5) Nitrogen Pump Equipment

Coiled Tubing Handbook ndb ook Nitrogen Pumping Equipment — Nitrogen Pumps and Vaporizer Systems

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This document contains proprietary and confidential information which belongs to National Oilwell Varco; it is loaned for limited purposes only and remains the property of National Oilwell Varco. Reproduction, in whole or in part; or use of this design or distribution of this information to others is not permitted without the express written consent of National Oilwell Varco. This document is to be returned to National Oilwell Varco upon request and in any event upon completion of the use for which it was loaned.  National Oilwell Varco

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TABLE OF CONTENTS 1 OVERVIEW OVERVIEW AND FEATURES ............................... ........................................................ ................................................. .................................. .......... 6 1.1 Heat Recovery Design ............................. ...................................................... ................................................. ...................................... .............. 6 1.2 Complete Unit Line .......................... .................................................. ................................................. ............................................... ...................... 6 1.3 NP 1600 Quintaplex High Pressure P ressure Nitrogen Pump ............................................... ............................................... 6 1.5 NP 1000 Quintaplex High Pressure P ressure Nitrogen Pump ............................................... ............................................... 7 1.6 NP 400 Triplex High Pressure Nitrogen Pump ....................................................... ....................................................... 9 1.7 NP 200 Triplex High Pressure Nitrogen Pump ..................................................... ..................................................... 11 1.8 Skid Mounted Units.............................................. ....................................................................... ................................................. ........................ 12 1.8.1 180,000 scfh – Nitrogen Pumping Unit Sound Proofed– ZII DNV 2.7-3 .... 12 1.8.2 180,000 scfh Nitrogen Pumping Unit (Open Skid) Zone II / DNV .............. .............. 15 1.8.3 90,000 - 180,000 1 80,000 - 270,000 scfh Skid Mounted Unit – ZII DNV 2.7-3 ........ 18 1.8.4 The New Standard................................................. ......................................................................... .................................... ............ 19 1.9 Merlin – Nitrogen Vaporizer Automation System .......................................... .................................................. ........ 19 1.10 180,000 scfh Trailer mounted nitrogen n itrogen pump with Merlin Control System ............ 20 1.11 180,000 scfh Nitrogen Pump and Vaporizer Systems .......................................... .......................................... 21 1.12 Automated Pump, Tank and Data Acquisition Systems........................................ ........................................ 21 1.13 Nitrogen/Fluid Combination pumping unit ................................................. ............................................................. ............ 22 1.13.1 840,000 scfh Chassis Mounted Unit ................................................ ........................................................ ........ 23 1.13.2 Down-to-Earth Engineering ................................................................. ..................................................................... .... 24 1.13.3 Latest Technology ................................................................... ................................................................................... ................ 24 1.13.4 180,000 SCFH; 10,000 PSI working pressure ………………………… …………………………….27 ….27

1.14 1.15 1.16 1.17 1.18

1.13.5 Performance and Precision ..................................................... ..................................................................... ................ 25 1.13.6 Basic Design....................... Design............................................... ................................................. ............................................. .................... 25 1.13.7 1,000,000 scfh Trailer Mounted Nitrogen Unit ................................. ......................................... ........ 26 Boost Pump General Features ..................................................... ............................................................................. ........................ 26 Cryogenic Components – Cold Ends ................................................ .................................................................... .................... 27 Nitrogen Pumping P umping Unit Service Department Depa rtment ................................................. ......................................................... ........ 28 Direct Fired Nitrogen Vaporizer .................................................... ............................................................................ ........................ 29 1.17.1 The Nitrogen pumping unit service department ....................................... ....................................... 31 Liquid Nitrogen Storage Tanks T anks ......................................................... ............................................................................. .................... 33 1.18.1 Typical Offshore and Land La nd Based ............................................... ........................................................... ............ 33 1.18.2 Typical 2,000 Gallon Offshore Tank .................................... ........................................................ .................... 33 1.18.3 Offshore Tank with general piping and connections arrangement ........... 33 1.18.4 General Features................................................. ......................................................................... .................................... ............ 34 1.18.5 Typical 4,000 Gallon Ga llon Portable/Offshore Tank .......................................... .......................................... 34 1.18.6 Typical Hydraulic Schematic....................... Schematic................................................ ............................................. .................... 35

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Vaporization Process ............................................................................................ 36 1.19.1 Simple View of the Coolant Flow Path..................................................... 37 1.19.2 Water Pump (Coolant Pump)................................................................... 37 1.19.3 Vaporizer ................................................................................................. 37 1.19.4 Heat Exchangers ..................................................................................... 38 1.19.5 Water Plumbing Installation ..................................................................... 39 1.19.6 Typical Coolant Schematic ...................................................................... 40 1.19.7 Engine Heat Exchanger ........................................................................... 41 1.19.8 Exhaust Heat Recovery ........................................................................... 41 1.19.9 Power Control Valve and Back Pressure Valve ....................................... 41 1.19.10 Water Brake........................................................................................... 42 1.19.11 Typical Hydraulic Schematic.................................................................. 43 1.20 Nitrogen Tanks ..................................................................................................... 44 1.20.1 Hydra Rig® Nitrogen Tank ....................................................................... 44 1.20.2 Acceptable Vacuum Levels ..................................................................... 45 1.20.3 Pressure Ratings ..................................................................................... 45 1.20.4 Filling the Tank ........................................................................................ 45 1.20.5 Nitrogen Tank .......................................................................................... 46 1.20.6 Saturated LN 2. ......................................................................................... 47 1.20.7 Inside a Nitrogen Tank ............................................................................ 48 1.21 Troubleshooting .................................................................................................... 48 1.22 Properties and Uses ............................................................................................. 52 NITROGEN ..................................................................................................................... 53 2.1 Calculations .......................................................................................................... 53 2.1.1 Example 1 E .............................................................................................. 53 2.1.2 Example 1 M ............................................................................................. 54 2.1.3 Example 2 E .............................................................................................. 54 2.1.4 Example 2 M ............................................................................................. 55 2.2 Nomenclature ....................................................................................................... 56 2.3 Nitrogen Compressibility Factor ............................................................................ 57 2.3.1 Nitrogen Compressibility Factor (English) ................................................. 57 2.3.2 Nitrogen Compressibility Factor (Metric) ................................................... 57 2.4 Volume Factor - Low Pressure ............................................................................. 58 2.4.1 Volume Factor - Low Pressure (English) ................................................... 58 2.4.2 Volume Factor - Low Pressure (Metric) ..................................................... 58 2.4.3 Volume Factor - Medium Pressure ............................................................ 59 2.4.4 Volume Factor - Medium Pressure (English) ............................................. 59 www.nov.com


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2.4.5 Volume Factor - Medium Pressure (Metric) ............................................... 59 Volume Factor - High Pressure............................................................................. 60 2.5.1 Volume Factor - High Pressure (English) .................................................. 60 2.5.2 Volume Factor - High Pressure (Metric) .................................................... 60 Volume Factor - High Temperature ...................................................................... 61 2.6.1 Volume Factor - High Temperature (English) ............................................ 61 2.6.2 Volume Factor - High Temperature (Metric) .............................................. 61 Pressure vs. Depth for Well Full of Nitrogen ......................................................... 62 2.7.1 Pressure vs. Depth for Well Full of Nitrogen (English)............................... 62 2.7.2 Pressure vs. Depth for Well Full of Nitrogen (Metric)................................. 62

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OVERVIEW AND FEATURES

1.1 Heat Recovery Design Our patented heat recovery nitrogen pump and vaporizer system is an example of the engineering excellence that has placed us at the forefront of nitrogen pumping technology. Unused engine horsepower and waste system heat are converted to usable heat through the use of a dynamometer (water brake). Utilization of the dynamometer eliminates the fired vaporizer and hydraulic engine loading systems of conventional units, reducing fuel costs, maintenance and down time. The result is a safe, dependable unit capable of operating under the most demanding oilfield conditions. 1.2 Complete Unit Lin e Units are available ranging from flow rates of 60,000 SCFH to 540,000 SCFH in the patented heat recovery design. Truck and trailer mounted for land operation, or skid mounted for combination land and offshore use. All units are available with full certification where necessary, including DNV and BP200 certification, for the demanding conditions required of equipment operating in the North Sea.

