

.

.

. .

. VAPOURISING POT

LN2 LOW PRESSURE INLET VALVES

.

BOOST PUMP BYPASS

LN2 LOW PRESSURE OUTLET VALVES

GAS BLEED VALVE

HIGH PRESSURE GAS DISCHARGE

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

.

.

.

. ENGINE EXHAUST PIPE

. TEMPERING VALVE

RAPID "COOL DOWN" VALVE

"CLOSED"

"OPEN"

BOOST PUMP BY PASS VALVE

"CLOSED" COLD END RECIRCULATION VALVE

"OPEN"

. VENT VALVE

"OPEN"

DISCHARGE VALVE

"CLOSED"

. .

. .

"OPEN"

. LN2 LOW PRESSURE INLET VALVES

.

.

.

.

.

"OPEN"

.

.

.

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.

LN2 LOW PRESSURE OUTLET VALVES

A BJ SERVICES COMPANY Page 181 of 224

.

. GAS BLEED VALVE

"OPEN"

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 "

.

. .

.

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.

.

. 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

. T E M P E R IN G VALVE

COLD END R E C IR C U L A T IO N VALVE

" V A R IA B L E "

.

"O P E N / CLO SE"

HOT W ATER " IN "

COOLER W ATER "O U T"

D IS C H A R G E VALVE

"O P E N "

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V A P O U R IS IN G P O T

. GAS BLEED VALVE

"C L O S E D "

A BJ SERVICES COMPANY Page 182 of 224

H IG H P R E S S U R E G A S D IS C H A R G E

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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

. R A P ID " C O O L D O W N " VALVE

"O P E N "

"O P E N "

"O P E N "

.

T E M P E R IN G VALVE

COLD END R E C IR C U L A T IO N VALVE

VENT VALVE

"O P E N "

D IS C H A R G E VALVE

"C LO S E D "

. .

.

. .

.

.

LN2 LOW PRESSURE IN L E T V A L V E S

"O P E N "

.

.

.

.

. .

. .

.

. GAS BLEED VALVE

LN2 LOW PRESSURE 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

. . .

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.

VAPOURISING POT LN2 LOW PRESSURE INLET VALVES

LN2 LOW PRESSURE OUTLET VALVES

NOTE: ALL VALVES MUST BE SHUT AND PROTECTIVE CAPS FITTED

A BJ SERVICES COMPANY Page 183 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual N2 PUMPER SCHEMATIC

A BJ SERVICES COMPANY Page 184 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

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

A BJ SERVICES COMPANY Page 185 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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

A BJ SERVICES COMPANY Page 186 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 1. GAS LIFT DESIGN (Continued) TABLE WHP Multiplier using Tbg Depth_______Ft T.V.D. = ________(11) Wellhead Press. Multiplier ( Depth______Ft. T.V.D. Max Tubing Head Press.

X

H.G______psi/Ft

)

/______(11)

=

_______psi

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.

A BJ SERVICES COMPANY Page 187 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

TO N2 CONVERTER

TEST STRING

9 5/8" CASING

4 1/2", 19.2 LBS/FT TUBING

KILL FLUID 9.2 LB/GAL BRINE

KILL FLUID

KILL FLUID 9.2 LB/GAL BRINE

D.S.T. STRING PRIOR TO N2 CUSHION

CIRC. VALVE CIRCULATING TVD:- 9000 VALVE CLOSED MD:- 1O000 TEST VALVE RETRIEVABLE

CLOSED

PACKER

T.C.P. GUNS

4900 PSI

MD:- 11500

KILL FLUID

FORMATION KILL FLUID

FORMATION TVD:- 10500

TEMP. GRAD:1.6 Deg. F/100ft

A BJ SERVICES COMPANY Page 188 of 224

This illustration shows a well ready to be perforated and the formation contents flowed back to surface for assessment in productivity. At this stage the well is filled with kill fluid which exerts a hydrostatic pressure of 5023 psi. This situation is called "overbalance", i.e. the fluid column pressure overbalances the formation pressure. If the well was to be perforated in this situation, perforation debris could enter the newly made perforations and block them. Additionally, because of the overbalance, the well would not flow. One solution is to circulate the well with a lighter fluid so the well fluid hydrostatic pressure "underbalances" the formation.

