Instructions Manual: Nitrogen Pumping Unit [PDF]

Zitiervorschau

2016 Instructions Manual

Nitrogen Pumping Unit

GOES GmbH German Oilfield Equipment & Services Münchener Str. 32 29392 Wesendorf | Germany

Table of contents Scope of delivery

1 1 2

Table of contents TABLE OF CONTENTS .................................................... 2 FUNDAMENTAL INFORMATION ..................................... 9

2.1 Scope of delivery ............................................................ 9 2.2 Documentation ............................................................. 11 2.2.1 Content and Set-up...................................................... 11 2.2.2 Conventions of Labelling ............................................. 11 2.2.3 Documentation from other Manufacturers ................... 12 2.2.4 Inspection and Maintenance Intervals ......................... 13 2.3 User Groups ................................................................. 15 2.4 Responsibilities............................................................. 16 2.4.1 Responsibility of the Manufacturer .............................. 16 2.4.2 Norms and Guidelines ................................................. 16 2.4.3 Responsibility of the Operator ..................................... 16 2.5 2.6 2.7 2.8 3

Interfaces ...................................................................... 18 Legal Information .......................................................... 19 Warranty ....................................................................... 20 Service Address ........................................................... 20 SAFETY ........................................................................... 21

3.1 Following the Operating Instructions ............................ 21 3.2 Conventions of the Safety Notes .................................. 22 3.2.1 Structure of the Warning Notes ................................... 22 3.2.2 Danger Levels.............................................................. 23 3.2.3 Safety Symbols / Pictograms ....................................... 24 3.2.4 Mandatory Signs .......................................................... 27 3.3 3.4 3.5 3.6 3.7 3.7.1 3.7.2 3.7.3 3.7.4 3.7.5

Intended Use ................................................................ 29 Foreseeable Misuse ..................................................... 29 Range of Application .................................................... 30 Personnel Requirements .............................................. 30 Residual Risks .............................................................. 32 Electrical system .......................................................... 32 Pressurised Components ............................................ 33 Operating and auxiliary materials ................................ 34 Working areas.............................................................. 35 Temperature ................................................................ 35

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Table of contents Scope of delivery

3.7.6

Nitrogen ........................................................................ 36

3.8 Conduct in an Emergency ............................................. 37 3.8.1 First aid ......................................................................... 37 3.8.2 Emergency plan ........................................................... 38 3.8.3 Electrical accidents ....................................................... 38 3.8.4 Fire ............................................................................... 38 3.8.5 Cryogenic burns ........................................................... 39 3.8.6 Environmental hazard .................................................. 39 4 5

TECHNICAL DATA .......................................................... 41 STRUCTURE AND FUNCTION ....................................... 43

5.1 5.2 5.3 5.4 5.5 5.6 5.6.1 5.6.2 5.6.3 5.6.4

Side Definition ............................................................... 43 Functional description ................................................... 44 Off-road-truck ................................................................ 45 Nitrogen tank skid ......................................................... 47 N2 pump skid ................................................................ 49 N2 pump, drive .............................................................. 51 Drive Motor ................................................................... 52 Pump distributor gearbox ............................................. 53 Pump S90 ..................................................................... 54 Pump S45 ..................................................................... 55

5.7 N2 pump, water circuit .................................................. 56 5.7.1 Heat exchanger charge air cooler ................................ 57 5.7.2 Heat exchanger Lubrication oil ..................................... 58 5.7.3 Heat exchanger Hydraulic return .................................. 59 5.7.4 Heat exchanger Heat load ............................................ 60 5.7.5 Heat exchanger Engine Jacket water ........................... 61 5.7.6 Heat exchanger Exhaust gas ....................................... 62 5.8 N2 pump, nitrogen circuit .............................................. 64 5.8.1 Booster pump ............................................................... 65 5.8.2 Triplex pump ................................................................. 66 5.8.3 Vaporizer ...................................................................... 68 5.8.4 Transfer interface ......................................................... 69 5.9 N2 pump, preheater ...................................................... 70 5.10 N2 pump, connections .................................................. 74 5.11 EMERGENCY STOP Devices ...................................... 75 5.11.1 Right EMERGENCY STOP button ............................... 77 5.11.2 Left EMERGENCY STOP button ................................. 78 5.11.3 EMERGENCY STOP panel .......................................... 78

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Table of contents Scope of delivery

5.12 Operator Workstation ................................................... 79 5.13 Cabin heating ............................................................... 80 5.14 Operating panel ............................................................ 82 5.14.1 Overview ...................................................................... 82 5.14.2 Triplex pump controls .................................................. 83 5.14.3 Heat load controls ........................................................ 87 5.14.4 Boost pump controls .................................................... 89 5.14.5 Motor and system controls ........................................... 90 5.14.6 Readjustments and cool down..................................... 92 5.14.7 Exhaust gas control ..................................................... 95 6 7

ASSEMBLY / COMMISSIONING .................................... 97 DELIVERY AND TRANSPORT ....................................... 99

7.1 Safety ........................................................................... 99 7.2 Delivery....................................................................... 100 7.3 Transport .................................................................... 100 7.3.1 Personnel................................................................... 100 7.3.2 Preparation ................................................................ 100 7.3.3 Nitrogen skid .............................................................. 101 7.3.4 Departure check ........................................................ 102 8 9 9.1 9.2 9.3 9.4 9.5

STORAGE ..................................................................... 103 INSTALLATION CONDITIONS ..................................... 105 Safety ......................................................................... 105 Installation site ............................................................ 105 Substrate .................................................................... 106 Attachment ................................................................. 106 Connections................................................................ 106

10 OPERATION .................................................................. 107 10.1 Safety ......................................................................... 107 10.2 Filling the nitrogen tank .............................................. 107 10.2.1 Valve overview........................................................... 108 10.2.2 Preparation ................................................................ 110 10.2.3 Initial filling ................................................................. 110 10.2.4 Filling ......................................................................... 111 10.3 Cool down................................................................... 112 10.3.1 General inspections ................................................... 112 10.3.2 Reducing the overpressure ........................................ 113

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Table of contents Scope of delivery

10.3.3 10.3.4 10.3.5 10.3.6 10.3.7

Starting the drive motor .............................................. 114 Building up admission pressure ................................. 116 Boost pump ................................................................ 117 High-pressure pump ................................................... 122 Return flow ................................................................. 124

10.4 Pumping nitrogen ........................................................ 124 10.5 Take out of operation .................................................. 128 10.6 Operation after Emergency Stop ................................. 131 10.7 Operation after a Prolonged Downtime ....................... 132 10.8 Miscellaneous. ............................................................ 133 10.8.1 Operation with cabin heating ...................................... 133 10.8.2 Operation with preheating .......................................... 135 11 FAULTS AND TROUBLESHOOTING ........................... 137 11.1 11.2 11.3 11.4 11.5

Drive motor .................................................................. 137 Filters .......................................................................... 138 Battery ......................................................................... 139 Exhaust gas heat exchanger ....................................... 140 Plate heat exchanger .................................................. 143

12 INSPECTION AND MAINTENANCE.............................. 145 12.1 Safety .......................................................................... 147 12.2 Truck ........................................................................... 149 12.3 Nitrogen skid ............................................................... 149 12.3.1 Before each operation ................................................ 150 12.3.2 Inspection after 2.5 years ........................................... 152 12.3.3 Inspection after 5 years .............................................. 152 12.4 Pump unit .................................................................... 152 12.4.1 Drive motor ................................................................. 152 12.5 Heating circuit ............................................................. 156 12.5.1 Exhaust gas heat exchanger ...................................... 156 12.5.2 Plate heat exchanger ................................................. 158 13 DECOMMISSIONING ..................................................... 161 13.1 13.2 13.3

Safety .......................................................................... 161 Disassembly ................................................................ 163 Disposal ...................................................................... 164

14 ADDITIONAL DOCUMENTS ......................................... 165

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Table of contents Scope of delivery

14.1 Manufacturer’s Certificate ........................................... 165 14.1.1 Device pass ............................................................... 165 14.1.2 Certificate of Conformity ............................................ 165 14.1.3 Certificate of Origin .................................................... 165 14.1.4 Certificate of Warranty ............................................... 166 14.1.5 Full Application Test .................................................. 166 14.2 Machine Structure ...................................................... 166 14.2.1 Overall drawing .......................................................... 166 14.2.2 Construction BOM ..................................................... 167 14.3 Hydraulics ................................................................... 167 14.3.1 Hydraulic plan ............................................................ 167 14.3.2 Hydraulics BOM ......................................................... 168 14.4 Electronics .................................................................. 168 14.4.1 Electronics plan ......................................................... 168 14.4.2 Electronics BOM ........................................................ 168 14.5 Flow chart ................................................................... 169 14.5.1 Heat recovery circuit .................................................. 169 14.5.2 Heat recovery circuit BOM ......................................... 169 14.5.3 Nitrogen circuit ........................................................... 169 14.5.4 Nitrogen circuit BOM.................................................. 170 15 SUPPLIER DOCUMENTATION .................................... 171 15.1 Truck........................................................................... 171 15.2 Nitrogen Tank Skid ..................................................... 171 15.3 N2 pump, drive ........................................................... 171 15.3.1 Drive motor ................................................................ 171 15.3.2 Pump distributor gearbox........................................... 172 15.3.3 Hydraulic pump S90 .................................................. 172 15.3.4 Hydraulic pump S45 .................................................. 173 15.4 N2 pump, water circuit ................................................ 173 15.4.1 Circulation pump ........................................................ 173 15.4.2 Charge air cooler heat exchanger ............................. 173 15.4.3 Plate heat exchanger ................................................. 174 15.4.4 Exhaust gas heat exchanger ..................................... 174 15.5 N2 pump, nitrogen circuit............................................ 175 15.5.1 Booster pump ............................................................ 175 15.5.2 Triplex pump .............................................................. 175 15.5.3 Gearbox ..................................................................... 175

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15.5.4 Hydraulic motor .......................................................... 176 15.5.5 Vaporizer .................................................................... 176 15.5.6 Plug valve ................................................................... 176 15.6 15.7 15.8

Cabin heating .............................................................. 177 Electric components .................................................... 177 Control system components ........................................ 177

16 ANNEX ........................................................................... 179 16.1 16.2

List of Figures .............................................................. 179 Table Headings ........................................................... 181

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Fundamental Information Scope of delivery

2

Fundamental Information

2.1

Scope of delivery

The delivered product consists of the following functional main components: 1. 2. 3. 4.

Off-road-Truck Nitrogen tank in skid construction Nitrogen pump in skid construction Operator cabin

Through the interaction of the components results in a complex function unit. The N2-Skid is referred in accordance with technical, normative and legal standards as machine The Nitrogen Pumping Unit machine is completely assembled, set-up, calibrated and tested as it is transferred to the customer. All main components are placed on the off-road-truck. The customer therefore receives a complete product that is ready to be used upon delivery. Table 1: Scope of delivery

The delivery scope includes: Truck Manufacturer Type Series number

MERCEDES BENZ ACTROS 4141 8x8/4 See Passport

Nitrogen tank Manufacturer

GAZGIR TOC

Type

CZN-H/S-8.2K

Series number

See Passport

Nitrogen pump Manufacturer

Instructions Manual

Nitrogen Pumping Unit

Original translation, English

Version 01, [12.07.2016]

GOES GmbH

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Fundamental Information Scope of delivery

Type Series number

NU500 See Passport

Operator cabin Manufacturer

GOES GmbH

Type Series number

Accessories

See Passport  Pullout Ladders, 2 pcs. (front and cabin access)  Handrails Assembly for Cabin Ladder  Stainless steel hoses DN40, 2 x L=3,05 m and 1 x L= 4,57 m  45deg elbow, 2 pcs.  Fire extinguisher

Documentation

The main documentation for the machine Nitrogen Pumping Unit, version 01, in original translation in English and Russian. This instruction manual for the machine N2 Skid, version 01, in original translation in English and Russian.

Supplier documentation

Existing supplier documentation is listed in Chapter 15 and is supplied as accompanying documents.

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Fundamental Information Documentation

2.2

Documentation

The operating instructions are designed as a print version and shall be transferred to the customer as such. These operating instructions help you,   

Familiarize yourself with the machine Nitrogen Pumping Unit Operate the machine safely and properly And avoid unintended usage.

You are in a position to operate the machine safely if you use these operating instructions as a quick reference, a source of information and a guidance for actions. You must have understood the safety and warning notes contained here in context and observe them at all times. These operating instructions must always be kept in the vicinity of the machine as they are a key component of the product.