1.3 NP 1600 Quintapl ex High Pressure Nitrogen Pump STANDARD UNIT OVERVIEW The NOV® Hydra Rig® NP 1600 satisfies the market requirement for high pressure pumping rates up to 1,828,000 scfh. The unit is specifically designed to deliver high flow rates at high pressure while providing exceptional low flow rate turndown. The pump utilizes low friction roller bearings and a pressure feed lubrication system for positive lubrication, insuring increased pump life over conventional pumps. Standard Weights and Dimension s Model NP 1600 Weight (lbs/kg) 5,000 / 2268 Length (in/cm) 70 / 178 Width (in/cm) 40.5 / 103 Height (in/cm) 39 / 99 Maximum RPM 900Stroke (in/cm)

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2.25 / 5.72


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NP 1600 Pump Rate and Pressur e Capability Operation Characteristics at 90% Volumetric Efficiency and 900 RPM Cold End Diameter in/mm

2.000 / 50.80

2.500 / 63.50

2.875 / 73.025

3.000 / 76.20

3.250 / 82.55

Maximum Flow, GPM / l/min

124 / 469

193 / 733

255 / 969

279 / 1055

327 / 1238

Maximum Flow, scfh / m³/hour

692,000 / 19,600

1,082,000 / 30,600

1,431,000 / 40,500

1,558,000 / 44,100

1,828,000 / 51,700

Maximum Pressure, psi/MPA

15,000 / 103

15,000 / 103

11,200 / 77

10,000 / 69

8,800 / 61

ADVANTAGES: 1.4 NP 1000 Quintapl ex High Pressure Nitrogen Pump NP 1000 Trip lex High Pressu re Nitro gen Pump STANDARD UNIT OVERVIEW The NOV® Hydra Rig® NP 1000 satisfies the market requirement for high pressure pumping rates up to 1,097,000 scfh. The unit is specifically designed to deliver high flow rates at high pressure while providing exceptional low flow rate turndown. The pump utilizes low friction roller bearings and a pressure feed lubrication system for positive lubrication, insuring increased pump life over conventional pumps. Specifi cations and Dimensions Model NP 1000 Weight with Cold Ends and Lube Oil 2,550 / 1156.66 Length (in/cm) 37.25 / 94.62 Width (in/cm) 40.5 / 102.87 Height (in/cm) 21.94 / 55.73 Maximum RPM 900 Stroke (in/cm) 2.25 / 5.72

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NP 1000 Pump Rate and Pressur e Capability Operation Characteristics at 90% Volumetric Efficiency and 900 RPM 3.250 / 82.55

Cold End Diameter, in/mm

2.000 / 50.80

2.500 / 63.50

2.875 / 73.025

3.000 / 76.20

Maximum Flow, GPM / l/min

74 / 281

116 / 440

153 / 581

167 / 633

196 / 743

Maximum Flow, scfh / m³/hour

415,200 / 11,700

649,000 / 18,400

858,000 / 24,300

935,000 / 26,500

1,097,000 / 31,000

Maximum Pressure, psi / MPA

15,000 / 103

15,000 / 103

11,200 / 77

10,000 / 69

8,800 / 61

ADVANTAGES: This NOV Hydra Rig pump is not merely another version of the same design that has been around for years, but rather the result of necessary product advancements. Durability This new design approach starts by utilizing low friction roller bearings rather than journal bearings. This greatly enhances durability particularly at low speeds where other pumps using journal bearings are most vulnerable. This design also operates at a much cooler temperature. This means less lube oil system requirements, which saves weight without sacrificing unit durability. Simplif ied Design The unit is internally balanced so that an externally mounted counter balance does not compromise the reliability of the pump. This enhancement also provides a much smoother pump by balancing each cylinder rather than compensating from the end of the shaft. Enhanced Performance

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Maximum rod load is increased to 73,500 lbs. (versus 58,000 lbs. for competitive offerings). This allows for nearly 27% increased working pressure without changing to smaller cold ends. Compatibility The pump will accept existing cold ends and increase their capabilities. 1.5

NP 400 Tripl ex High Pressure Nitrogen Pump STANDARD UNIT OVERVIEW The NOV® Hydra Rig® NP 400 satisfies the market requirement for high pressure pumping rates up to 467,000 scfh. The unit is specifically designed to deliver high flow rates at high pressure, while providing exceptional low flow rate turndown. The pump utilizes low friction roller bearings and a pressure feed lubrication system for positive lubrication, insuring increased pump life over conventional pumps. Specifi cations and Dimensions Model NP 400 Weight without Cold Ends and Gear Box (lbs./kg) Length (in/cm) Width (in/cm) Height (in/cm) Maximum RPM Stroke (in/cm)

1,750 / 795 35.0 / 88.9 39.0 / 99.1 21.0 / 53.3 900 2.00 / 5.08

NP 400 Pump Rate and Pressu re Capabilit y Operation Characteristics at 90% Volumetric Efficiency and 900 R PM

Cold End Diameter (in / cm) Maximum Flow, GPM / l/min Maximum Flow, SCFH / m³/hr.

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1.875 / 47.62

2.000 / 50.80

2.250 / 57.15

64 / 244 324,000 / 9,200

73 / 278 369,000 / 10,400

93 / 352 467,000 / 13,200


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NP 400 Pump Rate and Pressu re Capabil ity Operation Characteristics at 90% Volumetric Efficiency and 900 RPM Cold End Diameter (in / cm) 1.875 / 47.62 2.000 / 50.80 2.250 / 57.15 Maximum Flow, GPM / l/min 64 / 244 73 / 278 93 / 352 Maximum Flow, SCFH / 324,000 / 369,000 / 10,400 467,000 / m³/hr. 9,200 13,200 Maximum Pressure, PSI / 15,000 / 103 13,000 / 89.6 10,000 / 68.9 MPA

ADVANTAGES: NOV Hydra Rig’s NP 400 pump is a medium rate version of the NP 1000 Hydra Rig pump that has proven it’s durability for years. Durability This new design approach starts by utilizing low friction roller bearings rather than journal bearings. This greatly enhances durability particularly at low speeds where other pumps using journal bearings are most vulnerable. The NP 400 design also operates at a much cooler temperature. Simplif ied Design NOV Hydra Rig’s pump is internally balanced on each cylinder for smooth pumping operation. Enhanced Performance The maximum rod load is 42,000 lbs. This allows for 15,000 psi working pressure at rates up to 324,000 scfh

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NP 200 Tripl ex High Pressure Nitrogen Pump STANDARD UNIT OVERVIEW The NOV® Hydra Rig® NP 200 satisfies the market requirement for high pressure pumping rates up to 270,000 scfh. The unit is specifically designed to deliver flow rates at high pressure while providing exceptional low flow rate turndown. The pump utilizes low friction roller bearings and a pressure feed lubrication system for positive lubrication, insuring increased pump life over conventional pumps.

Specifi cations and Dimensions Model Weight with Cold Ends and Lube Oil (lbs./kg) 1,750 / 793.79 Length (in/cm) Width (in/cm) Height (in/cm) Maximum Rod Load (lb/kg) Maximum RPM Stroke (in/cm)

NP 200 25.625 / 65.09 39.625 / 100.65 23.5 / 59.69 21,500 / 9752.2 975 1.375 / 3.49

NP 200 Pump Rate and Press ure Capabili ty Operation Characteristics at 90% Volumetric Efficiency and 975 RPM Cold End Diameter, in / mm 1.250 / 31.75 1.625 / 41.275 2.000 / 50.80 Maximum Flow, GPM / l/min 19 / 73 32 / 123 49 / 186 Maximum Flow, scfh / m³/hour 107,500 / 3040 181,600 / 5140 275,000 / 7780 Maximum Pressure, psi / MPA 15,000 / 103 10,000 / 69 6,000 / 41

ADVANTAGES: Durability The NP 200 Triplex Nitrogen pump is designed for durability. Low friction roller and ball bearings are used rather than common journal bearings. This greatly enhances

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durability, particularly at low speeds where journal bearings are most vulnerable. The design also operates at a wider temperature range and produces less heat in the bearings. This means less lube oil system requirements for preheating and cooling the lube oil. Welded Steel Case The welded steel case design allows strength where it is needed while reducing excess weight. Steel construction gives ductility and allows repairs if damaged. Compact Dimensions The NP 200 is compact in size for minimal footprint when installed. Typical hydraulic drive packaging enhances flexible installation of the nitrogen pump without drive shafts to align. Compatibility Many cold end brands may be mounted to the NP 200 pump for flexibility in use. 1.7 Skid Mounted Units

1.7.1

180,000 scfh – Nitr ogen Pump ing Unit Sound Proo fed(ATEX)– ZII DNV 2.7-3 GENERAL FEATURES: • A Skid Mounted and Sound proofed Liquid Nitrogen Pumping and Vaporizing unit, Gross Weight : Estimate 13.50 Tons • L 5200 mm/205” x W 2438 mm/96” x H 2560 mm/100” approx. • Fuel Capacity : 375 Liters/100 US Gallons • System is designed and constructed to meet D.N.V. 2.7.1.and BS EN12079 approvals

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Fully sound proofed skid and four point lift frame complete with stainless steel inlet and outlet attenuators Walls and doors of sound proofed area constructed of corrugated steel for extra strength and protection Safety Non-slip material on all ladder rungs and a harness point at the top of each ladder Shot blasting to SA 2½, zinc rich priming and paint finishing to NOV Hydra Rig® Specifications to customer color Unit all fully tested prior to shipping

