Weatherford 180K Nitrogen Trailer Operation & Maintenance Manual

Total Equipment And Service Operation & Maintenance Manual Table Of Contents
4801 Glen Rose Hwy
Granbury, Texas 76048
Phone: [phone]
Fax: [phone]
November 2007 Weatherford 180K Russian Nitrogen Trailer i
Section Overview
Section 1: Introduction
Section 2: Safety
Section 3: Specifications and Drawings
Section 4: Nitrogen Basics and Fluids (MSDS)
Section 5: Operating the Unit
Section 6: Parts Lists and Schematics
Section 7: Manuals
Section 8: Testing

Total Equipment And Service Operation & Maintenance Manual Table Of Contents
4801 Glen Rose Hwy
Granbury, Texas 76048
Phone: [phone]
Fax: [phone]
November 2007 Weatherford 180K Russian Nitrogen Trailer ii
TABLE OF CONTENTS
SECTION 1: INTRODUCTION...........................................................................1-1
1.1 General Use .........................................................................................................................1-1
1.2 Warranties of Quality and Title.............................................................................................1-2
1.3 Basic Equipment Report.......................................................................................................1-5
1.4 Nitrogen Tank Dossier..........................................................................................................1-5
SECTION 2: SAFETY .........................................................................................2-1
2.1 General Warning Information...............................................................................................2-1
2.2 Safety and Health.................................................................................................................2-1
2.2.1 Qualified Personal............................................................................................................2-1
2.2.2 Personal Protective Equipment (PPE).............................................................................2-2
2.2.3 Safety Practices...............................................................................................................2-2
2.2.4 Unauthorized Personnel ..................................................................................................2-2
2.2.5 High Pressures.................................................................................................................2-2
2.2.6 Unauthorized Maintenance..............................................................................................2-2
2.2.7 Lifting................................................................................................................................2-2
2.2.8 Use of Solvents or Paints.................................................................................................2-2
2.2.9 Compressed Air Usage....................................................................................................2-2
2.2.10 Moving Parts....................................................................................................................2-3
2.2.11 Visibility............................................................................................................................2-3
2.2.12 Pre-Start...........................................................................................................................2-3
2.2.13 Work Areas ......................................................................................................................2-3
2.2.14 Transporting the Unit........................................................................................................2-3
2.3 Lubricants Safety and Health...............................................................................................2-3
2.3.1 Fire Hazards.....................................................................................................................2-3
2.3.2 Health Hazards ................................................................................................................2-4
2.4 Nitrogen Safety.....................................................................................................................2-5
2.4.1 General Information .........................................................................................................2-5
2.5 Safety Bulletin.......................................................................................................................2-6
2.5.1 Safety Bulletin from CGA.................................................................................................2-6
2.5.2 Oxygen Deficient Atmospheres .......................................................................................2-7
2.5.3 Oxygen Enriched Atmospheres.......................................................................................2-7
2.5.4 Nitrogen and Argon..........................................................................................................2-8
2.6 Safety for Handling and Exposure .......................................................................................2-8
2.6.1 Characteristics of Nitrogen...............................................................................................2-8
2.6.2 Properties of Nitrogen......................................................................................................2-9
2.6.3 Qualified Personnel..........................................................................................................2-9
2.6.4 Personal Protective Equipment (PPE).............................................................................2-9
2.6.5 Safety Practices...............................................................................................................2-9
2.6.6 Unit Operation................................................................................................................2-10
2.6.7 Unauthorized Personnel ................................................................................................2-10
2.6.8 High Pressures.............................................................................................................2-110
2.6.9 Unauthorized Maintenance............................................................................................2-10
2.6.10 Lifting..............................................................................................................................2-10
2.6.11 Use of Solvents or Paints...............................................................................................2-10
2.6.12 Compressed Air Usage..................................................................................................2-10
2.6.13 Moving Parts..................................................................................................................2-10
2.6.14 Visibility..........................................................................................................................2-11
2.6.15 Pre-Start.........................................................................................................................2-11
2.6.16 Work Areas ....................................................................................................................2-11