2.2.1 Content and Set-up These operating instructions contain all the information you need to correctly assemble, commission, transport, operate, clean, service and decommission the machine. The set-up complies with DIN EN 82079-1, VDI 4500 and the product lifecycle.

2.2.2 Conventions of Labelling Two columns can be found in the page header of this manual. Column 1 indicates the chapter, column 2 indicates the subchapter in which you currently find yourself. Trademarks and company names of third parties in this manual are depicted here in small capitals, irrespective of original lettering. The figures are numbered consecutively and are marked with a caption. The caption is situated beneath the figure, the table of figures can be found in the Annex under the Chapter 16.1.

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Original translation, English

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Fundamental Information Documentation

The tables are numbered consecutively and are marked with a table heading. The table heading is situated above the table, the list of tables can be found in the Annex under the Chapter 16.2. The captions and table headings appear in bold and are 3 pt smaller than the basic font. If figures contain position numbers relating to components or assemblies, these are associated with the figure number and comply with the convention in the text: Figure number / Position number (23 / 5) Button and switch denominations are given in square brackets [Button 1]. Button or switch positions are depicted in block capitals in text, descriptions and directives. Example: ON, OFF Abbreviations used in the text are clarified when they occur for the first time. The abbreviations used are in parentheses after the associated designation, Example: MD (Machinery directive). Cross-references within this manual are linked. In printed form, the cross-references correspond to the convention of blue font colour and underlined Example. The user-defined display preferences are used in online documents and PDF. Information concerning the designation of the machine, language version and revision of the manual, as well as the page number, can be found in the footer.

2.2.3 Documentation from other Manufacturers Instructions and technical documents of the components supplied can be found in Chapter 15 and in the annex.

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Fundamental Information Documentation

The conventions and language versions of documents originating from other manufactures may deviate from the conventions used in these operating instructions. Familiarize yourself with the conventions used in the applicable material first of all to avoid any misunderstandings upon usage. We have no influence over supplier documentation.

2.2.4 Inspection and Maintenance Intervals These Instructions Manual uses inspection and maintenance intervals. Table 2: Inspection and Maintenance Intervals

Time interval

Operating hour interval

W00

As required

B10

After 10 OprHrs

W10

Before each run

B20

After 25 OprHrs

W20

Daily

B30

After 50 OprHrs

W30

Weekly

B40

After 100 OprHrs

W40

Every 2 weeks

B50

After 250 OprHrs

W50

Monthly

B60

After 500 OprHrs

W60

Quarterly

B70

After 750 OprHrs

W70

Every 6 months

B80

After 1000 prHrs

W80

Annually

B90

After 1500 OprHrs

W90

Every 2 years

B100

After 2000 OprHrs

W100

every 3 years

B110

After 2500 OprHrs

W110

Every 4 years

B120

After 3000 OprHrs

W120

Every 5 years

B130

After 3500 OprHrs

W130

Every 6 years

B140

After 4000 OprHrs

W140

Every 7 years

B150

After 4500 OprHrs

W150

Every 8 years

B160

After 5000 OprHrs

W160

Every 9 years

B170

After 6000 OprHrs

W170

Every 10 years

B180

After 7000 OprHrs

B190

After 7500 OprHrs

B200

After 8000 OprHrs

B210

After 9000 OprHrs

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Fundamental Information Documentation

Time interval

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Operating hour interval B220

After 10000 OprHrs

B230

After 11000 OprHrs

B240

After 12000 OprHrs

B250

After 12500 OprHrs

B260

After 13000 OprHrs

B270

After 14000 OprHrs

B280

After 15000 OprHrs

Nitrogen Pumping Unit

Instructions Manual

Version 01, [12.07.2016]

Original translation, English

Fundamental Information User Groups

2.3

User Groups

The Instructions Manual are intended for those who        

assemble the machine or parts of the machine commission the machine transport the machine or parts of the machine put into storage the machine or parts of the machine operate the machine clean the machine service the machine and / or remedy faults decommission the machine and disassemble it

These individuals must be qualified, instructed and trained specifically for the activities. Operator The operator is the owner or renter of the machine. They use it for commercial purposes and bear responsibility for the safe handling and for the operation as intended. Specialist personnel Specialist personnel (e.g. electricians, industrial mechanics) may carry out tasks entrusted to them on the basis of their specialist training and are fully aware of any possible dangers. They must also be aware of the relevant provisions, accident prevention regulations and the specific operating conditions. Operating personnel Operating personnel are sufficiently trained and have experience in operating the machine and are aware of any possible dangers that may result in the event of improper behaviour. They are aware of the necessary protective devices, protective measures, relevant provisions, accident prevention regulations and operating conditions.

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Fundamental Information Responsibilities

2.4

Responsibilities

2.4.1 Responsibility of the Manufacturer The notes, descriptions and guidance given in this Instructions Manual are used for the safe handling of the machine throughout the entire product life cycle. They exclusively refer to the Nitrogen Pumping Unit machine named in Chapter 2.1. The manufacturer is responsible for   

the planning, design, manufacturing and assembly the quality control, testing and inspection of components and the product as a whole the documentation and the required certification of the product.

2.4.2 Norms and Guidelines The Nitrogen Pumping Unit machine is designed built in accordance with norms and regulations of the industry standard and the current level of knowledge applicable at the time of manufacture. The machine is operationally reliable at the time of handover to the customer. The fundamental safety and health requirements of the relevant laws and guidelines have been applied in the development and production of the machine. All the information in these operating instructions are based on the currently valid national laws and regulations and directives of the European Union. In addition, the valid directives on accident prevention and environmental protection must be observed.

2.4.3 Responsibility of the Operator All work on the machine may only be performed by those who are authorized by the manufacturer and have been especially trained for that purpose. Qualifications as well as the scope of the instruction / training are described in detail in Chapter 3.6.

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Fundamental Information Responsibilities

The operator must also ensure, that 



        





the individuals authorized by them, that are tasked with assembly, commissioning, operation, cleaning, maintenance, troubleshooting and decommissioning, have read and understood these operating instructions. the operating instructions and the other valid documentation are placed in the vicinity of the machine during work. The operating instructions are a key product component. all local safety-related special regulations are observed and complied with. all local legal special regulations for the commissioning or operation of the system are adhered to. the safety equipment and all safety-relevant devices are fully present and functional before commissioning. all necessary protective equipment is provided for the specialist and operating personnel. the safety equipment and all safety-relevant devices are fully functional during system operation. the machine is used as intended. the general safety regulations are observed and continuously monitored. maintenance work is carried out regularly, according to the maintenance schedule. All components from suppliers are serviced in accordance with the maintenance instructions of the respective manufacturer. work on the electrical systems is only carried out by individuals with specialist knowledge in electrical engineering (electricians). only maintenance or replacement parts are used that have been specified and approved by the manufacturer.

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Original translation, English

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Fundamental Information Interfaces

2.5

Interfaces

The Nitrogen Pumping Unit machine has the following interfaces: Table 3: Interfaces

Input

 Interface for filling the nitrogen tank  Interface between nitrogen tank and nitrogen pump

Output

 Interface for dispensing the temperate nitrogen with an increase in pressure

Internal

 Data link / diagnostics  Operating panel cable connection / cabin for lighting and heating

The machine is otherwise autonomous.

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Fundamental Information Legal Information

2.6

Legal Information

The operating instructions are a key product component. Should you transfer or sell this machine, then these operating instructions, and any other supplier documentation, must also be transferred with it. All information in these operating instructions has been put together and verified with the utmost care. Nevertheless, discrepancies or errors cannot be completely ruled out. Any necessary corrections will be documented in the subsequent version. The complete documentation contains documents from third party suppliers (supplier documentation). The manufacturer has no influence in this case and assumes no liability for these documents. This applies in particular for      

typographical, technical or other inaccuracies of the layout errors and omissions in the documents content and accuracy information on compatibility, performance, reliability compliance with the copyright laws, legality, decency, or any other aspect references to third party products and services in this documentation. These in no way imply a specific recommendation to the third party products and services by the manufacturer.

In so far as the use of brand names, trademarks, trade names or commercial names are used in the operating instructions, then this is explicitly done recognizing all the rights of their respective owners, even if this is not immediately indicated or recognisable. The manufacturer reserves the copyright of this document. Therefore, this document may not be reproduced, duplicated, distributed or used for competitive purposes in whole or in part without the written permission of the manufacturer.

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Original translation, English

Version 01, [12.07.2016] Page 19 of 182

Fundamental Information Warranty

2.7

Warranty

The manufacturer assumes warranty within the scope of the statutory provisions for the machine and its equipment. Deviations or additions optionally form an integral part of the contract. Any liability and all warranty claims are voided when external parts are installed and used (accessories or replacement parts that have not been approved by the manufacturer) The manufacturer is not liable for incorrect operation, nonobservance of the operating instructions, improper use, misuse and the resulting damage and any violation of the responsibilities of the operator (see Chapter 2.4.3). The user/operator alone bears the risk in this case.

2.8

Service Address

GOES GmbH German Oilfield Equipment & Services Münchener Straße 32 29392 Wesendorf Phone: +49 (53 76) 9 76 47-0

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Safety Following the Operating Instructions

3

Safety

The following safety notes are of fundamental significance for the handling of the machine. In order to avoid irregularities, malfunctions or accidents, all individuals working directly on the machine must demonstrate a solid understanding of the employment protection provisions and develop a high and committed safety awareness. This presupposes in-depth knowledge of the complex influences on the machine. All employees concerned must therefore be specifically instructed on safety issues at regular intervals. The specialist personnel must be authorized and appointed by the operator or superior for these tasks. The warning notices attached to the machine must be observed and followed. Make sure that all employees have a thorough knowledge of first aid, fire detection and fire-fighting procedures. Observe the permissible operating limits during operation.

3.1

Following the Operating Instructions

General safety and special warning notes, which must be strictly observed and complied with, are contained in these operating instructions. These safety and warning notes must be followed by all those, who       

enter the hazardous area of the machine transport and erect the machine commission the machine operate the machine clean, service or repair the machine decommission the machine and disassemble it carry out any other work on the machine

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Version 01, [12.07.2016] Page 21 of 182

Safety Conventions of the Safety Notes

The operating instructions, safety and warning information in the manuals of the manufacturer, whose products are installed in the machine, are likewise valid. Operating and maintenance instructions of the installed components can be found in the Annex and in the Supplier Documentation chapter.

3.2

Conventions of the Safety Notes

3.2.1 Structure of the Warning Notes The warning notes denote safety-relevant information and indicate hazards that may occur during the individual procedures or with the machine itself. They are in line with the ANSI 535.6 and the SAFE method:     

Preceding warning symbol (pictogram) Severity of the hazard (signal word) Type and source of the hazard Consequence if the hazard is disregarded Escape (measures to avert the hazard)

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Safety Conventions of the Safety Notes

3.2.2 Danger Levels The warning notes are classified in the following danger levels in line with the ANSI 535.6: DANGER Indicates an extraordinarily hazard / dangerous situation If this note is ignored, then fatal or serious permanent injuries will result.

WARNING Indicates a particularly hazard / dangerous situation If this note is ignored, serious, permanent or fatal injuries could result.

CAUTION Indicates a hazard or dangerous situation If this note is ignored, minor or moderate injuries may occur.

ATTENTION Indicates a non-personal hazard If this note is ignored, material damages or environmental damages may occur.

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Safety Conventions of the Safety Notes

3.2.3 Safety Symbols / Pictograms The safety notes in these operating instructions correspond to the norm DIN EN ISO 7010 and are integrated into the warning notes in accordance with DIN ISO 3864 in order for the hazard to be visualized. The following symbols are used within the warning notes of these operating instructions: General warning of a danger, a danger point or a dangerous situation Warning of a danger, a danger point or a dangerous situation due to explosive substances or media. Warning of a danger, a danger point or a dangerous situation due to non-ionizing radiation. Warning of a danger, a danger point or a dangerous situation due to a magnetic field. Warning of a danger, a danger point or a dangerous situation due to obstacles in the path. (Tripping and/or falling). Warning of a danger, a danger point or a dangerous situation due to slipping or falling (fall). Warning of a danger, a danger point or a dangerous situation due to low temperature and cold. Warning of a danger, a danger point or a dangerous situation with smooth or slippery ground (risk of slipping). Warning of a danger, a danger point or a dangerous situation due to electrical voltage (electrical shock / short circuiting / electrical current through the body).