EQUIPMENT SPECIFICATION: • Certified by DNV • Equipment designed to meet, but not limited to, the requirements of 3G T3 2A (Zone II), DNV 2.7-1, PED approval, C.E. marking PUWER and LOLER Compliance • Engine conforms to BP 200 requirements for the protection of diesel engines working in 3G T3 (Zone II) areas • Engine ATEX Zone II classified protection equipment for use in 3G T3 gas group 2A areas up to 200°C surface temperature at +50°C ambient to include exhaust gas heat exchanger, exhaust gas flame traps, air inlet shut down valve and a Hydra Rig electronic engine protection system • Hydra Rig designed and built 1½” x 2½” x 6” centrifugal charge pump, PED/DNV approved high pressure vaporizer and 1-5/8” cold end pumps DNV approved, 10,000 psi working pressure, 180,000 scf/h flow • Power Unit: Detroit Series 60 500HP at 2100 RPM turbo charged and after cooled. Engine compliant to USA flexibility scheme to allow Stage 2 emission engine to operate in the USA or Canada PERFORMANCE DATA: • Maximum Working Pressure: 690 Bar/10,000 psig • Hydrostatic Test Pressure: 1035 Bar/15,000 psig Maximum Flow Rate: 4700 NM3/Hr180,000 scf/h • Design Maximum Flow Rate Temperature: 20°C / 70°F Maximum Simultaneous Flow Rate And Pressure: 4700 NM3/Hr/10,000 psig at 690 Bar/ 180,000 scf/h • Design Ambient Temperature: 50°C • Design Environment: Offshore/Marine/Desert INSTRUMENTATION AND CONTROLS: • A local panel containing all instrumentation and controls for ease of operation to meet ATEX, Zone II and CE marking regulations. • Gauges

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Engine controls Start, Stop Emergency Stop Engine RPM Oil Pressure Air Pressure Water Temperature Engine Speed Control Hour Meter Nitrogen HP Pump and Discharge System Hydraulic Charge Hydraulic Charge Pressure Digital Rate Display Nitrogen Discharge Temperature Discharge Control Valve Pump Speed Control Lubricating Oil Pressure and Temperature Hydraulic Oil Temperature Vaporizer Circuit Temperature

FUEL/AIR SHUTDOWN VALVES TO CLOSE AUTOMATICALLY ON: • Engine Over Speed • Emergency Stop • High Coolant Temperature • Low oil Pressure • High Exhaust Temperature • Low Hydraulic oil level SPECIAL FEATURES: • The engine and cryogenics area to be fully enclosed and soundproofed, to a sound level maximum of 80dba at any point one meter from skid with an average below 78 dba • Engine to be equipped with an Ingersoll Rand air start system • Stainless steel engine air inlet, engine exhaust pipe work and silencer • Solder dipped radiator suitable for onshore use up to 50°C • All cryogenic piping to be Stainless Steel type 316 or 304 • Fuel and hydraulic tanks to be Stainless Steel • Stainless Steel floor in all areas exposed to possible cryogenic spillage • Cryogenic long stem ball valves for the liquid nitrogen circuit • Tempering line around nitrogen vaporizer to control the gaseous nitrogen discharge temperature • Discharge relief valve set at 11,000 psi and a gas line check valve for unit

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Cryogenic suction, boost pump bypass and return fittings to be 1½” CGA Hydraulically operated discharge valve to be a 2 x 1 valve with a ‘Danfoss’ actuator High pressure safety shut down system

1.7.2 HR-180,000 scfh Nitrogen Pumping Unit (Open Skid) Zone II / DNV The NOV® Hydra Rig® open frame 180K Zone 2 nitrogen unit is a compact diesel engine driven nitrogen unit, utilizing mechanical engines, the units are specifically designed for a wide range of applications outside of Europe. Zone 2 safety engine protection package including, basic shutdown system, exhaust gas cooler, air inlet flame trap, shut down valve and exhaust spark arrester; maximum surface temperature is 200°C The unit is capable of up to 180,000 SCF/H at 10,000 psi, and is ideally suited to nitrogen stimulation with coiled tubing, pipeline testing and pigging, purging and leak detection, and most land based and offshore operations requiring nitrogen. The standard unit offers a cost effective, simple to use and easy to maintain product that will give the operator a reliable and dependable unit, while maintaining the necessary performance. Compact designed skid dimensions: 2438 mm wide to meet ISO8’ for shipping •

Choice of design temperatures from -20°C up to +60°C

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Choice of operating environment

SPECIFICATIONS: •

Maximum working pressure: 690 Bar/10,000 psig

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Maximum flow rate: 4700 NM3/Hr 180,000 scf/h**

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Hydrostatic test pressure: 1035 Bar/15,000 psig

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Design maximum flow rate temperature: 20°C/ 70°F

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•

Standard Design Ambient Temperatures up to +60°C

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Design Environments: Offshore/Onshore/Tropical/Desert

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Gross weight (estimate): 8,500 kg ± *

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Dimensions: L 4569 mm/ 179” x W 2438 mm/96” x H 2600 mm/102”

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Fuel Capacity: 375 Liters/100 US Gallons

STANDARD FEATURES: •

Outer 4 point lift frame

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Forklift pockets for yard handling

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Unit all fully tested prior to shipping

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Safety Non-slip material on all ladder rungs

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Standard mechanical diesel engines: Detroit 8V92N rebuilt ** or Caterpillar 3406; other engine options on request

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Hydraulic heat load system

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Hydra Rig NP200 power end

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Hydra Rig 1.625” 10,000 psi Cold Ends (DNV approved)

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Hydra Rig 1.5” x 2.5” x 6” centrifugal boost pump

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Hydra Rig 10,000 psi rated vaporizer pot. (DNV approved)

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Heavy duty cooling system climate rated, 100% humidity

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Pneumatic fail safe shutdown and engine protection system

SPECIAL STANDARD FEATURES ON EVERY UNIT: •

Engine to be equipped with an Ingersoll Rand air start system

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Engine air inlet, engine exhaust pipe work and silencer

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Solder dipped radiator rated to design ambient temperature

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All cryogenic piping to be Stainless Steel type 316 or 304

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Stainless Steel floor in all areas exposed to possible cryogenic spillage

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Cryogenic long stem ball valves for the liquid nitrogen circuit

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Tempering line around nitrogen vaporizer to control the gaseous nitrogen discharge temperature

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Discharge relief valve set at 11,000 psi and a gas line check valve for unit

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Cryogenic suction; return fittings to be 1½" CGA (NIT150); other makes on request

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High pressure safety shut down system

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2” x 1” Fig-1502 discharge valve

*

Detroi t – 8.5 kg * Caterpil lar – 9.5 kg

**

Typical rates are 170K to 180K dependent on ambient conditi ons

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INSTRUMENTATION AND CONTROLS: A local panel containing all instrumentation and controls for ease of operation. Panels can be side or end mounted. Standard panels include the following gauges and controls: •

Engine controls

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Start, Stop

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Emergency Stop

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Engine RPM

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Oil Pressure

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Air Pressure

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Water Temperature

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Engine Speed Control

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Nitrogen HP Pump and Discharge System

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Hydraulic Charge Pressure

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Digital Rate Display

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Nitrogen Discharge Temperature

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Boost Pump Speed Control

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Boost Pump Pressure Gauge

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Lubricating Oil Pressure and Temperature

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Vaporizer Circuit Temperature

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Shutdown indicators

OPTIONAL FEATURES — AVAILABLE ON REQUEST: •

Hydraulically operated discharge valve to be a 2 x 1 valve with a ‘Danfoss’ actuator

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Stainless Steel Fuel and hydraulic tanks

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Outer 4 point lift frame can be designed in accordance with DNV.2.7.1/ BS EN 12079

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Certification by DNV or BV

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Treating iron racks for long joints and Chicksans

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Transfer hoses; choice of end connections available

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Storage tubes for transfer hoses up to 10 ft. long

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Boost pump bypass and/or second LN2 inlet

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Upgrade to 15,000 psi working pressure at 90,000 scfh by changing cold ends and PRV

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OPP shut down connection

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FUEL/AIR SHUTDOWN VALVES TO CLOSE AUTOMATICALLY ON: •

Engine Over Speed

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Emergency Stop

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High Coolant Temperature

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Low Oil Pressure

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Low Air Pressure

1.7.3

90,000 - 180,000 - 270,000 scfh Skid Mounted Unit – ZII DNV 2.7-3 The Non-Fired Skid Mounted unit provides a self-contained unit that can be transported offshore or other places inaccessible to traditional land based units. This unit is available with maximum flow rates up to 270,000 scfh in a single engine configuration. Unit orientation: The unit is a skid mounted, self-contained nitrogen pump and vaporizer system.