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

PRESSURIZED N2 GAS

KILL FLUID 9.2 LB/GAL BRINE

KILL FLUID

KILL FLUID

KILL FLUID 9.2 LB/GAL BRINE

This illustration shows the initial purge of the TO N2 CONVERTER fluid contents, by TEST STRING nitrogen, into the 4 1/2"; 19.2 LBS/FT TUBING annulus. The fluid is displaced down the test COMMENCEMENT string, through the circulating valve, OF ANNULUS installed in the test VOLUME D.S.T. STRING string and out into the MONITERED IN PITS annulus. The N2 CUSHION 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 from the tubing. CIRC. VALVE VALVE OPEN TVD:- 9000 Displacement should MD:- 10000 stop 500 feet from the TEST VALVE circulation valve to CLOSED prevent the over displacement of nitrogen into the annulus and also to give a water cushion FORMATION FORMATION PRESSURE between the nitrogen TVD:- 10500 4900 PSI and the formation. MD:- 11500 TEMP. GRAD:500 feet may sound a 1.6 Deg. F/100ft 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. A BJ SERVICES COMPANY Page 189 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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:

A BJ SERVICES COMPANY Page 190 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual "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.

A BJ SERVICES COMPANY Page 191 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 SCF/BBL AT 3525 PSI:- (1095 + 1107) / 2 = 1101 scf/bbl SCF/BBL AT 3537 PSI:- (1107 + 1101) / 2 = 1104 scf/bbl SCF/BBL AT 3531 PSI:- (1104 + 1101) / 2 = 1103 scf/bbl

A BJ SERVICES COMPANY Page 192 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual Using 140° F: SCF/BBL AT 3550 PSI:- (1054 + 1079) / 2 = 1067 scf/bbl SCF/BBL AT 3525 PSI:- (1054 + 1067) / 2 = 1060 scf/bbl SCF/BBL AT 3537 PSI:- (1067 + 1060) / 2 = 1063 scf/bbl SCF/BBL AT 3531 PSI:- (1063 + 1060) / 2 = 1062 scf/bbl 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.

A BJ SERVICES COMPANY Page 193 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

A BJ SERVICES COMPANY Page 194 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 The N2 Vol. given in this result is the calculated pumped volume . Allow at least 25% extra for Losses.

A BJ SERVICES COMPANY Page 195 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 N2 Hydrostatic

-(BHIP_____psi/

(4)____WHPM))

X(1-(9)____FF)

=____(11)

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.

A BJ SERVICES COMPANY Page 196 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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)

A BJ SERVICES COMPANY Page 197 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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

A BJ SERVICES COMPANY Page 198 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

A BJ SERVICES COMPANY Page 199 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 [email protected].(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

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 The N2 Vol. given in this result is the calculated pumped volume . Allow at least 25% extra for Losses. 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

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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 The N2 Vol. given in this result is the calculated pumped volume . Allow at least 25% extra for Losses. 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

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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)

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NITRIFIED TREATMENT DESIGN EXAMPLE (Continued)

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)

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 4.

NITRIFIED TREATMENT DESIGN EXAMPLE (Continued)

( (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

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 [email protected].(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

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

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)

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 B = ---- ---- ---Z T Ps

Ts where Zs = 1 , ---- = 35.495 Ps (a Constant)

P Thus :- B = ----- 35.495 SCF / Cu.Ft. TZ To get Scf per Barrel we use 5.6146 Cu.Ft. per Barrel P 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.