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Safety Conventions of the Safety Notes

Warning of a danger, a danger point or a dangerous situation due to industrial trucks. Warning of a danger, a danger point or a dangerous situation due to suspended loads. Warning of a danger, a danger point or a dangerous situation due to poisonous substances. Warning of a danger, a danger point or a dangerous situation due to hot surfaces (burning / reflex reaction). Warning of a danger, a danger point or a dangerous situation due to automatic start-up / restart. Warning of a danger, a danger point or a dangerous situation due to wedging / crushing of the body. Warning of a danger, a danger point or a dangerous situation due to obstacles in the head area. Warning of a danger, a danger point or a dangerous situation due to flammable substances. Warning of a danger, a danger point or a dangerous situation due to pointed or sharp objects. Warning of a danger, a danger point or a dangerous situation due to corrosive substances. Warning of a danger, a danger point or a dangerous situation due to crushing (hands). Warning of a danger, a danger point or a dangerous situation due to offsetting and co-rotating shafts, rollers or wheels (danger of infeed).

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Safety Conventions of the Safety Notes

Warning of a danger, a danger point or a dangerous situation due to batteries. Warning of a danger, a danger point or a dangerous situation due to oxidizing substances. Warning of a danger, a danger point or a dangerous situation through which environmental damage may occur. Warning of a danger, a danger point or a dangerous situation due to pressurized or bursting components. Warning of a danger, a danger point or a dangerous situation due to pressurized or bursting pipes. Warning of a danger, a danger point or a dangerous situation due to leaks from pipes. Warning of a danger, a danger point or a dangerous situation due to contact with sensitizing substances. Warning of a danger, a danger point or a dangerous situation that leads to crushing of the feet. Warning of a danger, a danger point or a dangerous situation that leads to loss of consciousness.

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Safety Conventions of the Safety Notes

3.2.4 Mandatory Signs Notice Additional documents or documents from other manufacturers are referred to here. Notice Wear reflective clothing or high visibility vest. Notice Wear safety helmet / hard hat. Notice Wear safety shoes. Notice Wear safety gloves. Notice Wear protective clothing. Notice Wear ear protection. Notice Wear protective goggles. Notice Wear dust mask. Notice Wear breathing mask. Notice Wear welding mask, goggles, protection.

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Version 01, [12.07.2016] Page 27 of 182

Safety Conventions of the Safety Notes

Notice Perform grounding. Notice Use this/these attachment point(s) Notice Observe this note

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Safety Foreseeable Misuse

3.3

Intended Use

The Nitrogen Pumping Unit is a low temperature unit. The intended use includes     

pumping of extremely cold and liquid nitrogen Increasing the nitrogen pressure Converting physical form into a gas Increasing the temperature of the gas Facilitating the onward processing procedure

All other usages are not classed as “proper intended usage”.

3.4

Foreseeable Misuse

It is prohibited to use the Nitrogen Pumping Unit machine in areas with explosive atmospheres. It is prohibited to mix, pump or pump off viscous mixtures that are not permitted in accordance with the technical data. It is prohibited to operate the N2 Skid in connection with an unauthorized or uncertified nitrogen tank. It is prohibited to operate the N2 Skid if it is not fully assembled or on a vehicle other than that supplied. It is prohibited to mix, pump or pump off chemicals with the Nitrogen Pumping Unit. It is prohibited to mix, pump or pump off foodstuffs with the Nitrogen Pumping Unit. It is prohibited to mix, pump or pump off liquids with the Nitrogen Pumping Unit, which are not expressly permitted in Chapter 3.3. It is prohibited to use the Nitrogen Pumping Unit to transport people. It is prohibited to use the Nitrogen Pumping Unit to transport materials.

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Version 01, [12.07.2016] Page 29 of 182

Safety Range of Application

It is prohibited to use the Nitrogen Pumping Unit as a recreational or break room. It is prohibited to use the Nitrogen Pumping Unit as a storage point for materials or other goods. It is prohibited to carry out applications, activities or work with the Nitrogen Pumping Unit that deviate from the operating instructions and are not expressly authorized. Misuse of the machine is also included here.

3.5

Range of Application

The Nitrogen Pumping Unit machine may only be used in the industrial sector. Usage in the offshore sector and in situations with explosive atmospheres is forbidden.

3.6

Personnel Requirements

These operating instructions are intended for personnel that are instructed and qualified and especially trained for the task inhand, i.e. transporting, storing, commissioning, operating, cleaning, servicing, troubleshooting and decommissioning the machine. Table 4: Personnel Qualification

Activity Transporting

Page 30 of 182

Training / Instruction  HGV driving licence  Transportation permits for hazardous goods  Permit for operating a crane  Briefing for o the HGV type o the crane o known attachment points o load securing

Nitrogen Pumping Unit

Instructions Manual

Version 01, [12.07.2016]

Original translation, English

Safety Personnel Requirements

Activity

Training / Instruction

Assembly work

 Training as an industrial mechanic or comparable position  Instruction in the hazards posed during assembly

Electrical work

 Training in an electrotechnical profession  Instruction in the electrical system of the machine as a whole and the hazards posed

Operation

 Professional qualification with machine operation (operating parameters, processing steps, identifying malfunctions)  Instruction in the hazards posed during operation of the machine

Cleaning

 Instruction in the hazards posed during cleaning work

Maintenance Work

 Training as an industrial mechatronics engineer or electrotechnical profession  Instruction in the hazards posed during maintenance work

Fault removal

 Training as an industrial mechatronics engineer or electrotechnical profession  Instruction in the hazards posed during work on fault removal

Disassembly

 Training as an industrial mechatronics engineer or electrotechnical profession  Instruction in the hazards posed during disassembly of the system

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Version 01, [12.07.2016] Page 31 of 182

Safety Residual Risks

3.7

Residual Risks

3.7.1 Electrical system There is a residual risk with the hazard:  Short circuiting with electrical current through the body  Arcing Work on the electrical system may only be carried out by authorized and sufficiently qualified personnel (see chapter 3.6). Before you begin work 1. 2. 3. 4. 5. 6. 7.

Switch off the system and components. Perform the steps prescribed in VDE 0105: Isolate Secure against re-start Ensure that there is no voltage Ground and short circuit Wear personal protective equipment (PPE) in accordance with DIN EN 340.

Work when the system is live or when the components are under voltage may only be carried out in exceptional cases. The following must also be observed if necessary: 8.

Secure the system against unintentional or automatic restart. 9. Cover or isolate any adjacent parts under voltage. 10. Use insulated tools in accordance with DIN EN 60900. 11. Wear specialized personal protective equipment (sPPE) in accordance with VDE 0682-301.

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Safety Residual Risks

The work must not lead to any safety restrictions or reduced intervals

3.7.2 Pressurised Components There is a residual risk due to pressurized components (hydraulic / pneumatic / liquid) and their active media with the hazard: Sensitization  due to skin contact or inhalation of aerosol. Poisoning  due to swallowing or intake of aerosol Injury  due to penetration of the pressurized media Injury  due to foreign bodies (bursting pipe) Injury  due to lashing pipes and hoses

Work may only be carried out by authorized and sufficiently qualified personnel (see Chapter 3.6). Before you begin work 1. 2. 3. 4. 5.

Decommission the system Secure the system against unintentional commissioning Lock manual valves against unintentional control Depressurize hydraulic and/or pneumatic system Release accumulator

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Version 01, [12.07.2016] Page 33 of 182

Safety Residual Risks

Work when the system is pressurized may only be performed in exceptional cases. The following must be observed if necessary: 1. 2.

Secure the system against unintentional or automatic restart. Lock valves against unintentional control.

3.7.3 Operating and auxiliary materials There is a residual risk due to fuels, lubricants, hydraulic oils and chemical auxiliary materials with the hazard: Sensitization  due to skin contact or inhalation of aerosol. Poisoning  due to swallowing or intake of aerosol Corrosion  due to contact with alkaline or acidic substances. Environmental Hazard  due to careless handling with the substances mentioned

Work may only be carried out by authorized and sufficiently qualified personnel (see chapter 3.6). Before you begin work 1. 2. 3. 4. 5.

Decommission the system. Secure the system against unintentional commissioning. Wear personal protective equipment. Have a collecting container or binding agent ready. Familiarize yourself and observe the warning labels applied to the operating materials and auxiliary goods.

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Safety Residual Risks

3.7.4 Working areas There is a residual risk due to components and assemblies which protrude into working areas with the hazard: Injuries due to  Bruising and limb injuries  Bruising and head injuries Injuries due to  Tripping Injuries due to  Falling

Work areas may only be accessed by authorized personnel (see Chapter 3.6). Before you begin work 1. 2. 3.

Decommission the system. Secure the system against unintentional commissioning. Wear personal protective equipment.

3.7.5 Temperature There is a residual risk both due to high as well as also due to low temperatures with the hazard: Burns  on hot surfaces at over 60 °C Affective reactions  due to touching hot surfaces at over 60 °C Frostbite  due to touching cold surfaces

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Version 01, [12.07.2016] Page 35 of 182

Safety Residual Risks

Before you begin work 1. 2. 3. 4.

Decommission the system. Secure the system against unintentional commissioning. Wear personal protective equipment. Let the machine cool down.

3.7.6 Nitrogen There is a residual risk from liquid nitrogen (LIN). Loss of consciousness / suffocation  Vaporising nitrogen reduces the oxygen concentration in the air.  Less than 17 vol.-% oxygen in the breathing air leads to unconsciousness and suffocation. Frostbite  LIN has a temperature of approx. -196 °C.  Contact with skin or eyes very quickly leads to frostbite.  Inhalation of cryogenic nitrogen gas leads to frostbite of the respiratory passages and lungs. Bursting  LIN will inevitably take warmth from the surroundings and transfer into a gaseous state.  Vaporization under confinement will lead to a rise in pressure. System components may burst if this pressure is not relieved.

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Safety Conduct in an Emergency

Increased risk of fire  On system parts which contain LIN and are not insulated (e.g. pipelines on LIN tanks), condensed air. Dripping condensate will accumulate - due to the regasification of the oxygen nitrogen content.  There will be an increased risk of fire if this oxygen-rich condensate penetrates into flammable solids (e.g. wood or organic insulating material).

Before you begin work 1. 2. 3. 4.

5. 6.

3.8

Decommission the system. Secure the system against unintentional commissioning. Wear special personal protective equipment. Only work on the system outdoors or in areas with good ventilation and extraction in terms of a specialized suction device. Always work on the side exposed to the wind. Carry portable oxygen-deficiency warning equipment.

Conduct in an Emergency

3.8.1 First aid At least two persons must be trained first aiders in each industrial premises / production facility. Carry out the following steps if an accident occurs: 1. 2. 3. 4.

Switch off the machine (EMERGENCY STOP) and secure against restart / reconnection. Rescue the injured from the danger zone and provide first aid. Inform the emergency services. Make sure that any other individuals are prevented from entering the danger area.

Inform the superiors or the management, who will in turn undertake further measures on their part.

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Version 01, [12.07.2016] Page 37 of 182

Safety Conduct in an Emergency

3.8.2 Emergency plan Access to the production facility must be kept passable and free of obstacles at all times for motor vehicles to allow rapid assistance in an emergency. There must be an emergency plan situated at the entrance of the industrial premises.

3.8.3 Electrical accidents The machine must be immediately switched off using the EMERGENCY STOP button in the event of an electrical accident.  



You must always initially exclude other people being affected by the hazard when rescuing those affected. Auxiliaries and safety devices, which are used for rescue purposes, must always consist of nonconductive material. Always consult a doctor even if there is only a slight electrical shock.

3.8.4 Fire Before any work takes place, a plan must be drawn up, which governs personnel behaviour in the event of a fire. All individuals must be briefed on the location and operation of fire extinguishers. There may be considerable risks in part, when attempts are made at extinguishing fires, if the prescribed minimum distance from the source of the fire is not respected or unsuitable extinguishing agents used. Carry out the following actions in the event of a fire:  

 

Remove any individuals from the danger zone. Attempt to fight the fire by your own means if there is a relative prospect of success, always notify the fire department should the fire spread. Leave the danger area. Take any persons in danger with you.

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Safety Conduct in an Emergency

3.8.5 Cryogenic burns Cryogenic burns can also occur even with brief contact with extremely cold substances such as cryogenic liquid nitrogen. The resulting injuries are comparable with severe burning. Carry out the following actions in the event of cryogenic burns:     



Remove any individuals from the danger zone. Do not endanger anybody else and observe your own safety. Immediately seek medical help. Bring those concerned to a warm area (> 22 °C). Carefully remove clothing from the affected area. Rinse affected skin area with plenty of lukewarm water. Avoid direct heat through hot water or using heating equipment. Protect frozen areas using dry, sterile compresses.