Rates and Pressures Model Cold End Diameter (in / mm) SK90 1.250 / 31.75 Sk180 1.625 / 41.275 SK270 1.250 / 31.75 1.625 / 41.275

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Maximum Flow (scfm / m³/hr.) 90,000 / 2,548 180,000 / 5,097 270,000 / 7,645

Maximum Pressure (psi / mpa) 15,000 / 103 10,000 / 69 10,000 / 69


1.7.4

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The New Standard Leadership in an industry must be earned. By maintaining an ongoing research and development effort, our Team has combined existing design with innovative new technology to produce the new standards of the industry in Nitrogen Pumping and Vaporization systems. These systems are efficient, dependable, safe, and built to perform in the field year after year.

1.8 Merlin – Nitrogen Vaporizer Automatio n System NOV® Hydra Rig® has developed an Automated Discharge Temperature Controller for NOV Hydra Rig's Direct Fired Nitrogen Vaporizers. The Merlin – Nitrogen Vaporizer Automation System has been developed to allow the operator to input the desired discharge temperature on a touch screen HMI and let the controller operate the vaporizer to control the discharge temperature, thus allowing the operator to focus on rate and pressure control. The system is available on the full range of models of NOV Hydra Rig Direct Fired Nitrogen Vaporizers and can be included on new build units or retrofit onto existing units with NOV Hydra Rig Direct Fired Nitrogen Vaporizers. Special attention was given to the design of the operator’s control panel. Operation of the unit has been simplified without reducing any of the system’s integrated control functions. With foresight gained from years of field experience, the functional, accessible layout of all components contributes to the overall efficiency, operator control, and maintenance.

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1.9

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180,000 scfh Trailer mounted nitrogen pump with Merlin Control System FEATURES •

Automatically maintains operator preset discharge temperature

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Automatic fuel and fan control improves vaporizer efficiency

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Built in data acquisition system

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Auto re-ignition on flame out

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Built in self-diagnostics

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Remote monitoring

BENEFITS •

Reduces temperature variations during rate and/or pressure changes

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Provides cleaner emissions and improved fuel efficiency

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Provides data for job analysis and customer reports

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System monitors for flame out and reacts quickly to maintain preset temperature

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Pinpoints problem area and provides potential solutions

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Safety warnings and system shutdown to protect critical components

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Reduces costly repairs and downtime

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Provides real time data to control center and/or office location.

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1.10 180,000 scf h Nitro gen Pump and Vaporizer Systems

1.11 Automated Pump, Tank and Data Acquisiti on Systems Auto Tank Pressure Control, Auto Boost Pump Prime, Auto Boost P ump Control, Data Acquisition System and Live Data Stream

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1.12 1.12 Nitrog en/Fluid en/Fluid Combin Combin ation pumping uni t Options include Chemical additive system, Fluid tab divider, remote control and a selection of different configuration of open top tanks.

The NOV® Hydra Rig Nitrogen Fluid combination pumping unit is trailer mounted, combination fluid and nitrogen pumping unit. The fluid sides of the unit consists of an independent power unit, triplex pump and 10 barrel tank, (2) centrifugal and discharge plumbing. The nitrogen side of the unit consists of independent power unit, Ln2 storage tank, nitrogen boost pump, nitrogen triplex pump, water bath vaporizer, exhaust vaporizer and discharge manifolding. Both nitrogen and fluid pump are controlled from a common, climate controlled cabin on unit. Both nitrogen and fluid pump can be run independently or simultaneously. General •

Climate controlled operators cabin

• Maintenance

friendly design

• Drop

deck design Fluid system • 10

bbl. Open top fluid tank

• Capable

of pressures up to 15,000 psi.

• Capable

of flow rates up to 12 gpm.(500 gpm)

• Actuated

valves allow for system control from operators cabin for both pumps. Nitrogen system • Non-fired

nitrogen vaporization system utilizing proprietary exhaust and water bath vaporizers.

• Liquid

nitrogen storage tank

• Capable

of pressures up to 15,000 psi.

• Capable

of flow rates from 12,000 to 180,000 scfh.

• Equipped

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with storage accommodations for treating iron


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1.12. 1.12.1 1 840, 840,000 000 scfh Chassis Mount ed Unit The unit provides a condensed footprint that makes it an excellent choice for hard to access locations. This unit is ideal for Frac applications or any any situation where a high flow rate is required

Unit Orientation: The pumping unit is fabricated on a tractor chassis. The unit consists of a tractor complete with a main engine, an auxiliary engine, a transmission, a reduction/drop box, a triplex nitrogen pump, a nitrogen boost pump, a direct fired vaporizer, hydraulics, a nitrogen storage tank and all necessary piping and controls. Pump Specifications Cold End Size 2.0" 2.5" 2.875" Maximum Rate (scfh) 415,200 648,720 857,940 Maximum Pressure (psi) 15,000 15,000 11,000

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CHASSIS: Customer preference — can be manufactured on any major brand of truck chassis VAPORIZER SPECIFICATIONS: • Hydra Rig DF 840 vaporizer • Rated to 15,000 psi • Includes single dial vaporizer control for ease of operation • CONTROLS AND UNIT OPERATION: • Ground Control is standard • Merlin Vaporizer Automation control system available 1.12. 1.12.2 2 Down-to-Earth Engineerin g Down-to-earth oilfield engineering is what made Hydra Rig the world’s largest manufacturer of coiled tubing equipment. And that same down-to-earth engineering is at work for you in our nitrogen pumping systems. No matter how they are used, these nitrogen pumping systems will meet the toughest standards of oilfield performance, simply because they have more “oilfield tough” in their design than any other system on the market. 1.12. 1.12.3 3 Latest Techn Techn ology olo gy NOV offers the latest technology in both fired and non-fired designs (see figures below).

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1.12.4

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180,000 SCFH CHASSIS MOUNTED NITROGEN UNIT; Unit orientation: The pumping unit is mounted on a tractor chassis complete with main engine, transmission, reduction/drop box, triplex nitrogen pump, boost pump nonfired hot water bath vaporizer an exhaust vaporizer, hydraulics, nitrogen storage tanks and all necessary piping and controls.

Cold End Size (in /mm) 1.25”/ 31.75 1.625” / 41.275 Maximum Rate (scfh / m3/hour) 90,000 / 2548 180,000 / 5097 Maximum Pressure (psi / mpa) 15,000 15,000 1.12.5 Perform ance and Precisi on From the addition of field iron racks to the simple accessibility of its components, oilfield engineering is evident in every aspect of the design and operation of these units. The result is reliable performance — dividends that the customer can depend on. These are some of the good reasons how down-to-earth, oil field engineering can benefit the customer. 1.12.6 Basic Design The standard features of the Nitrogen Pump and Vaporizer Systems are also available in trailer mounted units as well as skid and truck mounted. Standard systems are available from 60,000 SCFH to 1,000,000 SCFH, in both fired and heat recovery vaporization designs. Models NP600 a nd NP200 Nitrogen Triplex Pumps utilize low friction roller bearings and a dry sump lubrication system to operate at 0-900 RPM, significantly extending the system’s range.

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1.12.7 1,000,000 scf h Trailer Mounted Nitrogen Unit The NOV® Hydra Rig® 1,000,000 scfh Trail er Mounted u nit provides a platfor m for super high-rate flows. Its high volume capabilities allow for reduced equipment requirements on large volume jobs. The chassis is made to order trailer based on customer selected options. 1,000,000 scfh / 15,000 MAWP: Trailer mounted unit employs a 1,000 HP engine, a 2,000 gallon nitrogen tank and NOV Hydra Rig's 1200K vaporizer. DF 1200 is capable of vaporizing up to 1,200,000 scfh. Ground control station is shown with centralized controls for unit operation. Pump Specifications RATES AND PRESSURES @ 900 RPM Cold End

2.00 / 50.80

2.52 / 64.00

Size (in / mm)

2.875 /

3.00 / 76.20

3.25 / 82.55

73.03

Maximum

415,200 /

659,400 /

858,200 /

934,200 /

1,096,380 /

Rate (scfh /

11,753

18,610

24,300

26,443

31,034

15,000 / 103

15,000 / 103

11,200 / 77

10,000 / 69

m³/hr.) Maximum

8,800 / 61

Pressure (psi / mpa)

VAPORIZER SPECIFICATIONS: • Model DF 1200 vaporizer • Rated to 15,000 PSI • Includes single dial vaporizer control for ease of operation CONTROLS AND UNIT OPERATION: • Standard: Ground Control • Optional: Elevated control stand, climate controlled operator’s cabin • Merlin Vaporizer Automation control system available UNIT ORIENTATION: • The pumping unit is fabricated on a drop deck trailer. The unit consists of a trailer complete with a main engine, auxiliary engine, transmission, triplex nitrogen pump, nitrogen boost pump, direct fired vaporizer, hydraulics, nitrogen storage tank and all necessary piping and controls. 1.13

Boost Pump General Featur es NOV® Hydra Rig® manufactures four boost pumps sized perfectly to meet the supply requirements: Range of cold ends from the low flow 1.25" through to high demand 3.25" • 1.5" x 2.5" x 6" pump provides the necessary flow and pressure for outputs up to 540K scfh • 2" x 3" x 6" pump provides the necessary flow and pressure for outputs up to 1000K scfh • 2" x 4" x 6" pump provides the necessary flow and pressure for outputs up to 1000K scfh

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Document number Revision Page • • • • • •

1.14

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3" x 4" x 8.5" pump provides the necessary flow and pressure for high rate bulk transfer or multiple unit supply Installed on NOV Hydra Rig equipment and also compatible with other manufacturers worldwide Design of our boost encompasses the reliability of field proven components together with unique concepts Double Lip Seal and Replaceable Sleeve together ensure the operator a reliable, user friendly pump Easy to maintain in the field without any need for special tools, which minimizes downtime and reduces repair costs Especially effective when used with Hydra Rig power ends and cold ends, providing a total cryogenic package for most nitrogen pumping applications.