Total Equipment And Service Operation & Maintenance Manual Table Of Contents
4801 Glen Rose Hwy
Granbury, Texas 76048
Phone: [phone]
Fax: [phone]
November 2007 Weatherford 180K Russian Nitrogen Trailer iii
2.6.17 Transporting the Unit......................................................................................................2-11
SECTION 3: SPECIFICATIONS AND DRAWINGS............................................3-1
3.1 General Unit Specifications..................................................................................................3-1
SECTION 4: NITROGEN BASICS AND FLUIDS (MSDS)..................................4-1
4.1 Nitrogen Basics ....................................................................................................................4-1
4.1.1 Nitrogen Properties..........................................................................................................4-1
4.1.2 Safety Precautions / Handling Liquid Nitrogen................................................................4-2
4.1.3 First Aid for Frostbite (Freeze Burns)...............................................................................4-2
4.1.4 Liquid Air Combustion Hazard.........................................................................................4-3
4.1.5 Oxygen Deficiency Hazard ..............................................................................................4-3
4.1.6 Cryogenic Materials and Components.............................................................................4-4
4.1.7 Noncryogenic Materials and Components.......................................................................4-4
4.1.8 Equipment Precautions....................................................................................................4-5
4.1.9 Low Temperature Limits ..................................................................................................4-5
4.1.10 Compressed Gas Hazard................................................................................................4-5
4.1.11 Pressure Buildup from Trapped Nitrogen........................................................................4-5
4.1.12 Storage and Transportation.............................................................................................4-5
4.2 Fluids....................................................................................................................................4-6
4.2.1 Material Safety Data Sheets............................................................................................4-6
SECTION 5: OPERATING THE UNIT.................................................................5-1
5.1 Nitrogen Components and Use............................................................................................5-1
5.1.1 Liquid Nitrogen Tank........................................................................................................5-1
5.1.2 High-Pressure Triplex Pump............................................................................................5-1
5.1.3 Vaporizer..........................................................................................................................5-1
5.1.4 Pumping Power Train ......................................................................................................5-1
5.1.5 Summary..........................................................................................................................5-2
5.2 Checklists.............................................................................................................................5-2
5.2.1 Pre-Trip / Post-Trip Checklist...........................................................................................5-2
5.2.2 On-Site, Pre-Job Checklist...............................................................................................5-3
5.3 Operating the Nitrogen Unit..................................................................................................5-3
5.3.1 Operating Procedure........................................................................................................5-3
5.3.2 Selecting the Correct Pumping Rate................................................................................5-5
5.3.3 Rigging Up the Discharge Manifold .................................................................................5-5
5.3.4 Blowing Down the Tank ...................................................................................................5-8
5.3.5 Conditioning the Liquid Nitrogen.......................................................................................10
5.3.6 Reducing Tank Pressure for Road Transportation........................................................5-10
5.3.7 Warming Up the Unit......................................................................................................5-10
5.3.8 Testing the Discharge Manifold for Leaks......................................................................5-10
5.3.9 Pressurizing the Tank....................................................................................................5-11
5.3.10 Procedure for Pressurizing ............................................................................................5-11
5.3.11 Cooling Down and Priming the Boost Pump..................................................................5-12
5.3.12 Cooling Down the Cold Ends.........................................................................................5-13
5.3.13 Priming the Cold Ends...................................................................................................5-13
5.3.14 Bringing the Unit Online.................................................................................................5-14
5.3.15 Monitoring the Controls..................................................................................................5-15
5.3.16 Operating the Vaporizer.................................................. 5-Error! Bookmark not defined.
5.3.17 Vaporizer Shutdown........................................................ 5-Error! Bookmark not defined.
5.3.18 Vaporizer Fan Speed Adjustment................................... 5-Error! Bookmark not defined.
5.3.19 Changing Rates During the Job.....................................................................................5-16
5.3.20 Filling the Tank While Pumping .....................................................................................5-19
5.3.21 Shutting Down the Unit..................................................................................................5-19