Smoking and alcoholic drinks reduce the blood supply and should therefore be avoided

3.8.6 Environmental hazard The improper use of the machine or insufficient or improper maintenance can lead to environmental hazards. Carry out the following actions in the event of an environmental hazard:  

Notify the fire department and competent authorities. Specify information on the hazardous substances in question.

Inform the executive management or the project management, who in turn will continue to take measures on their part.

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Version 01, [12.07.2016] Page 39 of 182

Technical Data Conduct in an Emergency

4

Technical Data

Nitrogen Pumping Unit Truck mounted Table 5: Technical data of the product

Product

Nitrogen Pumping Unit Manufacturer Type Series number

GOES GmbH NU500 Please see Passport

Length

12 000 mm

Width

2 550 mm

Height

4 000 mm

Weight (dry)

31 600 kg

Total weight

39 000 kg

Manufacturer

MERCEDES BENZ

Truck

Type

4141 AK 8x8/4

Chassis number

Please see Passport

Number of axes

4

Permissible total weight

44 000 kg

Cryotank Manufacturer Type Series number

GAZGIR CZN-H/S-8.4K Please see Passport

N2 pump: Manufacturer Type Series number

Instructions Manual

Nitrogen Pumping Unit

Original translation, English

Version 01, [12.07.2016]

GOES GmbH NU500 Please see Passport

Page 41 of 182

Structure and Function Side Definition

5

Structure and Function

5.1

Side Definition

Left side

Right side

Front

Cabin

Figure 1: Side Definition

Instructions Manual

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Original translation, English

Version 01, [12.07.2016]

Rear

Page 43 of 182

Structure and Function Functional description

5.2

Functional description

All components of the product are placed on an off-road-truck. Thus, the machine is deployed for mobile applications and the work-location can be changed. The truck has been approved for use on public roads.

Off-road-truck

A double-walled cryotank can be found to the rear of the truck load area. The cryotank is filled with liquid nitrogen and provides the nitrogen to the pumping unit. The cryotank is installed to a skid, certified in accordance with ADR and may be transported using public roads with the appropriate labelling and qualification of the driver.

Nitrogen tank

A pump unit can be found to the front of the truck. A diesel aggregate is used to power the hydraulic motors and pump flow. The heat generated by the motor and hydraulic components is used for the nitrogen evaporation process.

Pump unit

The liquid nitrogen is supplied to a triplex pump and brought to the desired discharge pressure by the lifting piston. The liquid nitrogen that is now under high pressure then flows through the nitrogen / water heat exchanger, is vaporized, heated to a temperature of 20 °C and made available for further processing procedures – e.g. to the coiled tubing unit – via a transfer interface. The transfer of heat energy between the water circuit / nitrogen circuit is undertaken via a vaporizer. An operator cabin can be found between the nitrogen tank and the pump unit. The machine can be controlled and monitored using the control platform.

Page 44 of 182

Operator cabin

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Instructions Manual

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Structure and Function Off-road-truck

5.3

Off-road-truck

Figure 2: Off-road-truck Table 6: Technical data Off-road-truck

Manufacturer

MERCEDES BENZ

Type

ACTROS 4141 8x8/4

Chassis No.

Please refer passport

Dimensions: Length

11 950 mm

Width

2 450 mm

Height

3 400 mm

Empty weight

13 850 kg

Permissible total weight

44 000 kg

Number of driven axes

4

Engine Displacement Number of cylinders Engine power

Instructions Manual

Nitrogen Pumping Unit

Original translation, English

Version 01, [12.07.2016]

12 l 6 300 kW

Page 45 of 182

Structure and Function Off-road-truck

The off-road-truck forms the basis for the containment of the machine components.

Functional description

The locking on the load area is undertaken using Twistlocks.

Figure 3: Twistlock

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Structure and Function Nitrogen tank skid

5.4

Nitrogen tank skid

Figure 4: Nitrogen skid Table 7: Technological data of the nitrogen skid

GAZGIR TOC

Manufacturer

CZN-H/S-8.2K

Type

Please refer passport

Series number Dimensions: Length

3 645 mm

Width

2 438 mm

Height

2 591 mm

Unladen weight

4  963 kg

Permissible total weight

11  620 kg

Weight

Payload

6  657 kg

Tank Holding capacity

Instructions Manual

Nitrogen Pumping Unit

Original translation, English

Version 01, [12.07.2016]

8 400 l

Page 47 of 182

Structure and Function Nitrogen tank skid

Medium

Cryogenic liquid nitrogen (LIN)

Operational pressure

max. 3.1 bar

Temperature range Approval

-196 °C to +50 °C  DNV 2.7.1  ADR / RID / IMDG  EN 12079

The nitrogen tank stockpiles cryogenic liquid nitrogen (LIN) and provides this for the processing procedure.

Functional description

The nitrogen tank is installed in a skid for safe transport and operation. The skid is placed on the truck and secured with container locks.

Figure 5: Container corner with twistlock

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Structure and Function N2 pump skid

5.5

N2 pump skid

Figure 6: N2 pump, frame Table 8: Technical data of the N2 pump, frame

GOES GmbH

Manufacturer

Please refer passport

Series number Dimensions: Length

4 572 mm

Width

2 438 mm

Height

2 350 mm

Weight inclusive Components

10 000 kg

Temperature range

Functional description

-40 °C to +50 °C

The N2 pump machine is installed in a skid for safe transport and operation. The skid is placed on the truck and secured with container locks.

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Version 01, [12.07.2016] Page 49 of 182

Structure and Function N2 pump skid

Figure 7: Container corner with N2 skid twistlock

Page 50 of 182

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Instructions Manual

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Structure and Function N2 pump, drive

5.6 Functional description

N2 pump, drive

The driving energy for the N2 pump is generated by a diesel aggregate. Mechanical energy is transferred to three hydraulic pumps via a pump distributor gear. The hydraulic drive energy for the individual components of the machine is provided via the hydraulic pumps.

Figure 8: N2 pump, drive

1

Engine radiator

1

Drive engine

2

Pump drives gearbox

3

Pump S45

4

Pump S90

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Version 01, [12.07.2016] Page 51 of 182

Structure and Function N2 pump, drive

5.6.1 Drive Motor

Figure 9: Drive motor Table 9: Technical data of the drive motor

Manufacturer Type Serial number Fuel Performance Cylinder number Cubic capacity Weight (wet)

VOLVO PENTA TAD 1650VE-B Please refer passport Diesel 405 kW 6 16 l. 1 395 kg

Motor oil quantity motor side, initial filling

53 l

Motor coolant motor side

100 l

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Structure and Function N2 pump, drive

5.6.2 Pump distributor gearbox

Figure 10: Pump distributor gearbox Table 10: Technical data of the pump distributor gearbox

GOES item No, Manufacturer Type Performance Rotational speed

STIEBEL 4396 700 kW 2000 rev/min

Ratio

0.9184

Weight (dry)

283 kg

Gear unit oil quantity

Instructions Manual

Nitrogen Pumping Unit

Original translation, English

Version 01, [12.07.2016]

9.5 l.

Page 53 of 182

Structure and Function N2 pump, drive

5.6.3 Pump S90

Figure 11: Hydraulic pump S90 Table 11: Technical data of the hydraulic pump S90

GOES item No, Manufacturer

108156 DANFOSS Series 90 Size 250 cm3

Type Operating conditions Rotational speed

min. 500 rev/min max. 2 500 rev/min

System pressure

max. 480 bar

Volumetric flow Media temperature

575 l/min -40 °C to 104 °C

This pump is installed twice. The first pump ensures the hydraulic volume flow rate for driving the triplex pump. The second pump ensures the hydraulic volume flow rate for driving the heat load unit.

Page 54 of 182

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Structure and Function N2 pump, drive

5.6.4 Pump S45

Figure 12: Hydraulic pump S45 Table 12: Technical data of the hydraulic pump S45

GOES item No, Manufacturer

108155 DANFOSS Series 45 Size 100 cm3

Type Operating conditions Rotational speed System pressure Volumetric flow Media temperature

min. 500 rev/min max. 2 880 rev/min rated 2 450 rev/min max. 400 bar rated 310 bar 245 l/min -40 °C to 104 °C

This regulated pump ensures the volume flow rate and drives the circulation water pump, the booster pump, the lubricant pump of the triplex pump and the cylinder discharge device.

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Version 01, [12.07.2016] Page 55 of 182

Structure and Function N2 pump, water circuit

5.7

N2 pump, water circuit

The nitrogen pump unit functions based on a passive principle, this means that the liquid nitrogen is not vaporized by the supply of external heat energy (fired principle), but by heat energy which is generated by the pump unit itself (non-fired principle). The media of all heat-emitting components are administered by heat exchangers in this instance and circulated in a water circuit.

Functional description

The circulation is brought about using a hydraulically driven pump.

Figure 13: Water circuit circulation pump

1

Circulation pump

2

Hydraulic drive motor

3

Adapter and coupling

Table 13: Technical data of the circulation pump

GOES item No, Manufacturer Type

Page 56 of 182

108357 EDUR

NU604 D160L

Nitrogen Pumping Unit

Instructions Manual

Version 01, [12.07.2016]

Original translation, English

Structure and Function N2 pump, water circuit

Operating conditions Environmental temperature: Media temperature Permissible operating pressure

-20 °C to 40 °C

max. 90 °C 25 bar

Flow

18 to 42 m3/h

Rotational speed

2 900 rev/min

5.7.1 Heat exchanger charge air cooler

Figure 14: Heat exchanger charge air cooler Table 14: Technical data of the heat exchanger charge air cooler

GOES item No

108290

Manufacturer

BOWMAN PK190

Type Performance Charge Air Flow Water Flow Heat rejection

Instructions Manual

Nitrogen Pumping Unit

Original translation, English

Version 01, [12.07.2016]

40,3 kg/min 200 l/min 100 kW

Page 57 of 182

Structure and Function N2 pump, water circuit

The drive motor has a charge air cooler. The heat energy that is generated here is administered via a heat exchanger. The heat energy accumulated is supplied for the nitrogen vaporization process.

Functional description

5.7.2 Heat exchanger Lubrication oil

Figure 15: Lubrication oil heat exchanger Table 15: Technical data of the lubrication oil heat exchanger

GOES item No,

108334

Manufacturer

FUNKE TPL 02 K 24 11

Type

3 kW

Heat duty Operating conditions Environmental temperature: Media temperature Permissible operating pressure

Page 58 of 182

-20 °C to 40 °C -196 °C to 200 °C 25 bar

Nitrogen Pumping Unit

Instructions Manual

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Structure and Function N2 pump, water circuit

Functional description

A variety of mechanical components are lubricated during operation. The lubrication oil stores heat energy in this instance, a portion of the heat energy is released to the water circuit with this heat exchanger.

5.7.3 Heat exchanger Hydraulic return

Figure 16: Hydraulic oil heat exchanger Table 16: Technical data of the hydraulic oil heat exchanger

GOES item No,

108335

Manufacturer

FUNKE TPL 02 K 16 11

Type

40 kW

Heat duty Operating conditions Environmental temperature: Media temperature Permissible operating pressure

Instructions Manual

Nitrogen Pumping Unit

Original translation, English

Version 01, [12.07.2016]

-20 °C to 40 °C -196 °C to 200 °C 25 bar

Page 59 of 182

Structure and Function N2 pump, water circuit

A number of the mechanical components are driven hydraulically. The hydraulic oil stores heat energy in this instance, a portion of the heat energy is released to the water circuit with this heat exchanger.

Functional description

5.7.4 Heat exchanger Heat load

Figure 17: Heat load heat exchanger Table 17: Technical data, heat load heat exchanger

GOES item No,

108336

Manufacturer

FUNKE TPL 02 K 80 22

Type

300 kW

Heat duty Operating conditions Environmental temperature: Media temperature Permissible operating pressure

Page 60 of 182

-20 °C to 40 °C -196 °C to 200 °C 25 bar

Nitrogen Pumping Unit

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Structure and Function N2 pump, water circuit

Functional description

Heat energy is generated here by means of a closed hydraulic circuit. The hydraulic oil stores heat energy in this instance, a portion of the heat energy is released to the water circuit with this heat exchanger.

5.7.5 Heat exchanger Engine Jacket water

Figure 18: Cooling water heat exchanger

GOES item No,

108338

Manufacturer

FUNKE TPL 02 K 30 11

Type

211 kW

Heat duty Operating conditions Environmental temperature: Media temperature Permissible operating pressure

Functional description

-20 °C to 40 °C -196 °C to 200 °C 25 bar

The drive motor is kept at the optimum operating temperature during operation using a coolant. The coolant stores heat

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Structure and Function N2 pump, water circuit

energy in this instance, a portion of the heat energy is released to the water circuit with this heat exchanger.