Cryogeni c Components – Cold Ends NOV® Hydra® Rig offers a range of cryogenic cold ends specifically designed to complement our NP200 power end (Triplex). The units are also compatible with most other leading manufacturers' power ends using a 1.38" stroke. In addition to the NP200 cold end range, NOV Hydra Rig offers a range of larger cryogenic cold ends specifically designed for use with NP1000/16000 Power Ends. These units are also compatible with most other leading manufacturers' power ends using 2.00" and 2.25" stroke. Large cryogenic cold ends used for high flow and pressure

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applications, such as nitrified fracturing, foam cement and pipeline pigging. NOV Hydra Rig offers cold ends for the NP1000/16000 in a range of sizes from 1," to 3.5", output flows from 360,000 scfh to 420,000 scfh and working pressure from 7,000 psi to 15,000 psi. All NOV Hydra Rig cold ends are available with DNV approval and designed to comply with the European Pressure Equipment Directive (P.E.D.).

1.15

Nitrogen Pumpi ng Unit Service Departm ent With the addition of a service truck and trailer (below and above right), the NOV® Hydra Rig® facility at Duncan, Oklahoma (above left) now offers field service at customer locations. Services offered include repair or rebuild of vaporizers, pumps, and other nitrogen equipment, repair of hydraulic systems, etc. OVERVIEW: The NOV® Hydra Rig® Nitrogen Division occupies a 54,000-sq. ft. facility in Duncan, Oklahoma. This division of National Oilwell Varco® specializes in the manufacture and rebuild of both fired and heat recovery nitrogen pumping equipment as well as combination fluid and nitrogen pumpers used for coiled tubing support. The NOV Hydra Rig Nitrogen Division manufactures an extensive line of nitrogen pumping equipment for oilfield and industrial service. Nitrogen vaporizers designed and manufactured include heated water nitrogen vaporizers, exhaust-to-nitrogen vaporizers and diesel fired nitrogen vaporizers. High pressure pumps specifically designed by the Nitrogen Division are manufactured in 200, 400, 1000 and 1600 horsepower sizes. All nitrogen pumps are capable of 15,000 PSI when equipped with suitable cold ends. One major objective is to provide "best-in-class" nitrogen pumping equipment to the industry. Nitrogen pumping equipment is only as reliable as the components used in its manufacture. That is the primary reason that NOV Hydra Rig designs and manufactures the majority of its cryogenic components internally.

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This operational model also offers our customers one point of responsibility — one phone call — for spares parts, technical support, and maintenance. QUALITY COMMITMENT: The Nitrogen Division in Duncan, Oklahoma has built a reputation of providing top quality equipment to our customers' worldwide. Certified in-house Quality Assurance programs follow the products before, during and after construction. NOV Hydra Rig has proven that it stands behind that equipment with qualified engineering, technical, and service support, gaining a reputation envied by our competitors. The ability to meet our customers' needs with both standard and specialized equipment has kept our product line innovative and expanding. It is this commitment to our customers' success that keeps NOV Hydra Rig at the leading edge. SERVICE: The Nitrogen Division builds and services, liquid nitrogen pump and vaporization systems as well as cryogenic components such as high pressure pumps, cold ends, boost pumps and vaporizers. The service department offers hydraulic trouble shooting and repair of systems along with field training on nitrogen equipment and operation. NOV Hydra Rig also offer in-house training at our facility on nitrogen equipment and operation. Services Offered • Repair or rebuild vaporizers, nitrogen boost pumps and cold ends • Repair of hydraulic systems • Hydraulic trouble shooting • Field training on nitrogen equipment and operation Customer in house training on nitrogen equipment and operation 1.16

Direct Fired Nitrogen Vaporizer These units have been in production at the NOV® Hydra Rig® facility in Duncan, Oklahoma since 1999. Compact design and exceptional performance are the key to market acceptance of our Direct Fired Nitrogen Vaporizers. The same technology is embodied in all NOV Hydra Rig direct fired vaporizers, enabling us to apply new innovations across the product line, rather than being platform specific. Our line of Direct Fired Nitrogen Vaporizers satisfies the Market Requirement for Vaporization rates up to 1,200,000 scfh.

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• • • • • • • • • • •

STANDARD FEATURES: Proprietary diesel-fired burner assembly Propane assisted ignition system Integrated fuel/fan controls for simplified unit operation Easy to maintain: Hinged Fan Assembly for easy access Single Igniter for simplicity 12 volt system Reduced component count Stainless steel construction Quench Air System More uniform temperature increases vaporizer efficiency

• • • • • • • • • • • • •

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Protects heat exchanger from over temperature Burns clean; tested to CAB standard High Air Flow Design Uses ambient heat to improve efficiency Fan Speed Sensor Quenches flame Single Combustion Chamber Single Flame Detector Inherent Flame Relight design Four (4) viewports Flame sensor Two (2) Temperature Sensors Standard 15,000 psi Heat Exchanger

OPTIONS: • Fuel pre-heater system • Flameout indicator

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1.16.1 The Nitro gen pum ping unit service department

OVERVIEW: The NOV® Hydra Rig® Nitrogen Division occupies a 54,000-sq. ft. facility in Duncan, Oklahoma. This division of National Oilwell Varco® specializes in the manufacture and rebuild of both fired and heat recovery nitrogen pumping equipment as well as combination fluid and nitrogen pumpers used for coiled tubing support. The NOV Hydra Rig Nitrogen Division manufactures an extensive line of nitrogen pumping equipment for oilfield and industrial service. Nitrogen vaporizers designed and manufactured include heated water nitrogen vaporizers, exhaust-to-nitrogen vaporizers and diesel fired nitrogen vaporizers. High pressure pumps specifically designed by the Nitrogen Division are manufactured in 200, 400, 1000 and 1600 horsepower sizes. All nitrogen pumps are capable of 15,000 PSI when equipped with suitable cold ends.

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D391000792-MKT-001 02 32

One major objective is to provide "best-in-class" nitrogen pumping equipment to the industry. Nitrogen pumping equipment is only as reliable as the components used in its manufacture. That is the primary reason that NOV Hydra Rig designs and manufactures the majority of its cryogenic components internally. This operational model also offers our customers one point of responsibility — one phone call — for spares parts, technical support, and maintenance. QUALITY COMMITMENT: The Nitrogen Division in Duncan, Oklahoma has built a reputation of providing top quality equipment to our customers' worldwide. Certified in-house Quality Assurance programs follow the products before, during and after construction. NOV Hydra Rig has proven that it stands behind that equipment with qualified engineering, technical, and service support, gaining a reputation envied by our competitors. The ability to meet our customers' needs with both standard and specialized equipment has kept our product line innovative and expanding. It is this commitment to our customers' success that keeps NOV Hydra Rig at the leading edge. SERVICE: The Nitrogen Division builds and services, liquid nitrogen pump and vaporization systems as well as cryogenic components such as high pressure pumps, cold ends, boost pumps and vaporizers. The service department offers hydraulic trouble shooting and repair of systems along with field training on nitrogen equipment and operation. NOV Hydra Rig also offer in-house training at our facility on nitrogen equipment and operation. Services Offered Repair or rebuild vaporizers, nitrogen boost pumps and cold ends Repair of hydraulic systems Hydraulic trouble shooting Field training on nitrogen equipment and operation Customer in house training on nitrogen equipment and operation

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1.17

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Liq uid Nitrogen Storage Tanks

1.17.1 Typical Offshore and Land Based LN 2 storage tanks are offered for both offshore and land operation. LN2 tanks are in operation around the world and are specifically designed for oilfield service.