Total Equipment And Service Operation & Maintenance Manual Table Of Contents
4801 Glen Rose Hwy
Granbury, Texas 76048
Phone: [phone]
Fax: [phone]
November 2007 Weatherford 180K Russian Nitrogen Trailer iv
5.3.22 Transferring Liquid Nitrogen Into or Out Of the Tank ....................................................5-20
SECTION 6: PARTS LISTS AND SCHEMATICS...............................................6-1
SECTION 7: MANUALS......................................................................................7-1
SECTION 8: TESTING........................................................................................8-1
TABLE OF TABLES
A - Table 3.1: General Specifications ........................................................................................................3-1
B - Table 4.1: Physical Properties of Nitrogen...........................................................................................4-1
C - Table 4.2: Symptoms of Oxygen Deficiency........................................................................................4-3
D - Table 4.3: Fluids...................................................................................................................................4-6
E - Table 5.1: Instrument Values During Normal Operation....................................................................5-15
F - Table 5.2: Fan Speeds and Fuel Flows............................................... 5-Error! Bookmark not defined.
G - Table 5.3: Suggested Pumping Rate Ranges ...................................................................................5-16
H - Table 5.4: Pump Rate Chart ..............................................................................................................5-17
I - Table 5.5: Tank Chart..........................................................................................................................5-22
TABLE OF FIGURES
A - Figure 3.1: Driver's and Passenger's Side Views ................................................................................3-2
B - Figure 5.1: Nitrogen Control Panel.......................................................................................................5-4
C - Figure 5.2: Nitrogen Exterior Gauge Panel..........................................................................................5-5
D - Figure 5.3: Rig-Up Configuration for Single Units................................................................................5-6
E - Figure 5.4: Rig-Up Configuration for Multiple Units..............................................................................5-6
F - Figure 5.5: High Pressure Nitrogen..................................................... 5-Error! Bookmark not defined.
G - Figure 5.6: Low Pressure Nitrogen......................................................................................................5-9
H - Figure 5.5: Simplified Schematic of Vaporizer.................................... 5-Error! Bookmark not defined.
I - Figure 5.6: Combustion Airflow............................................................ 5-Error! Bookmark not defined.
J - Figure 5.7: Quench Airflow .................................................................. 5-Error! Bookmark not defined.

Total Equipment And Service Operation & Maintenance Manual Section 1
4801 Glen Rose Hwy Introduction
Granbury, Texas 76048
Phone: [phone]
Fax: [phone]
November 2007 Weatherford Russian 180K Nitrogen Trailer 1 -1
SECTION 1: INTRODUCTION
1.1 General Use
Total Equipment And Service's equipment was engineered for simple operation and maintenance. This
equipment manual provides the operator with the information necessary to learn the fundamentals of
successful operation. This manual is not a textbook on mechanics, electronics, or hydraulics. Study this
manual carefully before making any attempt to operate this equipment. Pay special attention to the
Warning outlined in the safety summary. During operation or maintenance of this equipment, personnel
safety should always be of utmost importance.
This equipment was designed and all components were specified to provide maximum performance.
Maintenance procedures outlined in this manual should be considered as minimum requirements to
maintain satisfactory performance. Maintenance schedules should be followed as closely as possible.
In the event of equipment failure or decreased performance, maintenance personnel will find valuable
troubleshooting, circuit analysis and component information in this manual.
It is impossible to include all situations that may occur to cause substandard equipment performance or
failure. The abilities of operators or maintenance personnel to understand and use the system schematics
are vital when troubleshooting this equipment. Before operating, adjusting, or replacing any components,
be certain that ramifications and consequences of those actions are clearly understood. Ensure that
appropriate precautions are taken.
If problems cannot be readily resolved, it is strongly recommended that you contact a Total Equipment
And Service Service Technician for assistance. A Service Technician is on call 24 hours a day. Total
Equipment And Service stands behind all equipment and is willing and able to provide replacement parts
and field service on request.
TOTAL EQUIPMENT AND SERVICE
4801 Glen Rose Highway
Granbury, TX 76048
Phone: [phone]
Fax: [phone]
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