5.7.6 Heat exchanger Exhaust gas

Figure 19: Exhaust gas heat exchanger Table 18: Technical data of the exhaust gas heat exchanger

GOES item No,

108190

Series number Manufacturer

ENKOTHERM

Type

ASN-15-3-EG251

Performance

200 kW

Surface heat transfer

9.7 m2

Through the piping Medium

Flue gas

Mass flow

2460 kg/h

Inlet temperature

480 °C

Outlet temperature

200 °C

Maximum operating temperature

550 °C

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Structure and Function N2 pump, water circuit

Maximum operating overpressure

0.1 bar

Around the piping Medium

Water / glycol (50% / 50%)

Quantity

36300 kg/h

Volumetric flow Inlet temperature

Functional description

34.2 Bm3/h at Tmean 25 Bm3/h minimum 54.8 °C

Outlet temperature

60 °C

Max. operating temperature

110 °C

Max. operating overpressure

6 bar

The drive motor is a combustion motor according to the selfignition principle (diesel) which produces very hot exhaust gases during operation. In the exhaust gas heat exchanger, a portion of the heat energy is detracted from the exhaust air of the combustion motor and supplied to the water circuit. The exhaust gas flows through the piping here, the coolant circulates around the piping and is heated by the exhaust gas.

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Version 01, [12.07.2016] Page 63 of 182

Structure and Function N2 pump, nitrogen circuit

5.8

N2 pump, nitrogen circuit

Figure 20: Nitrogen circuit

1

Liquid nitrogen primary inflow connection

2

Liquid nitrogen return feed connection

3

Booster pump

4

Triplex pump

5

Vaporizer

6

Gaseous nitrogen transfer interface

7

Liquid nitrogen secondary inflow connection to work without boost pump

The nitrogen circuit is divided into the low pressure section (shown in gray) and high pressure (shown in red).

Functional description

Low pressure Liquid nitrogen is fed from the nitrogen tank via the inflow (20/1). The booster pump (20/3) pushes the liquid nitrogen to the triplex pump with approx. 7.5 bar (20/4). Excess liquid

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Structure and Function N2 pump, nitrogen circuit

nitrogen is returned to the nitrogen tank via the return flow (20/2).

High pressure The liquid nitrogen is applied with intense pressure in the pressure cylinders of the triplex pump (20/4) and pushed to the vaporizer (20/5) via the high pressure line. The liquid nitrogen is vaporized in the vaporizer by means of heat energy from the water circuit and heated to a temperature of 20°C. This results in a strong volume intensification (1 litre LIN = 697 litres gaseous N2) and pressure increase. The pressure by the triplex pump must be kept as high as such, that more and more liquid nitrogen is passed into the vaporizer. The now gaseous and tempered nitrogen is released via the transfer interface (20/6).

5.8.1 Booster pump

Figure 21: Booster pump Table 19: Technical data of the booster pump

Manufacturer

ACD

Type

AC18HD, 1.5 x 2.5 x 6

Serial number

Please refer passport

Operating conditions

Instructions Manual

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Version 01, [12.07.2016] Page 65 of 182

Structure and Function N2 pump, nitrogen circuit

Rotational speed

max. 4 366 rev/min

System pressure

max. 55 bar

Volumetric flow

151 l/min

5.8.2 Triplex pump

Figure 22: Triplex assembly

1

Triplex pump

2

Gear unit

3

Hydraulic drive motor for triplex pump

4

Triplex pump lubrication tank

5

Hydraulic drive motor for lubrication

6

Triplex pump lubrication pump

7

Coupling

The components two to six are omitted from the description at this point. The technical documents for these components can be found Chapter 15.5.

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Structure and Function N2 pump, nitrogen circuit

Figure 23: Triplex pump Table 20: Technical data of the triplex pump

GOES item No

108617

Manufacturer

ACD 3-GUPD

Type Series number

Please refer passport

Operating conditions Rotational speed

max. 940 rev/min

System pressure

max. 689 bar

Volumetric flow Volumetric efficiency

Functional description

121 l/min 85 %

The triplex pump receives a continuous volumetric flow of LIN from the booster pump. The liquid nitrogen is applied with increased pressure in the Fluid End (Cold End) of the triplex pump. The Fluid End must always be supplied with liquid, bubble-free nitrogen. The pressure built up by the triplex pump must always be as high as such, that liquid nitrogen is pushed into the vaporizer.

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Nitrogen Pumping Unit

Original translation, English

Version 01, [12.07.2016] Page 67 of 182

Structure and Function N2 pump, nitrogen circuit

5.8.3 Vaporizer

Figure 24: Vaporizer

1

Liquid nitrogen inlet of the triplex pump

2

Gaseous nitrogen outlet for the transfer

3

Water circuit inlet

4

Water circuit outlet

Table 21: Technical data of the vaporizer

Manufacturer

CRYOQUIP

VWP 145-10

Type

Please refer Passport

Series number Operating conditions

Page 68 of 182

Water side

10 bar at 20 - 90 °C

Nitrogen side

689 bar at -196 °C

Nitrogen Pumping Unit

Instructions Manual

Version 01, [12.07.2016]

Original translation, English

Structure and Function N2 pump, nitrogen circuit

5.8.4 Transfer interface

Figure 25: Transfer interface Table 22: Technical data of the plug valve

GOES item No,

103099 SPM

Manufacturer

1A14443

Type Operating conditions Temperature System pressure

Instructions Manual

Nitrogen Pumping Unit

Original translation, English

Version 01, [12.07.2016]

-30 °C to 110 °C max. 1 034 bar

Page 69 of 182

Structure and Function N2 pump, preheater

5.9

N2 pump, preheater

The machine is equipped with an auxiliary heater for the preheating of oil and fuel. The auxiliary heater can be found on the left side of the machine in front of the operator cabin. You will find the auxiliary heater here

Figure 26: Position of the auxiliary heater

The auxiliary heater is installed in a storage box (Figure 27/2).

2 | Fuel tank for preheater

1 | Housing with build preheater

Figure 27: Webasto storage box

The fuel tank (Figure 27/1) is situated directly above it and holds 55 litres of special “Arctic” diesel fuel.

Page 70 of 182

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Structure and Function N2 pump, preheater

Figure 28: Auxiliary heater

1

Fluid heater

2

Circulation pump auxiliary heating system

Table 23: Technical data of Spheros

GOES item No, Manufacturer Type

100201 SPEHROS 350

Table 24: Technical data of the AH circulation pump

GOES item No, Manufacturer Type

100195 SPEHROS U 4814

The fuel display is found on the front of the storage box together with the switch to switch on the auxiliary heater.

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Version 01, [12.07.2016] Page 71 of 182

Structure and Function N2 pump, preheater

Figure 29: Auxiliary heater switch

1

Tank display

2

Switch ON/OFF

3

Control light

Two manifolds for the circuits of the auxiliary heater are likewise located on the left side of the machine. These can be activated or pushed via the ball valves.

Auxiliary heater manifold

Figure 30: Auxiliary heater manifold

Page 72 of 182

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Structure and Function N2 pump, preheater

Figure 31: Auxiliary heater distributor supply

1

Hydraulic tank pre-heater circuit

2

Diesel tank pre-heater circuit

3

Lubrication oil tank pre-heater circuit

4

Motor cooling pre-heater circuit

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Original translation, English

Version 01, [12.07.2016] Page 73 of 182

Structure and Function N2 pump, connections

5.10 N2 pump, connections

4

3

1 2

Figure 32: Connections

1

Liquid nitrogen inflow

2

Liquid nitrogen return flow

3

Liquid nitrogen external inflow

4

Gaseous nitrogen outlet

The connections 1, 2 and 4 must be connected by default. Figure 32/1 illustrates the inflow connection. This connects the nitrogen tank to the nitrogen pump. The connection may only be established with the connection hose supplied and intended for this purpose. Figure 32/2 illustrates the return flow connection. This connects the nitrogen tank to the nitrogen pump. The connection may only be established with the connection hose supplied and intended for this purpose. Figure 32/4 illustrates the transfer interface. The connection must be established with the permissible high pressure iron here at the installation site.

Page 74 of 182

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Instructions Manual

Version 01, [12.07.2016]

Original translation, English

Structure and Function EMERGENCY STOP Devices

Figure 32/3 illustrates a special connection. The inflow for feeding in the liquid nitrogen can be established here without having to use the machines very own booster pump. This might be necessary if the booster pump breaks down or if a second N2 system is connected upstream.

5.11 EMERGENCY STOP Devices The safety equipment must always be fully functional and in good working order. Trained personnel are responsible and are obliged to regularly check the equipment for functionality and reliable operation. The machine must not be operated if  Part of the safety equipment is defective  Part of the safety equipment has been modified If a safety device is not in operation or is defective, then the personnel are obliged to stop the machine. Machines may only be put back into operation if all the safety equipment is fully functional again. Work on the safety equipment is only permitted when the machine is switched off, thus avoiding any hazards. Never bridge any safety equipment or make changes to the components that could lead to bridging. The safety equipment on the machine conforms to the requirements of the EC Machinery Directive.

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Original translation, English

Version 01, [12.07.2016] Page 75 of 182

Structure and Function EMERGENCY STOP Devices

The EMERGENCY STOP buttons must be triggered at least once a year for testing purposes by the responsible personnel, with the following checked for correct functioning:  Mechanical functionality  Electrical functionality  Secure mounting  Tampering and damages  Loose cable connections The machine has three EMERGENCY STOP devices in the form of buttons. Actuation is always made from RED to YELLOW.

Figure 33: EMERGENCY STOP button

If the EMERGENCY STOP button is actuated, then the electrical components / displays are disconnected from their power source and all moving parts brought to a standstill.

Page 76 of 182

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Structure and Function EMERGENCY STOP Devices

It must be ensured that the reason for such a triggering is resolved before the system is put back into operation. The EMERGENCY STOP button is then drawn out. Table 25: EMERGENCY STOP button

100778

GOES item No, Quantity

3

Contacts N/C

1

Contacts N/O

1

Protection class

IP 66

Unlocking device

Pull release

Miscellaneous

Tamper-proof in accordance with ISO 13850

5.11.1 Right EMERGENCY STOP button

Figure 34: Right EMERGENCY STOP button

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Version 01, [12.07.2016] Page 77 of 182

Structure and Function EMERGENCY STOP Devices

5.11.2 Left EMERGENCY STOP button

Figure 35: Left EMERGENCY STOP button

5.11.3 EMERGENCY STOP panel

Figure 36: EMERGENCY STOP panel

Page 78 of 182

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Structure and Function Operator Workstation

5.12 Operator Workstation

Figure 37: Operator workstation

The machine has an operator workstation. This can be found in the operator cabin. The machine is controlled and monitored from here using the console.

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Original translation, English

Version 01, [12.07.2016] Page 79 of 182

Structure and Function Cabin heating

5.13 Cabin heating The operator cabin is equipped with a cabin heating system.

1

2

Figure 38: Cabin heating

1

Toolbox with thermostat

2

Webasto air heater

Table 26: Technical data of the cabin heating system

GOES item No, Manufacturer

104179 WEBASTO Air Top Evo 3900

Type Performance

3 900 W

Operating conditions Heating medium

Page 80 of 182

Air

Nitrogen Pumping Unit

Instructions Manual

Version 01, [12.07.2016]

Original translation, English

Structure and Function Cabin heating

Fuel Environmental temperature: Miscellaneous

Functional description

Diesel -40 °C to 50 °C Fuel consumption 0.51 l/h

The cabin heating system consists of an independent hot-air unit that can be used when required. Heat energy is generated in the device by means of combustion and provided as a warm air stream using an air blower. Diesel fuel is used as a combustion medium from the Webasto main fuel tank. The exhaust gases generated are discharged outside through the cabin wall.

Instructions Manual

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Original translation, English

Version 01, [12.07.2016] Page 81 of 182

Structure and Function Operating panel

5.14 Operating panel The operating panel is found on the rear side of the N2 pump. The machine can be controlled and monitored using the operating panel. Access to the operating panel is possible both with and without an operator cabin attached.

5.14.1 Overview

Figure 39: Panel overview

1

Triplex pump controls

2

Heat load controls

3

Booster pump controls

4

Motor and system controls

Figure 40: Panel down overview

5

Exhaust diverter

6

Cool down and Readjustments

Page 82 of 182

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Structure and Function Operating panel

5.14.2 Triplex pump controls The triplex pump pushes the liquid nitrogen into the vaporizer with high pressure. The pump is controlled and monitored using this detailed area of the panel.