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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 ---- = ------- ----P 144 Z R T Pw 0

dD

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. A BJ SERVICES COMPANY Page 213 of 224

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual 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

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BOC SITING OF MSV’S

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

APPENDIX 1 FLANGE RATINGS

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TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

APPENDIX 2 COLDER PRODUCTS FITTINGS INFORMATION

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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 Length of engagement (tightened by hand)

Length of effective thread

Nominal size

Actual OD

Threads per inch

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

BSPT Male Thread

Figure 1 – BSPT Male with BSPP Female

BSPT Female Thread

BSPT Male 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 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 manufacturing processes. Pipe threads were originally designed as machined thread forms. With the use of thermoplastics and plastic injection molding in the manufacture of 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 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.

Figure 2 – BSPT Male with BSPT Female

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 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 and root control is still missing, but with thread sealant, a pressure tight joint would be easier to accomplish.

Female NPTF

Male NPTF

Figure 3 – NPTF, Hand Tight

A number of variations of the NPT thread have been introduced to overcome the problem of 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 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

Male NPTF Displaced Material

Figure 4 – NPTF, Fully Engaged (hand tight plus 1 turn)

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 these threads are considered Dryseal, a Teflon tape or liquid is still recommended to aid in the 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 combination of a parallel and tapered thread is not regarded as ideal but is widely used. Highquality plastic quick disconnect couplings typically use NPT threads.

4

Female BSPP

Male NPT

Figure 5 – Male NPT in a Female BSPP with Different Pitch

Another tapered thread is the British Standard 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 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 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 pitch difference, the NPT tightens with only a few turns.

Female BSPT

Male NPT

Binding Threads

Figure 6 shows an NPT tightened into a BSPT. The BSPT being wider at the opening will allow the NPT thread to engage further, but pitch difference eventually causes a binding of the threads. Pitch and thread angle differences will 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.

Figure 6 – Male NPT in a Female BSPT with Different Pitch

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 effectively together if an appropriate thread sealant is incorporated. Many issues arise when plastic quick disconnect couplings, with their corresponding injectionmolded 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

Female BSPT

Male NPT

Gaps Causing Spiral Leakage

Figure 7 – Male NPT in a female BSPT of the Same Pitch

Chemical attack can occur when improper thread 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. 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. Injectionmolded 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 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) Sizes:

BSPT (British Standard Pipe Taper) 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 [email protected].

6

TRAINING DEPARTMENT PRO 101 Process Nitrogen Operators Manual

APPENDIX 3 N2 PUMPER EDMONTON

A BJ SERVICES COMPANY 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 pump nitrogen for the use in stimulation treatments (acid & fracturing), completions, clean outs, pressure testing, and other well servicing operations. The high-efficiency nitrogen pump is powered by the chassis engine, with controls located for maximum operator visibility of all equipment during operations. The Unit illustrated here incorporates the heater, pump, and a 9.5 m3 nitrogen tank mounted on a single chassis.

Specifications: Nitrogen Pump Flow Rates: 955 m3/min to 5000 psi / with 2 7/8in Cold Ends 154 m3/min to 10000 psi / with 2 in Cold Ends 9.5 m3 tank with 5000 m3 pumpable

Dimensions: Height: 12 ft. 6 in. Width: 8 ft. Length: 36 ft. Gross Vehicle Weight: 22,400 kg.

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 Recirculation 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 Switch On.

B. NO POWER TO IGNITOR or ELECTRODES

C. WATLOW PYROMETER Indicator not working

D. FUEL PRESSURE No fuel pressure or low fuel pressure

E.. START UP Heater will not light with LOW ON button activated.

F. INTERMEDIATE BURNER BUTTON Fails to Ignite

G. HIGH BURNER BUTTON Fails to Ignite

IF BURNER FAILS TO LIGHT

Power cable not plugged in. Battery leads not connected. Low battery voltage.

Faulty switch. Bad permatune. Faulty ground wire. Faulty spark electrode.

Thermocoupler broken. No power to Walton.

No hydraulic pressure to fan and fuel pump motor. Pump not primed. No fuel. Clogged fuel filter.

Faulty fuel solenoid. Clogged fuel orifice. No power to button.