1.17.2 Typical 2,000 Gallo n Offsho re Tank Protective lift frame; front and rear fill connections; ISO corner locks; 4 leg sling assembly

1.17.3 Offshore Tank with general piping and connection s arrangement

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1.17.4 General Features • • • •

Nominal 2,000 US gallon capacity 43 PSI maximum working pressure Super Insulation Service temperature -320°F

1.17.5 Typical 4,000 Gallo n Portabl e/Offs hore Tank Protective lift frame; topside access ladders; front and rear fill connections; ISO corner locks

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1.17.6 Typical Hydrauli c Schematic

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1.18

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Vaporizatio n Process Heat generated by the unit (engine water, hydraulic oil, and lube oil) is transferred to a coolant mixture via the following: •

Lube heat exchanger

•

Hydraulic heat exchanger

Engine heat exchanger On larger units (360k or bigger), an optional exhaust heat recovery is also utilized. However, these are not found on the 90k and 180k units. And finally, some heat is generated by a water brake (commonly referred to as the "dyno" or dynamometer). The water brake consists of friction plates (rotors and stators). As the coolant mixture passes through these friction plates, it becomes hotter. The coolant mixture is a mixture of water and glycol. A larger percentage of water is used in desert locations where freezing is not a problem. Please note that the ratio of water to glycol will affect the performance of the unit. If you alter this ratio, your unit will perform differently. This is because water transfers heat better than glycol. The glycol is required to prevent components from rusting and the water from freezing. The heat from the coolant mixture must now be transferred to the nitrogen. This takes place at the heat exchanger commonly referred to as the vaporizer. Consider the coolant tank as the starting point while tracking the coolant mixture around the unit. The coolant mixture is taken from the tank, into the water pump to be pumped to the vaporizer (entering in a "heated" state but leaving in a much "cooler" state). Next, the coolant mixture flows through the lube, hydraulic, and engine heat exchangers. From there, fluid can be diverted to the water brake (during operations) and finally back to the coolant tank. •

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1.18.1 Simpl e View of the Coolant Flow Path 1.18.2 Water Pump (Cool ant Pump) The Water Pump is a positive displacement vane pump which propels the coolant mixture through the coolant circuit. 1.18.3

Vaporizer The Vaporizer is the only point where heat is transferred to the nitrogen. Liquid nitrogen enters the vaporizer (at approximately -320°F) through a piece of stainless tubing. Inside the vaporizer, the tubing is coiled tightly together so that a large amount of tubing is inside. Nitrogen exits the vaporizer in a gaseous state (maximum approximately 120°F). Also entering the vaporizer is the coolant mixture which floods the vaporizer and flows around the tubing bundle at a pressure of 80 to 150 psig. The gaseous N2 temperature is controlled by: •

Liquid N 2 flow rate through the triplex cold ends

•

Inlet coolant mixture temperature and flow rate — This coolant loop temperature is manually controlled to maintain a steady input to the vaporizer between 100° to 140°F (maximum 180°F)

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D391000792-MKT-001 02 38

This discharge gas is normally measured in SCFM (Standard Cubic Feet per Minute) or SCMM (Standard Cubic Meters per Minute) and shown on the control panel as the Pump Rate. This "nitrogen discharge rate" is a calculated figure using a magnetic pickup reading from the triplex (measuring the number of strokes) multiplied by an efficiency factor (e.g., 87%), and displayed in SCFM or SCMM. Note: There is no flow meter to monitor the exact amount of gas being pumped into the well. 1.18.4 Heat Exchangers There are two basic types of heat exchangers utilized: •

Shell and tube heat exchanger (on new units)

Plate heat exchanger (on older units). Both function virtually the same. A heat exchanger normally has two isolated fluid paths. As two different temperature fluids flow through these paths, the higher temperature fluid gives up heat to the fluid at the lower temperature. In the shell and tube type heat exchanger, the colder fluid flows through a tube. This tube is tightly wrapped inside the shell. The warmer fluid enters the shell and surrounds the tube. Consequently, the fluid inside the tube becomes warmer. •

1.18.4.1 Lube Heat Exchanger When the coolant mixture leaves the vaporizer, it passes through the lube heat exchanger. The coolant mixture is cooler than the lubrication oil passing by it. Consequently, a percentage of the heat from the lubrication oil is transferred into the coolant mixture. Its main purpose is to control the lube oil tank temperature. In cold weather, a reverse heat exchange is possible; the coolant loop (warmed by use of the water brake) transfers heat to the lube oil. This is desirable because it allows the unit to warm up faster, thus being able to start operations sooner. 1.18.4.2 Hydrauli c Heat Exchanger After leaving the lube heat exchanger, the coolant mixture enters the hydraulic heat exchanger. This allows the coolant mixture to absorb additional heat created from the hydraulic circuit. However, the hydraulic heat exchanger's main purpose is to control the hydraulic tank temperature. In cold weather, a reverse heat exchange is possible; the coolant mixture (containing fluid warmed by use of the water brake) transfers heat into the hydraulic oil. This is desirable because it allows a cold unit to warm up faster, thus starting operations sooner.

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1.18.5 Water Plumbing Installati on

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D391000792-MKT-001 02 39


1.18.6 Typical Coolant Schematic

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1.18.7 Engi ne Heat Exchanger The Engine Heat Exchanger is not the radiator. After leaving the hydraulic heat exchanger, the coolant mixture enters the engine heat exchanger. This allows the coolant mixture to absorb additional heat created by the engine "cooling" system (radiator water). It also helps control the engine temperature. The amount of heat transfer varies depending on the horsepower draw or the engine load. If the engine has to work hard, it will generate more heat in the radiator system. This heat is transferred to the coolant mixture and transferred again to heat the LN 2 to a gas. For example, the engine is capable of producing 540 horsepower. If you are pumping at maximum rate and 1,000 psi discharge pressure, you may only use 200 horsepower to drive the triplex. Little heat is created by the engine. Therefore, the water brake will have to be used. However, if you are pumping at maximum rate and 10,000 psi discharge pressure, you may use 350 horsepower to drive the triplex. More heat is created by the engine. Consequently, the water brake is used less or not at all. 1.18.8 Exhaust Heat Recovery Exhaust Heat Recovery is optional on larger units. Some larger nitrogen units (360,000 SCFH and larger) may use water cooled manifolds or an exhaust heat exchanger or both. By use of secondary or direct heat exchangers, the exhaust heat is transferred into the coolant fluid. 1.18.9 Power Contro l Valve and Back Pressure Valve The "Back Pressure Valve" is set at Hydra Rig for maximum performance and should not be adjusted. It is set to the required pressure to feed the water brake via the "Power Control Valve." It also allows the coolant mixture to go directly back to the coolant tank. Coolant mixture going to the water brake is controlled by the "Power Control Valve." If the "Power Control Valve" is closed, the water brake is still lubricated with the coolant mixture through the "Bleed Water" line. Remember, the water pump (or coolant pump) is a positive displacement vane pump. If it is running and both valves are closed, something will fail.

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D391000792-MKT-001 02 42

1.18.10 Water Brake Hydra Rig commonly refers to the water brake as the "dynamometer," "dyno," or "hydromatic brake." These terms are often used interchangeably. The water brake consists of "friction plates" or rotors and stators. When the engine is running, the rotors are always turning. The speed of the rotors is controlled by the speed of the engine. However, the operator should not adjust the engine rpm up and down but rather open and close the "Power Control Valve" to control the heat of the coolant mixture.

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1.18.11 Typical Hydraulic Schematic

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D391000792-MKT-001 02 43


1.19

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Nitrogen Tanks Nitrogen tanks consist of two tanks (a stainless steel inner and carbon steel outer tank). The tank piping is made of stainless steel while the fittings are made of cast bronze. Insulation is placed between the two tanks to keep the inner vessel as cold as possible. The insulation is either perlite or super-insulated material. You will find old tanks that used perlite. New tanks are manufactured with the super-insulated material (40 layers of fiber paper and aluminum). A vacuum is pulled between the tanks to get rid of all the air. Air will transfer heat. The vacuum level can be checked at any time using a special electronic gauge which measures in microns. The vacuum is pulled by connecting a vacuum machine to the evacuation valve on the front of the tank.

1.19.1 Hydra Rig ® Nitrogen Tank

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D391000792-MKT-001 02 45

1.19.2 Accept able Vacuum Levels •

Perlite-Insulated Tanks 200 microns or less while cold (with LN 2 in the tank), o 800 microns or less while warm (without LN 2 in the tank) o

Super-Insulated Tanks 50 microns or less while cold (with LN 2 in the tank) o 200 microns or less while warm (without LN 2 in the tank) o Low pressure tanks will typically lose about 0.75% of LN 2 per day. •

1.19.3 Pressure Ratings Most inner vessels are not designed to withstand external pressure (i.e., 2 psi may be enough to collapse the inner vessel). The inner vessel is made of stainless steel. It is pressure tested to 1½ times working pressure. During a job, a common low pressure tank pressure should be maintained at approximately 30 psig. This can be monitored by using the pressure gauge labelled "TANK PRESSURE". The main pop-off attached to the tank is set by Hydra Rig at 43 psig. There are also two burst discs valves (one is optional) attached to the tank which are set at 53 psig as an added safety feature. These burst discs are made of aluminum and plastic. While transporting the tank, the road relief valve is used. It is set at 15 psig. The small curved relief valves on the fill, fill/drain, and recirculation lines are set at 200 psi. 1.19.4

Filling the Tank How full do you fill the tank? Connect your N2 supply to one of the fill lines, open the trycock, and begin filling the N 2 tank. Stop filling the tank when LN 2 comes out of the trycock. When this happens, the tank is approximately 95% full. This leaves room for gas expansion. A gauge on the tank labelled “TANK CONTENTS” will show the amount of LN2 in the tank measured in "inches of water." A chart is placed on the tank to convert this measurement to gallons. To use this gauge correctly, the three small valves below the gauge (Equalizer Valve, Liquid Valve, and Gas Valve) should all be open.