Figure 41: Triplex pump panel field left

Figure 41/1

1

Pressure gauge – Triplex pump lubrication oil pressure

2

Pressure gauge – Triplex pump drive charge pressure

3

Digital display – Gaseous nitrogen discharge pressure

4

Digital display – Triplex pump lube oil temperature

5

Pressure gauge – Triplex pump drive pressure

6

Digital display – Gaseous nitrogen discharge temperature

The gauge for lubrication oil shows the current pressure of the lubrication oil. The display scale is read in bar and psi. The pressure in operation should be not less than 5 bar.

Figure 41/2

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Version 01, [12.07.2016] Page 83 of 182

Structure and Function Operating panel

This gauge shows you the current supply pressure from the hydraulic pump. The display scale is read in bar and psi. The pressure in operation should be at 28 bar. The digital display for the discharge pressure shows the values of a measuring sensor. The values are given in bar and conform to the current discharge pressure of the gaseous, vaporized nitrogen at the transfer interface. The permissible overpressure in operation are 700 bar.

Figure 41/3

The digital display for the lubrication oil temperature of the triplex pump shows the values of a measuring sensor. The values are given in degrees Celsius and conform to the current lubrication oil temperature in the oil circuit. In operation should be max. 80 °C.

Figure 41/4

This gauge shows you the current drive pressure from the hydraulic drive circuit. The display scale is read in bar and psi. The pressure in operation should be max. 320 bar.

Figure 41/5

The digital display for the discharge temperature (Figure 41/6) shows the values of a measuring sensor. The values are given in degrees Celsius and conform to the current discharge temperature of the gaseous, vaporized nitrogen at the transfer interface. The temperature should be between 20 °C and 32 °C.

Figure 41/6

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Structure and Function Operating panel

Figure 42: Triplex pump panel field middle

This gauge (Figure 42/1) shows you the current overpressure from the liquid nitrogen at the fluid end and in the high pressure nitrogen circuit. The display scale is read in bar and psi. The pressure in operation should be max. 700 bar. This switch (42/2) open and close the discharge valve. With this button (42/3), the safety mechanism of the overpressure shutdown can be reset.

Instructions Manual

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Original translation, English

Version 01, [12.07.2016] Page 85 of 182

Structure and Function Operating panel

Figure 43: Triplex pump panel field right

The pump speed of the triplex pump is controlled via a hydraulic valve. Using the rotary switch (43/1) for the manual adjustable valve. The maximum rotation speed is 910 rpm. This digital display (43/2) for the Triplex pump speed shows the values of a measuring sensor. The values correspond to the pump speed in rev/min. All major production and job data are recorded in a Memograph (43/3). The display indicates the current values of the pump rate and discharge pressure. Channel Measurement 1 2

Discharge pressure Pump rate

Page 86 of 182

AMS Nummer

Sensor Pressure-sensor 0-1034bar 4-20mA, BD1502 Speed-sensor, EDD 4.303

100399 100472

Nitrogen Pumping Unit

Instructions Manual

Version 01, [12.07.2016]

Original translation, English

Structure and Function Operating panel

5.14.3 Heat load controls The heat load circuit is used to keep the temperatures constant. The hydraulic circuit is controlled and monitored via this detailed section of the panel.

Figure 44: Heat load panel field

1

Pressure gauge – coolant pressure

2

Pressure gauge – hydraulic charge pressure of the hydraulic pump

3

Pressure gauge – hydraulic pressure in the heat load circuit

4

Rotary switch – selector switch between automatic and manual control

5

Rotary switch - Hydraulic load pump control with manual adjustable valve

6

Pressure gauge – aux Pump pressure

7

Digital display – Coolant temperature

The pressure gauge (Figure 44/1) shows the current pressure of the coolant fluid. The scale can be read in bar and psi.

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Original translation, English

Version 01, [12.07.2016] Page 87 of 182

Structure and Function Operating panel

The pressure gauge (Figure 44/2) shows the current charge pressure of the hydraulic pump. The scale can be read in bar and psi. The pressure gauge (Figure 44/3) shows the current pressure in the working area of the heat load circuit. The scale can be read in bar and psi. You can select the control mode with the rotary switch (Figure 44/4. Select the AUTO control mode, the hydraulic circuit is automatically controlled so that the temperature within the water circuit is kept constant. This is set as such, that the discharge temperature of the gaseous nitrogen at the transfer interface is 20°C. Select the MANUAL control mode, the temperature can then be controlled independently of the Automatic mode. This is carried out using the rotary switches: Load pump (Figure 44/5). The pump speed of the heat load pump is controlled in the manual adjustable valve using the rotary switch (Figure 44/5). This digital display (Figure 44/7) shows the values of a measuring sensor. The values correspond to the temperature in the water circuit in ° C.

Page 88 of 182

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Version 01, [12.07.2016]

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Structure and Function Operating panel

5.14.4 Boost pump controls

Figure 45: Boost pump panel field

1

Pressure gauge – pressure of the liquid nitrogen through the boost pump

2

Potentiometer – adjusts the speed of the boost pump

The liquid nitrogen is continuously fed to the triplex pump using the boost pump. The pressure gauge (Figure 45/1) shows the current delivery pressure of the boost pump. The pressure can be manually regulated. This is done by using the Potentiometer BOOST PUMP SPEED CONTROL (Figure 45/2).

Instructions Manual

Nitrogen Pumping Unit

Original translation, English

Version 01, [12.07.2016] Page 89 of 182

Structure and Function Operating panel

5.14.5 Motor and system controls

Figure 46: Motor and system control panel field

1

EMERGENCY STOP button

2

IDLE SPEED switch for the drive motor

3

System key / ignition key

4

Display – motor functions

5

Operating hours counter

6

Digital display – hydraulic oil temperature

7

Fuel Display

8

ON / OFF switch – working lights of the machine

9

ON / OFF switch – panel lights

10

Alarm LED – batteries charging

11

Alarm LED – return flow filter contaminated

12

Alarm LED – suction filter contaminated

13

Alarm LED – oil change

Page 90 of 182

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Instructions Manual

Version 01, [12.07.2016]

Original translation, English

Structure and Function Operating panel

The EMERGENCY STOP switch (Figure 46/1) disconnects all electrical components of the machine from the power supply when actuated. All moving components are stopped. See chapter 5.11 for more information about the emergency shutdown. The rotary switch (Figure 46/2) sets the engine speed back to idle speed. The IGNITION ignition lock (Figure 46/3) is used to protect against unauthorized operation of the machine. The drive motor cannot be started without the appropriate ignition key. The Motor Display (Figure 46/4) shows the different motor settings (speed, temperature ...). For more information look at the supplier documentation. The WORKING HOUR counter (Figure 46/5) shows the accumulated operating hours of the machine. The Display HYD. OIL TEMP: (Figure 46/6) shows the current temperature of the hydraulic oil. The FUEL indicator (Figure 46/7) shows the current reserve of fuel in the container tank of the machine. The work lamps of the machine can be switched on and off with the WORK LIGHTS switch (Figure 46/8). The lighting of the control panel can be switched on and off with the PANEL LIGHTS switch (Figure 46/9). The BATTERIES status (Figure 46/10) shows the charging current to the battery. This LED lights up when the alternator not supplies the necessary charging current for the machine. The red RETURN FILTER alarm (Figure 46/11) lights up when the return flow filters are contaminated. The red SUCTION FILTER alarm (Figure 46/12) lights up when the suction filters are contaminated. The red CHANGE OIL alarm (Figure 46/13) lights up when the oil pressure is too low or the oil filters are contaminated.

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Version 01, [12.07.2016] Page 91 of 182

Structure and Function Operating panel

Figure 47: Panel detail Volvo Penta

The green START button starts the drive motor. The red STOP button stops the drive motor. With the plus and minus button the speed of the drive motor is controlled. On the right site of the digital control panel you can switch with the up and down arrow the displayed function. There is also the possibility of setup settings.

5.14.6 Readjustments and cool down

Figure 48: Readjustments and cool down

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Structure and Function Operating panel

1

RAPID COOL DOWN Valve

2

METERING Valve

3

HIGH PRESSURE BLEED

4

RECIRCULATION Valve

5

TEMPERING Valve

6

HIGH PRESSURE RECIRCULATION Valve

The RAPID COOL DOWN Valve open or close the pipe to the outlet point. This will be used by the cool down process. The METERING Valve controls flow through vent ports on the cold ends. This will be used by the cool down process.

If the pressure of the gaseous nitrogen at the transfer interface is too high, then this can be readjusted manually using the valve HIGH PRESSURE BLEED. Open this valve to release the pressure.

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Version 01, [12.07.2016] Page 93 of 182

Structure and Function Operating panel

The return flow of the nitrogen to the nitrogen tank can be manually controlled using the recirculation valve

If the temperature of the gaseous nitrogen at the transfer interface is too high, then this can be readjusted manually using this valve. Open this valve so that additional liquid nitrogen is supplied so that the temperature can then be lowered.

The high pressure recirculation valve is used during cool down prodedure.

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Structure and Function Operating panel

5.14.7 Exhaust gas control

Figure 49: Exhaust gas control

The bypass flapper valve to the exhaust gas heat exchanger can be opened or closed via a control lever Process description

Instructions Manual

Nitrogen Pumping Unit

Original translation, English

Version 01, [12.07.2016] Page 95 of 182

Assembly / Commissioning Operating panel

6

Assembly / Commissioning

Assembly

Assembly of the machine Nitrogen Pumping Unit is carried out by the manufacturer’s employees. Assembly by the operator is not required.

Commissioning

“Commissioning” here refers to the initial commissioning of the machine in accordance with the current normative and legal definition. Commissioning of the machine is carried out by the manufacturer’s employees. As part of commissioning, the Nitrogen Pumping Unit machine has been   

set up calibrated tested

The test results can be found in the Full Application Test (FAT).

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Version 01, [12.07.2016] Page 97 of 182

Delivery and Transport Safety

7

Delivery and Transport

7.1

Safety DANGER

Fatal injuries due to falling machines / machine parts / loads  Never place yourself under raised loads.  Do not enter danger zones or swivelling ranges and immediately leave these as quickly as possible.  Communicate with crane drivers or accompanying persons.  Wear personal protective equipment. WARNING Vehicles in motion  Never move within vehicle or transport routes without addressing the drivers of vehicles or cranes or draw clear attention to yourself.  Wear a high visibility vest so that you are easily recognisable. WARNING Squeezing / crushing of body and limbs  Never position your moving body or parts thereof between machines / vehicles if these are moving towards each other.  Keep a sufficient safety distance.  Wear personal protective equipment.

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Version 01, [12.07.2016] Page 99 of 182

Delivery and Transport Delivery

7.2

Delivery

Delivery is not made by the manufacturer. The manufacturer’s employees prepare the machine for transport and make it available on the factory premises. Delivery and transport to the installation site is the responsibility of the operator.

7.3

Transport

7.3.1 Personnel Transport work on or with the machine may only be carried out by authorized and sufficiently qualified personnel (see chapter 3.6).

7.3.2 Preparation In principle, the Nitrogen Pumping Unit machine may only be transported in a "dry" state, so without operating materials, auxiliary materials or process materials. Transport with operational, processing and auxiliary materials may be a violation of national or international provisions of road and freight transport. 

  

Check the filling levels of the tanks and vessels. If the storage tanks have to be emptied before transport, then this must be done in accordance with the national valid working, operational safety and environmental protection guidelines. All moving parts must be fixed. Accessory parts must be stored safely for transport. Secure cabin doors against unintentional opening.

If moving away from the principle of “Transport in a dry state”, then it is the responsibility of the operator to implement all necessary measures and identification signs on the machine, which are necessary for safe transport in compliance with the national legislation.

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Delivery and Transport Transport

7.3.3 Nitrogen skid Transport the liquid nitrogen in the tank, thus the excess tank pressure is kept lower than the permissible operating pressure. Transport valve

A relief valve is installed for the transport in this instance (V-20, Road Relief Valve global). This is controlled by a Regulator Valve (R-1) which is factory set at 160 mbar.

Figure 50: Transport Valve

1

Valve V-20

2

Valve R-1

Valve settings for transport: 1. 2.