No power to button. Faulty intermediate fuel solenoid. Faulty power relay. Clogged fuel orifice. No power to button. Faulty intermediate fuel solenoid. Faulty power relay. Clogged fuel orifice SHUT OFF POWER AND SHUT OFF FUEL PUMP – 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 Pumping Main pump

Bad suction valve on cold end.

Minimum Boost Prime Pressure Model 600 Model 540 A & B

60 – 70 psi 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 Cold End

Worn packing.

Cross Head Oil Seal Leaking

Worn seal.

Low Lube Pressure Model 600 below 60 psi Model 540 A & B below 100 psi

Lube oil tank low. Lube pump failure. Lube pump not engaged.

Pump Rate Meter Erratic or Not Working

Broken pump gear. 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 Liquid 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

Gallons N2 6 17 32 49 69 91 115 141 168 197 227 259 292 326 361 397 434 472 511 550 591 632 673 715 758 801 845 889 933 978 1023 1068 1113

m3 Gas 15.80 44.83 84.38 129.18 181.94 239.93 303.19 371.77 442.93 519.39 598.50 682.86 769.88 859.53 951.81 1046.73 1144.25 1244.47 1347.29 1450.13 1558.22 1666.33 1774.42 1885.16 1998.52 2111.90 2227.91 2343.93 2459.94 2578.60 2697.24 2815.86 2934.50

Inches of Liquid 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65

Gallons N2 1158 1204 1249 1295 1340 1386 1431 1476 1521 1565 1610 1654 1679 1741 1783 1825 1867 1908 1948 1988 2027 2065 2102 2138 2173 2207 2240 2271 2302 2331 2358 2384

m3 Gas 3053.15 3174.43 3293.08 3414.36 3533.00 3654.29 3772.94 3891.58 4010.23 4126.25 4244.92 4360.91 4474.29 4590.30 4701.02 4811.79 4922.49 5030.60 5136.05 5241.53 5344.35 5444.54 5542.08 5637.01 5729.29 5818.94 5905.93 5987.65 6069.43 6145.86 6217.05 6286.60

Calibration Chart For 15.9 m3 Nitrogen Mini Inches of Liquid 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

m3 Gas 42.41 110.60 197.51 302.85 421.35 550.40 690.00 840.08 998.08 1166.62 1340.44 1519.51 1705.98 1901.36 2098.87 2301.65 2509.69 2723.00 2936.32 3157.53 3378.74 3605.22 3831.69 4063.44 4295.18 4526.93 4761.31 4998.32 5232.69 5469.71

Inches of Liquid 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

m3 Gas 5706.72 5943.73 6180.75 6415.12 6649.50 6881.25 7110.36 7339.47 7565.95 7789.80 8011.06 8226.95 8440.26 8650.94 8916.92 9056.29 9251.11 9440.84 9622.63 9801.59 9970.08 10130.92 10286.09 10428.53 10562.75 10686.49 10797.21 10891.79 10968.25 11020.92

Pump Chart For 2 7/8" Cold Ends 1st Gear Pumping RPM RATE m3 1000 42.48 1200 50.97 1400 59.46 1600 69.97 1800 76.46 2000 84.95

2nd Gear Pumping RPM RATE m3 1000 53.80 1200 65.13 1400 76.45 1600 87.78 1800 99.11 2000 110.44

3rd Gear Pumping RPM RATE m3 1000 72.21 1200 84.95 1400 101.94 1600 114.68 1800 127.43 2000 144.42

4th Gear Pumping RPM RATE m3 1000 96.28 1200 110.44 1400 131.67 1600 148.66 1800 169.10 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 PRO 101 Process Nitrogen Operators Manual

APPENDIX 4 N2 TRANSPORT EDMONTON

A BJ SERVICES COMPANY 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 pump nitrogen for the use in stimulation treatments (acid & fracturing), completions, clean outs, pressure testing, and other well servicing operations. The high- efficiency nitrogen pump is powered by an air cooled auxiliary engine, with controls located by the pump for operator visibility. The Unit illustrated here incorporates the pump, auxiliary engine and a 2725 litre nitrogen tank.