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1.19.5 Nitr ogen Tank

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1.19.6 Saturated LN 2 While sitting idle, the LN 2 in a tank will gradually absorb heat and generate pressures up to the relief valve setting. This will slightly increase the temperature of the LN 2, causing vapor to coexist within the LN 2 . As the tank becomes hotter, the pressure increases, the LN 2 becomes hotter, and more LN 2 changes to a gas. This gas remains trapped within the LN2 -referred to as saturated nitrogen. Saturated nitrogen means that gas and liquid are in equilibrium at a certain pressure and temperature; it may be a lot of gas or it may be a little gas depending on the pressure and temperature. There is another reason the LN 2 becomes hotter in the tank. Heat is introduced into the LN 2 while it is being circulated with the boost pump (due to friction and piping in direct contact with the atmosphere). Consequently, even more LN 2 changes into a gaseous state. Actually, the warmer gas coexists within the colder LN 2 ; this is what we refer to as "hot LN 2 ." When the "hot LN 2" is recirculated back into the top of the tank, you may hear someone say that "air bubbles enter the tank." It is not air, but nitrogen gas entering the tank. The saturated LN 2 will create problems trying to keep the boost pump and cold ends primed. You will have to blow down the tank (vent all the gas off), and then pressure up the tank again to get rid of the vapor trapped in the LN 2 . The illustration below may help you understand. "Boiling nitrogen" or "LN 2 boiling" refers to the condition when the surrounding area is warmer than the LN 2 . While the LN 2 tries to cool the surrounding area it looks like a pot of water boiling on the stove.

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1.19.7 Insid e a Nitrogen Tank 1.20

Troubleshooting Troubleshooting

(A) Engin e Starter Not Turni ng Over Probabl e Cause

Remedy

No Air Pressure

Check system air pressure

Faulty Start Button

Insure start valve is pressurizing diaphragm valve

Check Diaphragm Valve (Dump Valve to Starter) to be sure it is opening and delivering air supply to starter

Remove air pilot line and push start button. If good air pressure and volume comes through pilot line, re-install pil ot line. Remove supply hose to starter, push start button. If diaphragm valve opens and d ischarges large air volume, the valve is all right

Starter seized

If you are sure starter is getting good a ir volume and pressure, but starter will not turn, remove and repair or replace as necessary.

(B) Engin e Cranks But Will Not Start Probabl e Cause

Remedy

Slow cranking speed

Refer to A

Low ambient temperature

Using starting aid (ether) below 15°F. Check engine manual to be certain ether starting is approved

Engine not getting fuel

Check fuel tank level, fuel filters, fuel lines, valves, supply and return, and fuel pump

Check Normal Kill cylinder to see if it is stuck in Kill position

Repair or remove and replace normal kill cylinder

Throttle linkage binding

Check linkage and make adjustments as necessary

Poor quality fuel, incorrect fuel or water in fuel

Drain fuel, change filters, and replace fuel

Improper oil viscosity

Drain oil, change filters, and replace oil

Check the Emergency Kill “Flapper” to see if it is in closed position.

Reset Emergency Kill “Flapper”.

(C) Engine Misfiring Probabl e Cause

Remedy

Poor quality fuel

Drain fuel, change filters, and replace fuel

Air in fuel system

Check for air in fuel system mainly on suction side of fuel pump.

Broken or leaking fuel lines

Check for fuel leaks and replace defective parts

Restrictions in fuel lines

Check fuel flow. Replace fuel lines as necessary

Low fuel pressure

Check fuel level and kinks in fuel lines. Change fuel filters

Defective fuel injectors or pump

Contact authorized engine repair representative

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D391000792-MKT-001 02 49

(D) Engine Stalls Probabl e Cause

Remedy

Fuel tank vent plugged

Check tank vent and repair as necessary

Low fuel supply

Refer to C, Item 5

High parasitic loading (e.g., LN 2 pump hydraulic pump speed control.)

Check for engine loading during st arting

(E) Erratic Engine Speed Probabl e Cause

Remedy

Air leaks in fuel suction line

Check for air leaks and repair as necessary

Throttle linkage loose

Check throttle linkage

Engine governor problems

Contact authorized repair representative

(F) Low Power Probabl e Cause

Remedy

Restrictions in air intake system, clogged air filter

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

Poor fuel quality

Refer to B, Item 6

Damaged or restrictions in throttle linkage

Check linkage, adjust or replace if necessary

Emergency Kill “Flapper” partially closed

Check “Flapper”, reset or repair as necessary

Normal Kill cylinder partially extended

Reset cylinder or Repair as needed

(G) Engine Over-Heating Probabl e Cause

Remedy

Coolant level low

Determine cause, replace defective parts and replace coolant

Expansion tank cap

Replace expansion cap

Defective thermostat

Replace thermostat

Defective coolant pump

Replace coolant pump

Fan not engaging fully (full RPM) or turning

Inspect fan speed. Repair as necessary

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D391000792-MKT-001 02 50

(H) Low Engi ne Oil Pressure Probabl e Cause

Remedy

Coolant level low

Determine cause, replace defective parts and replace coolant

Expansion tank cap

Replace expansion cap

Defective thermostat

Replace thermostat


Replace coolant pump

Fan not engaging fully (full RPM) or turning

Inspect fan speed. Repair as necessary

Oil leakage, low level

Check for leaks and repair as necessary

Incorrect oil viscosity

Drain oil, change filters and replace oil

Defective oil gauge

Replace oil gauge

Clogged oil filter

Replace oil and filters

Defective oil pump


(I) Oil In Coolant Probabl e Cause

Remedy

Defective oil coolant core or seals


Blown head gasket


(J) Coolant i n Oil Probabl e Cause

Remedy

Defective oil coolant core or seals


Blown head gasket




Cylinder sleeve seals failure


(K) Low Flow Rate To Unit From LN 2 Tank Probabl e Cause

Remedy

Low tank pressure

Increase tank pressure

Supply valve not fully open

Open valve fully on LN 2 tank and skid

Return valve closed or partially closed

Open valve fully on LN 2 tank and skid

Suction strainer on LN2 tank clogged

Clean or replace strainer

Suction strainer on skid clogged

Clean or replace strainer

Clogged piping or transfer hoses

Inspect piping and hoses to insure free flow

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D391000792-MKT-001 02 51

(L) Moisture In Stem Packing Probabl e Cause

Remedy

Moisture in Stem Packing

Thaw valve and dry out packing

(M) Boost Pump Will Not Turn Probabl e Cause

Remedy

Hydraulic valve closed at boost pump

Open valve

Locked up from ice formation

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

Suction valve to hydraulic pump closed

Open valve

Defective hydraulic pump

Disconnect motor supply hose. Plug hose and cap motor. Test pump pressure if pump does not build pressure. Check system relief valve. If relief valve is all right, remove and replace pump

(N) Triplex Pump Will Not Rotate Probabl e Cause

Remedy

Over pressure shutdown is active or tripped

Reset to operating position

No hydraulic charge pump pressure

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

Check pump drive coupling to insure drive components are not slipping off input shaft

Replace damaged or broken drive coupling

Check main system pressure. If pressure rises above required to drive Triplex, one of the following is locked up: Hydraulic drive motor, Reduction gear box or Triplex pump

Remove Triplex dump drive coupling. A ttempt 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 h ydraulic motor does not turn, repair or replace the hydraulic motor

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D391000792-MKT-001 02 52

(O) Water Br ake Will Not Bu ild Heat In The Coolant Circuit Probabl e Cause

Remedy

Coolant pump is not operating

Check hydraulic drive system. If hydraulic system is turning pump, but pump is not building pressure, repair or repl ace coolant pump

Coolant pressure too high and coolant flow output low

Check return filter for blockage. Check lines for obstructions. Check back pressure system for closed gate valve or malfunctioning back pressure relief valve

Water brake inlet valve is not supplying the water brake properly

Open water brake load valve enough to reduce RPM of engine by 200 RPM. If it is not possible to reduce engine RPM by 200 RPM, remove water brake supply hose and measure supply flow at maximum engine RPM. Flow must be 25 GPM to generate full load at the water brake

After checking all of the above, unit will not perform

Contact Hydra Rig Customer Service Department for technical support

1.21

Properties and Uses For properties and uses of Nitrogen, please see the General Information section of this handbook.