Close all valves Open valve V-20

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Version 01, [12.07.2016] Page 101 of 182

Delivery and Transport Transport

7.3.4 Departure check WARNING Unretracted supports If the supports are still extended during the movement, then they might come into contact with the floor and lead to the trailer toppling.  Retract and secure supports. WARNING Unsecured crank Crank can swing out during transport and injure people.  Lock crank into place and secure.

Carry out an examination of the following points before starting each journey. Resolve any arising defects immediately.      

Inspection

Are the on-board documents in place? Does the vehicle conform to the conditions and loads given? Is the maximum permissible total weight? Do the lighting and signalling devices work? Do the tires have the specified corresponding air pressure? Is the vehicle marked in accordance with the national or international provisions for the transport of hazardous goods?

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Storage Transport

8

Storage

If the machine is not intended for immediate operation or if the machine is out of operation for a long time, then it must be stored in a dry, well-ventilated site with a low relative humidity. Large temperature deviations at the site of storage must be avoided. Nitrogen skid A residual amount of nitrogen should be left in the nitrogen tank if it is decommissioned for an extended amount of time. This is necessary to prevent any moisture from penetrating. The Nitrogen Pumping Unit machine may only be stored in a "dry" state, so without operating materials, auxiliary materials or process materials. Storage with operational, processing and auxiliary materials may be a violation of national or international provisions. Depressurize all pressurized components, check lines and hoses of the pneumatic and hydraulic systems. Clean motors, pumps, lines, hoses and containers. Also read and follow the instructions from the supplier with reference to the topic of storage. These documents can be found in the Supplier Documentation chapter and in the annex.

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Version 01, [12.07.2016] Page 103 of 182

Installation Conditions Installation site

9

Installation Conditions

9.1

Safety WARNING

Squeezing / crushing of body and limbs  Never position your moving body or parts thereof between machines / vehicles if these are moving towards each other.  Keep a sufficient safety distance.  Wear personal protective equipment. WARNING Vehicles in motion  Never move within vehicle or transport routes without addressing the drivers of vehicles or cranes or draw clear attention to yourself.  Wear a high visibility vest so that you are easily recognisable. CAUTION Wedging of the feet between the supports and floor  

9.2

Keep a sufficient safety distance to the supports. Wear safety shoes

Installation site

The N2 Skid as machine is not constructed and licensed for offshore and explosive areas. It is prohibit to install or operate the Nitrogen Pumping Unit in these areas. If the machine is operated in a system network, then the machine must be installed in accordance with the installation plan.

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Version 01, [12.07.2016] Page 105 of 182

Installation Conditions Substrate

9.3

Substrate

A level and secure working platform must be in place to ensure safe operation of the machine. The maximum capacity of the installation area must be observed. If there is no fixed working platform in place, then the floor space must be as compressed as such, that the stability should be at least sufficient under normal operating conditions. A deviation of more than three degrees to the horizontal is not permitted.

9.4

Attachment

The machine can be set up freely, fastening or anchoring to the substrate is not required. The machine must be set up horizontally. Use a spirit level in this case (not included as part of delivery). 

9.5

Secure the machine so it can’t roll away.

Connections

Connect the connections of the machine described in Chapter 2.5 and Chapter 5.10 with the interfaces / lines. This must only be carried out by personnel trained especially for it.

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Operation Filling the nitrogen tank

10 Operation 10.1 Safety 10.2 Filling the nitrogen tank DANGER Loss of consciousness and suffocation due to nitrogen Evaporating nitrogen displaces oxygen in the breathing air and leads to loss of consciousness and death due to suffocation without prior physical warning signs.   

Prevent nitrogen from escaping Only carry out filling outside or in well-ventilated areas with special extraction equipment Use warning apparatus / oxygen monitor WARNING

Cryogenic burns due to extremely cold media Contact with extremely cold media leads to cyrogenic burning of the skin, eyes, with a risk of blinding, and the respiratory tract.  Avoid any contact 

Do not touch piping, lines or containers



Wear specialist personal protective equipment when handling extremely cold media

Also read and follow the operating instructions / maintenance instructions of the manufacturer of such components. The documents are listed in Chapter 15.2 Supplier Documentation.

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Version 01, [12.07.2016] Page 107 of 182

Operation Filling the nitrogen tank

10.2.1 Valve overview

Figure 51: Valve overview nitrogen tank

This overview shows the circuit diagram of the valves on the nitrogen tank. The next picture show you the valve list. You also find both plates in front on the nitrogen tank.

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Operation Filling the nitrogen tank

Figure 52: Valve list nitrogen tank

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Version 01, [12.07.2016] Page 109 of 182

Operation Filling the nitrogen tank

10.2.2 Preparation 1.

2.

3.

4. 5.

The nitrogen tank can only be filled by personnel who have been especially trained and instructed to carry out this task. Make sure that the working area is kept free of obstacles, that the delivery vehicle has a secure access route. The emergency routes must be kept clear. Make sure that the type and data plates are present on the tank, well legible and match the certificates of the inspection organization / designated body. Make sure that the time period for the latest tank inspection period has not been exceeded.

Check before filling

Inspect the nitrogen skid, the nitrogen tank and the safety-relevant components before you start the filling process. The nitrogen tank may only be filled if all criteria listed have been complied with (see chapter 12.3).

10.2.3 Initial filling New nitrogen tanks and nitrogen tanks, which have been stored for extended periods, must have a residual amount of nitrogen and a low pressure in the internal container. This is necessary to prevent any moisture from penetrating. These tanks must be flushed with nitrogen before initial filling. The internal tank must not be colder than the boiling point of liquid nitrogen in this case (-195.79 °C). The liquid nitrogen can freeze if filled into a tank that is too cold. This results in incalculable pressure ratios and entails a high risk. The nitrogen tank is warm during the initial filling.  After the container has been filled with liquid nitrogen, open the gas exhaust valve (V4) and the cock valve (V3) or (V15) to thoroughly cool down the container.  Close the gas exhaust valve (V4) and the cock valve (V3 or V15) after the container has cooled down.

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Original translation, English

Operation Filling the nitrogen tank

10.2.4 Filling The nitrogen tank can be filled form above or from below with separate fill lines. A filling from abow is to prefer. Maximum filling quantity should not be more than 200 l per minute Monitor the pressure in the tank during the filling process. The primary safety valves are set to the maximum working pressure. The external filling pressure must therefore be set lower to prevent any unnecessary venting through the relief valve. The nitrogen tank has fill connections in the rear and the front. For more information see the valve schema plate on the tank.

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Operation Cool down

10.3 Cool down Some preliminary work is required before you can pump nitrogen with the machine. In particular, some components need to be cooled down.

10.3.1 General inspections 1.

Inspect  All water levels on the machine.  All oil levels on the machine.  Visual inspections for damages to the nitrogen tank and nitrogen pump  Visual inspection for leakages on components, lines and conduits.

2.

Check the hose connections between the nitrogen tank and nitrogen pump for damages. Check proper connection (see also Chapter 5.10 N2 pump, connections). All valves must be closed.

Flow out Return flow

Figure 53: Tank connections

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Operation Cool down

Inflow

Return flow

Figure 54: N2 pump connections

10.3.2 Reducing the overpressure Reduce any excess pressure within the nitrogen tank. 1.

Open valve V-3 (vent) for this.

Figure 55: Pressure reduction valve

2.

Observe the pressure gauge on the nitrogen tank.

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Operation Cool down

Figure 56: Pressure gauge

3.

Close the valve again if the excess pressure within the nitrogen tank has reached a value of less than 0.2 bar.

10.3.3 Starting the drive motor The N2 pump machine has a main switch for the electrical power supply. This battery master switch can be found on the left side of the N2 pump in front of the preheater-toolbox.

Figure 57:Battery master switch

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Operation Cool down

1.

Turn the battery master switch on the system to I.  The power supply for the machine is now activated.

2. 3.

Enter the operator cabin. Insert the ignition key into the ignition lock and turn the ignition key in the ignition lock to position I.  The control panel is now unlocked.

4.

Press the green START button on the engine control panel and keep it pressed down until the drive motor starts.

If the drive motor still doesn’t start after 10 seconds, then the process must be stopped to prevent damages to the starter system. Repeat the process after a break of 20 seconds. 5.

Set the speed of the motor using the

buttons.

All hydraulic drives and components are not in operation for the first 10 seconds after motor start. This serves to ensure a un-load motor start. After this 10 seconds all components ready for use.

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Operation Cool down

10.3.4 Building up admission pressure The liquid nitrogen in the nitrogen tank must be applied with an overpressure of 1.5 - 2.0 bar for the further processing. The nitrogen tank has its own vaporizer for this operational function that is activated. 1. 2.

Check that all valves are closed. Open valve V-4 (pressure build) on the nitrogen skid.

Figure 58: Valve N2-Tank vaporizer

3.

Observe the pressure gauge on the nitrogen tank.

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Operation Cool down

Figure 59: N2-Tank pressure gauge

4.

Set the admission valve by incremental opening / closing valve V-4 (pressure build) so that the admission pressure is kept constant. This process may have to be repeated during the subsequent preparatory work and the operation.

10.3.5 Boost pump A part of the low-pressure circuit and the boost pump must be prepared as soon as the desired admission pressure is present in the nitrogen tank. The following figure shows the area coloured in blue.

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Operation Cool down

Figure 60: Cool down boost pump Figure reference table 60

PRIMARY INLET VALVE SECONDARY INLET VALVE BOOST PUMP ISOLATION VALVE RAPID COOL DOWN VALVE RECIRCULATION VALVE METERING VALVE Discharge outlet

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Operation Cool down

Table 27: Cool down boost pump

1. Check that the METERING VALVE is closed. This valve is found on the operator panel and can be actuated from the operator cabin.

2. Check that the SECONDARY INLET VALVE is closed. This valve can be found on the right side in front of the operator cabin and must be actuated externally.

3. Check that the BOOST PUMP ISOLATION is open. This valve can be found on the right side in front of the operator cabin and must be actuated externally.

4. Open the valve V-6 for the outflow at the nitrogen tank. You find this valve on the right side on the nitrogen tank (viewing direction from the cabin). It must be actuated externally.

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Operation Cool down

5. Open the PRIMARY INLET VALVE. This valve can be found on the right side in front of the operator cabin. It can be actuated from the operator cabin about a push rod.

You find the grip of the push rod on the right site of the operator cabin under the window.

6. Open the RECIRCULATION VALVE. This valve is found on the operator panel and can be actuated from the operator cabin.

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Operation Cool down

7. Open the RAPID COOL DOWN VALVE. This valve is found on the operator panel and can be actuated from the operator cabin.

As soon as the RAPID COOL DOWN VALVE is opened, liquid nitrogen flows into the low pressure circuit of the N2 pump from the nitrogen tank. The liquid nitrogen very quickly absorbs heat energy and vaporizes. In this instance, the pipe lines and components / boost pump are intensely cooled – recognizable by the frost formation. The gaseous nitrogen is discharged into the environment via the pipeline. The outlet point is found on the left side in front of the operator cabin.

This procedure must be carried out until the nitrogen at the outlet point passes from gas into liquid. The boost pump can only pump liquid media.

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Operation Cool down

In the meantime, test whether the boost pump already has liquid nitrogen flowing through it. For this purpose, carefully actuate the BOOST PUMP SPEED CONTROL rotary switch (Figure 45/2) on the control panel and observe the LN2 BOOST PRESSURE gauge (Figure 45/1). The boost pump is ready for use as soon as a constant pressure is maintained.

10.3.6 High-pressure pump The circuit switches to the high-pressure pump as soon as the low-pressure circuit and the boost pump are prepared. The high pressure pump has a "warm" Power End and a "cold" Fluid End working area. The Fluid End area must be cooled down before operation of the pump. The following figure shows the area coloured in blue.

Figure 61: Cool down triplex

METERING VALVE Cool end of the high pressure pump

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Operation Cool down

1. Open the METERING VALVE. This valve is found on the operator panel and can be actuated from the operator cabin.

2. Pay attention to the Fluid End of the high pressure pump. The cylinder should exhibit a build up of frost after a short while.

3. Switch on the high pressure pump at minimum speed (max. 20 rev/min) using the TRIPLEX SPEED ADJUST rotary switch as soon as the first formation of frost is present.

This procedure must be carried out until the nitrogen at the outlet point passes from gas into liquid.

Although described in two sub-points in this manual, the "Boost pump" and "High pressure pump" steps can also be completed in parallel.

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Operation Pumping nitrogen

10.3.7 Return flow The return flow to the nitrogen tank is established once the lowpressure circuit has cooled down (liquid nitrogen is blown out of the outlet point). Only liquid nitrogen is conveyed back into the tank via the return flow line.