Specifications : Nitrogen Pump Flow Rates: 568 litres/min

2725 litre tank with 15,570 m3 pumpable

Dimensions: Height: 11 ft. 6 in. Width: 8 ft. Length: Trailer 42’.3” ft. Tractor Trailer 62’ ft. Gross Vehicle Weight: 17,460 kgs. Empty 43 inches on unit 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. 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 . 19

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 1632 3174 4176 6744 8772 11188 13604 16342 18081 22095 25109 28357 31606 35054 38503 42121 45739 49496 53254 57124 60995 64952 68910 72929 76949 81005 85062 89132 93202

Inches 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

m3 Gas 46.21 89.88 118.25 190.97 248.40 316.81 385.22 462.75 512.00 625.66 711.01 802.98 894.98 992.62 1090.28 1192.73 1295.18 1401.57 1507.99 0.00 1617.57 1727.19 1839.24 1951.31 2065.12 2178.95 2293.81 2408.69 2523.94 2639.19

97261 101320 105344 109368 113333 117299 121180 125062 128831 132600 136232 139865 143332 146799 150069 153340 156378 159417 162186 164955 167405 169855 171000 172900

Inches 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54

m3 Gas 2754.13 2869.06 2983.01 3096.96 3209.23 3321.54 3431.44 3541.36 3648.09 3754.81 3857.66 3960.54 4058.71 4156.89 4249.48 4342.11 4428.13 4514.19 4592.60 4671.01 4740.38 4809.76 4842.18 4895.98

Calibration Chart For 204 m3 Nitrogen Tank 1955 5400 9870 15177 21136 27654 34637 42179 50093 58380 67039 76071 85382 94972 104749 114898 125140 135754 146462 157356 168436 179702 191062 202514 214153 225978 237803 249721 261732 273743 285138 298138

Inches 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

m3 Gas 55.36 152.91 279.49 429.76 598.50 783.07 980.81 1194.38 1418.48 1653.14 1898.33 2154.09 2417.75 2689.31 2966.16 3253.55 3543.57 3844.13 4147.34 4455.83 4769.58 5088.59 5410.27 5734.56 6064.14 6398.99 6733.83 7071.31 7411.43 7751.54 8074.21 8442.33

310336 322533 334824 347114 359405 371602 383893 396090 408287 420392 432496 444507 456425 468250 479982 491621 503166 514526 525792 536872 547766 558474 568995 579330 589386 599256 608846 618157 627096 635755 644135 652049

Inches 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64

m3 Gas 8787.74 9133.12 9481.16 9829.18 10177.22 10522.60 10870.64 11216.02 11561.40 11904.18 12246.92 12587.04 12924.52 13259.37 13591.58 13921.16 14248.08 14569.76 14888.77 15202.52 15511.01 15814.22 16112.15 16404.80 16689.55 16969.04 17240.60 17504.26 17757.38 18002.58 18239.87 18463.97

Calibration Chart For 15.9 m3 Nitrogen Mini Inches of Liquid 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

m3 Gas 42.41 110.60 197.51 302.85 421.35 550.40 690.00 840.08 998.08 1166.62 1340.44 1519.51 1705.98 1901.36 2098.87 2301.65 2509.69 2723.00 2936.32 3157.53 3378.74 3605.22 3831.69 4063.44 4295.18 4526.93 4761.31 4998.32 5232.69 5469.71

Inches of Liquid 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

m3 Gas 5706.72 5943.73 6180.75 6415.12 6649.50 6881.25 7110.36 7339.47 7565.95 7789.80 8011.06 8226.95 8440.26 8650.94 8916.92 9056.29 9251.11 9440.84 9622.63 9801.59 9970.08 10130.92 10286.09 10428.53 10562.75 10686.49 10797.21 10891.79 10968.25 11020.92