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2

D391000792-MKT-001 02 53

NITROGEN 2.1

Calculations The density of nitrogen at a given temperature and pressure is:

Once the constants and unit conversions are included, this equation can be written for English units as:

In metric units it can be written as:

These densities are the "volume factors" in the following tables. Note that both of these densities express the weight or mass as a "standard" volume. Standard conditions are defined as atmospheric pressure (14.7 psia or 1 atm) and 60º F or 15º C. SCF stands for standard cubic feet and scm or sm³ stands for standard cubic meters. The Pressure vs. Depth for a Well Filled with Nitrogen graphs were based upon a surface temperature of 70º F (21ºC) and a gradient of 1.6º F per 100 ft. (2.92º C per 100 meters). Variations in the well temperature from these values make relatively small changes in the pressures. The following examples show how the graphs in this section can be used to solve nitrogen problems. 2.1.1

Example 1 E How much nitrogen is required to fill a 12,500 ft. reel of 2" OD X 0.156" wall CT to 3,500 psia at an average temperature of 75º F? 1. From the Coiled Tubing Volumes and Displacements table in the Pipe Sizes, Volumes and Displacements section of this handbook, read the internal volume for this size 2.768 bbls/1,000 ft. 2. Multiply this value by 12.5 thousand feet to obtain a total volume of 34.6 bbls 3. Using the Volume Factor - Medium Pressure graph, read the volume factor as 1,200 SCF/bbl. 4. Multiply the volume of the reel by the volume factor to obtain 41,520 SCF. This is the amount of nitrogen needed.

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D391000792-MKT-001 02 54

2.1.2

Example 1 M How much nitrogen is required to fill a 3,810 m reel of 50.8mm OD X 3.962mm wall CT to 24,100 kPa at an average temperature of 24º C? 1. From the Coiled Tubing Volumes and Displacements table in the Pipe Sizes, Volumes and Displacements section of this handbook, read the internal volume for this size 1.4438 liters/m which is the same as 1.4438 m³/1,000m. 2. Multiply this value by 3.81 thousand meters to obtain a total volume of 5.5m³ 3. Using the Volume Factor - Medium Pressure graph, read the volume factor as 221 scm/m³. 4. Multiply the volume of the reel by the volume factor to obtain 1,215 scm. This is the amount of nitrogen needed.

2.1.3

Example 2 E The same reel of CT as Example 1 E is being used to place nitrogen in a well. The CT will be run to 7,500 ft. Nitrogen will be pumped until the pressure at the end of the CT reaches 3,500 psia, filling both the well tubular, which is 3.5" 12.95 lb/ft. EU tubing and the CT. 1. From the Tubing Sizes, Volumes and Displacements table in the Pipe Sizes, Volumes and Displacements section of this handbook, read the internal volume for this size tubing as 7.35 bbls/1,000 ft. 2. Multiply this value by the depth of 7.5 thousand feet to obtain a well volume of 55.125 bbls. 3. From the Coiled Tubing Volumes and Displacements table in the Pipe Sizes, Volumes and Displacements section of this handbook, read the internal volume for this coiled tubing size as 2.768 bbls/1,000 ft. and the external displacement as 3.886 bbls/1,000 ft. 4. Multiply these values by 7.5 thousand feet to obtain an internal volume of 20.76 bbls and the external displacement as 29.145 bbls. 5. The total volume in the well to be filled with nitrogen is 55.125 - 29.145 + 20.76 = 46.74 bbls. 6. From the Pressure vs. Depth for a Well Filled with Nitrogen graph, find the point where the pressure is 3,500 psia at 7,500 ft. of depth. Follow the curves upward to read an approximate surface pressure of 2,750 psia. 7. The average pressure is (3,500 + 2,750)/2 = 3,125 psia. 8. The estimated bottom hole temperature is 70º F + 1.6 * 75 hundred feet = 190º F. The average temperature is (190 + 70)/2 = 130º F. 9. The Volume Factor for this average temperature and pressure is approximately 950 scf/bbl. 10. Multiplying this volume factor by the well volume from step 5 yields a nitrogen requirement of 44,400 scf.

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D391000792-MKT-001 02 55

11. For the remaining 5,000 ft. of CT on the reel assume the pressure will be the same as the wellhead pressure which is 2,750 psia, and the temperature is 75º F. Using the Volume Factor - Medium Pressure graph, read the volume factor as 990 scf/bbl. The volume of this section of the coiled tubing is 2.768 * 5 thousand feet = 13.84 bbls. 12. Multiply the volume of this section by the volume factor to obtain 13,700 scf. 13. The total nitrogen required is 13,700 + 44,400 = 58,100 scf. 2.1.4

Example 2 M The same reel of CT as Example 1 M is being used to place nitrogen in a well. The CT will be run to 2,285 m. Nitrogen will be pumped until the pressure at the end of the CT reaches 24,100 kPa, filling both the well tubular, which is 88.9mm 19.27 kg/m EU tubing and the CT. 1. From the Tubing Sizes, Volumes and Displacements table in the Pipe Sizes, Volumes and Displacements section of this handbook, read the internal volume for this size tubing as 3.832 liters/m which is the same as 3.832 m³ per 1,000 meters. 2. Multiply this value by the depth of 2.285 thousand meters to obtain a well volume of 8.756 m³. 3. From the Coiled Tubing Volumes and Displacements table in the Pipe Sizes, Volumes and Displacements section of this handbook, read the internal volume for this coiled tubing size as 1.4438 liters/m and the external displacement as 2.0268 liters/m. 4. Multiply these values by 2.285 thousand meters to obtain an internal volume of 3.3 m³ and the external displacement as 4.631 m³. 5. The total volume in the well to be filled with nitrogen is 8.756 - 4.631 + 3.3 = 7.425 m³. 6. From the Pressure vs. Depth for a Well Filled with Nitrogen graph, find the point where the pressure is 24,100 kPa at 2,285 m of depth. Follow the curves upward to read an approximate surface pressure of approximately 19,000 kPa. 7. The average pressure is (24,100 + 19,000)/2 = 21,550 kPa. 8. The estimated bottom hole temperature is 21ºC + 2.92 * 2.2.85 hundred meters = 88ºC. The average temperature is (88 + 21)/2 = 55ºC. 9. The Volume Factor for this average temperature and pressure is approximately 170 sm³/m³. 10. Multiplying this volume factor by the well volume from step 5 yields a nitrogen requirement of 1,262 sm³.

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D391000792-MKT-001 02 56

11. For the remaining 1,525 m of CT on the reel assume the pressure will be the same as the wellhead pressure which is 1,900 kPa, and the temperature is 24º C. Using the Volume Factor - Medium Pressure graph, read the volume factor as 175 sm³/m³. The volume of this section of the coiled tubing is 1.4438 * 1.525 thousand meters = 2.2 sm³/m³. 12. Multiply the volume of this section by the volume factor to obtain 385 sm³. 13. The total nitrogen required is 385 + 1,262 = 1,647 sm³. 2.2

Nomenclature M

=

molecular weight of Nitrogen = 28.0134

P

=

absolute pressure (psi for English units, kPa for metric units)

= gas constant (1545 ft. /lb/lb mole °R - for English units, 0.08206 atmliters/gm mole °K)

R

T

=

absolute temperature (°F + 460 for English units, °C + 273 for metric

=

compressibility factor from the following Nitrogen Compressibility Factor

=

density in weight or standard volume per unit volume

units) Z

curves ρ

Note: For properties and uses of Nitrogen, please see the General Section of this handbook.

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2.3

Nitrogen Compressibil ity Factor

2.3.1

Nitrogen Compressibil ity Factor (Engli sh)

2.3.2

Nitrogen Compressibil ity Factor (Metric)

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D391000792-MKT-001 02 57


2.4

Volum e Factor - Low Pressure

2.4.1

Volum e Factor - Low Pressure (English)

2.4.2

Volum e Factor - Low Pressure (Metri c)

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D391000792-MKT-001 02 58


2.4.3

Volum e Factor - Medium Pressure

2.4.4

Volum e Factor - Medium Pressure (English)

2.4.5

Volum e Factor - Medium Pressure (Metric )

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D391000792-MKT-001 02 59


2.5

Volum e Factor - High Pressure

2.5.1

Volum e Factor - High Pressure (English )

2.5.2

Volum e Factor - High Pressure (Metric )

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D391000792-MKT-001 02 60


2.6

Volum e Factor - High Temperature

2.6.1

Volum e Factor - High Temperature (Engl ish)

2.6.2

Volum e Factor - High Temperature (Metri c)

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D391000792-MKT-001 02 61

5) Nitrogen Pump Equipment

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