1. Open the bypass valve V-12 below the main valve. 2. Close the bypass valve once again as soon as liquid nitrogen emerges at the valve outlet.

3. Open the valve V-1 for the return flow at the nitrogen tank incrementally. The reflux volume flow into the tank must be adjusted to the operating conditions here.

Cooling down and preparation of the N2 pump is thus completed. The N2 pump is now ready for operation.

10.4 Pumping nitrogen Discharge quantity, pressure and temperature of the nitrogen intended for pumping are variables, which are defined and determined by the customer. This is implemented using programming at the N2 pump.

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Operation Pumping nitrogen

1. Set the motor speed to the desired rotational speed using the using the buttons Boost Pump 5 – 7.5 bar

2.

3.

Read off feed pressure of the boost pump using the LN2 BOOST PRESSURE gauge. Set the speed of the boost pump with the BOOST PUMP SPEED CONTROL rotary switch. The feed pressure of the boost pump should amount to approx. 5 – 7.5 bar.

High pressure pump max. 910 rev/min max. 689 bar

4. Triggering the high pressure pump. The speed of the triplex pump is set via the TRIPLEX SPEED ADJUST rotary switch and can be read off from the TRIPLEX SPEED digital display over the rotary switch. The maximum permissible rotational speed is 910 rev/min.

5. The pressure in the highpressure circuit generated by the high-pressure pump can be read off from the LN2 DISCHARGE PRESSURE gauge. The max. permissible pressure is 689 bar.

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Operation Pumping nitrogen

6. The temperature of the warm water circuit can be read off in the COOLANT TEMP digital display. The machine features an Automatic mode to keep the water temperature constant and sufficiently high enough to vaporize the liquid nitrogen. The temperature can be manually controlled if necessary. In order to do so, switch from AUTO to MANUAL. The rotational speed of the hydraulic pump can now be increased using the HYDRAULIC LOAD CONTROL rotary switch.

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Operation Pumping nitrogen

7. The temperature of the vaporized nitrogen at the transfer interface is displayed in the GN2 DISCHARGE TEMP. digital display. If this is too high, then liquid nitrogen can be directly added by opening the TEMPERING VALVE.

8. Switch the DISCHARGE VALVE switch to OPEN to open the transfer valve at the discharge interface.

9. All relevant job data where displayed and record in a memograph.

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Operation Take out of operation

10.5 Take out of operation 1. Switch the DISCHARGE VALVE switch to CLOSE to close the transfer valve at the discharge interface.

2. Turn the TRIPLEX SPEED ADJUST rotary switch fully to the left. The high-pressure pump drive is therefore switched off. The current speed in the TRIPLEX SPEED digital display is at “0”.

3. Turn the BOOST PUMP SPEED CONTROL rotary switch fully to the left. The boost pump drive is therefore switched off. The display in the LN2 BOOST PRESSURE gauge drops to "0".

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Operation Take out of operation

4. Using the buttons on the Volvo display to turn the motor to idling speed. A second option is to use the idle speed switch in the motorpanel-section.

5. Close the flow valve V-6 at the nitrogen tank

6. Close the PRIMARY INLET VALVE on the N2 Pump.

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Operation Take out of operation

7. Open the HIGH PRESSURE BLEED valve. Thus, the remaining pressure in the pipe system is released.

8. The other three bleed vales must be open externally. You find them on the right site in front of the cabin. The bleed valve are try cocks, one each in the  primary inline  secondary inline  outline

9. Close the return flow valve V-1 at the nitrogen tank

10. Press the STOP button on the Volvo display. The motor is switched off.

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Operation Operation after Emergency Stop

11. Turn the ignition key in the IGNITION ignition lock to “0” and remove.

10.6 Operation after Emergency Stop In order to re-commission the system after an EMERGENCY STOP, it must be first ensured that the cause, which lead to the EMERGENCY STOP, has been remedied. All actuated EMERGENCY STOP switches must be reset to their initial position. Each activation of the emergency stop button leads causes that the Emergency air shut-off valve (also called Rig saver) closed and the drive engine stops. The Rig Saver must be reopened manually. For this you can find on the right side of the machine, at the drive engine cooler, a bowden.

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Operation Operation after a Prolonged Downtime

Bowden

To reopen pull the sling down.

10.7 Operation after a Prolonged Downtime Verify the following points when re-commissioning the machine after a prolonged downtime:    

All liquids must be inspected (cooler, motor, gear unit, hydraulics). All hoses must be checked for leaks. The the motor oil must be changed. The battery must be recharged or replaced if necessary

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Operation Miscellaneous.

10.8 Miscellaneous. 10.8.1 Operation with cabin heating

1 2

Figure 62: Operation with cabin heating

1

Thermostat and ON/OFF switch

2

Webasto Air Top

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Operation Miscellaneous.

The operator cabin can be warmed up with the auxiliary heater if the temperatures are low. Preparation Check the level in the diesel tank. The cabin heating uses the same fuel tank as the Preheater. Switching on the heating 1. 2. 3.

4. 5.

Switch on the heating with the rotary switch. The blower runs at low speed. The fuel transportation system is automatically activated after approx. 60 seconds and the air-fuel mixture in the combustion chamber ignited. The heating system now runs in normal mode. Set the desired heating power with the rotary switch.

The maximum heating capacity (POWER) is available after approx. three minutes. Switching off the heating 1. Turn the rotational switch to position 0 The fuel transportation system is automatically switched off The blower runs to dissipate the residual heat from the device

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Operation Miscellaneous.

10.8.2 Operation with preheating Preheating may be necessary using the auxiliary heater for temperatures of < 5 °C. Auxiliary heater 1.

2. 3. 4.

Check the filling level of the fuel storage tank and fill up with fuel (diesel) if necessary. The fuel storage tank can be found directly above the storage box of the auxiliary heater. Turn the rotary switch to the right. The heater is now ignited. The yellow indicator light lights up. The auxiliary heater is now ready for use.

Switching the circuit The liquid heated in the auxiliary heater is distributed to four circuits via a distributor.    

Hydraulic tank circuit Motor cooling circuit Diesel tank circuit Lubrication oil tank circuit

You will also find the distributor (one for forerun, one for return) and ball valves of the respective circuits to open / close here.

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Faults and Troubleshooting Drive motor

11 Faults and Troubleshooting 11.1 Drive motor Fault Cause Rectification

Motor does not start  Air intake shutoff valve closed  Check that the rig saver is open.  Inspection and Maintenance Chapter  Supplier Documentation

Fault

Alarm LED for oil pressure lights up on the control panel

Cause

 Too little motor oil present in the lubrication circuit  Lubrication oil pump does not build up enough pressure  Pressure sensor defect  Water in the lubrication oil

Rectification

 Check the motor oil filling level.  If the filling level is normal, then inform the service personnel.  Inspection and Maintenance Chapter  Supplier Documentation

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Faults and Troubleshooting Filters

11.2 Filters Fault

Alarm LED for suction filters lights up on the control panel

Cause

 The filter elements of the suction filters are contaminated.

Rectification

 Check the machine’s suction filters  Change the filter inserts of the suction filters.  Inspection and Maintenance Chapter  Supplier Documentation

Fault Cause

Rectification

Alarm LED for return flow filter lights up on the control panel  The filter elements of the return flow filters are contaminated.  Check the machine’s return flow filters.  Change the filter inserts of the return flow filters.  Inspection and Maintenance Chapter  Supplier Documentation

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Faults and Troubleshooting Battery

11.3 Battery Fault

Cause

Rectification

Status LED of the battery lights up on the control panel  The charge level of the battery is not functioning properly.  The charging current is too low  The battery acid level is abnormal.  Check the battery acid level.  Check the charging current to the battery  Inspection and Maintenance Chapter  Supplier Documentation

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Faults and Troubleshooting Exhaust gas heat exchanger

11.4 Exhaust gas heat exchanger ATTENTION Damage due to overheating Immediate switch-off leads to overheating damages to the exhaust gas heat exchanger.  Carry out circulation with the minimum flow rate for at least 15 minutes.

Table 28: Exhaust gas heat exchanger troubleshooting

Fault Cause

Rectification

Decreasing performance  Waterside contamination  Exhaust gas side contamination  Check waterside and clean if necessary  Check exhaust air side and clean if necessary  Inspection and Maintenance Chapter  Supplier Documentation

Fault

Cause Rectification

Increasing loss of pressure on the water side  Increased flow rate  Check circulation and pumps  Supplier Documentation

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Faults and Troubleshooting Exhaust gas heat exchanger

Fault

Cause Rectification

Increasing loss of pressure on the water side  Waterside contamination  Check waterside and clean if necessary  Inspection and Maintenance Chapter  Supplier Documentation

Fault

Cause Rectification

Increasing loss of pressure on the exhaust gas side  Increased flow rate  Check circulation  Check opening of a bypass  Check modifications to the installation  Supplier Documentation

Fault

Cause Rectification

Increasing loss of pressure on the exhaust gas side  Exhaust gas side contamination  Pipes blocked  Check exhaust air side and clean if necessary  Inspection and Maintenance Chapter  Supplier Documentation

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Faults and Troubleshooting Exhaust gas heat exchanger

Fault Cause Rectification

Water discharge at the condensate  Tube weldings on the shell side leaky  Decommission the system  Inform the manufacturer  Inspection and Maintenance Chapter  Supplier Documentation

Fault Cause Rectification

Flange and tube connections leaky  Seal defect  Replace seal  Inspection and Maintenance Chapter  Supplier Documentation

Fault Cause Rectification

Flange and tube connections leaky  Screw connections loose  Tighten screw connections  Inspection and Maintenance Chapter  Supplier Documentation

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Faults and Troubleshooting Plate heat exchanger

11.5 Plate heat exchanger Table 29: Faults plate heat exchanger

Fault

Declining plate heat exchanger capacity

Cause

 Calcium deposits or similar encrustations in the heat exchanger.

Rectification

 Cleaning of the plate heat exchanger through rinsing  Cleaning of the plate heat exchanger through rinsing with chemicals  Inspection and Maintenance Chapter  Supplier Documentation

The operating mode has a significant influence on the level of contamination and the service life of the plate heat exchanger. The media should be operated with the highest possible volume flow (according to the device specification) if possible. If the volume flow is too low or in the case of partial load operation, turbulence in the plate heat exchanger may decrease while the contamination tendency is greater. In the case of operating temperatures of more than 60 °C, calcium deposits will result dependant on the quality of the water. These reduce heat transfer efficiency.

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Inspection and Maintenance Plate heat exchanger

12 Inspection and Maintenance Maintenance is a part of the servicing process. Servicing is regulated by the standards DIN 31051 and DIN EN 13306. Delimitation

Inspection

Maintenance

This chapter solely focuses on inspection and maintenance. Repair and overhaul is not referred to in this manual. Inspection activities shall be performed by the site’s inspection team. These actions are carried out to determine the actual condition of a defined unit with a particular focus on proper, technically flawless operation, so that any hazards when the unit in question is used can be avoided during normal usage. All measures to delay the depletion of the wear reserves present in the reference unit are understood to be maintenance measures. These shall be employed on a machine during it’s entire service life. Maintenance must be undertaken by specialist personnel trained according to the technical regulations or manufacturer provisions at regular intervals. Maintenance shall include for example:     

readjustment lubrication preserving the refilling or replacing of operating materials or consumables (e.g. fuel, lubrication or water) the scheduled replacement of basic wear parts (e.g. filters or seals).

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Inspection and Maintenance Plate heat exchanger

The following does not belong to maintenance:  

Exchange or replacement of defective parts (this belongs to repair) Cleaning works (this must be carried out at the discretion of the operator or owner)

The operator of the machine must document the maintenance and compliance of the maintenance intervals in a suitable manner:  



Maintenance protocol

For purposes of safeguarding and quality assurance. For reasons of occupational safety and health, where failure of technical systems due to inadequate maintenance or non-compliance with maintenance intervals can lead to irreversible physical damage to human life and health. For reasons of environmental protection, where failure of technical systems due to inadequate maintenance or non-compliance with maintenance intervals can lead to irreversible damage to the environment.

In addition, the installation operator must observe the respective national laws, legislation and provisions valid for the installation site (e.g. the BetrSichV (Ordinance on Industrial Safety and Health) and ProdSG (Product Safety Law) in Germany). Inspection and Maintenance Intervals The values indicated are indicative and are dependent on the individual operating conditions. The operator of the system must adjust the inspection and maintenance intervals to the current operating conditions if necessary.

Intervals

The complete overview and significance of the interval definitions can be found in Chapter 2.2.4.

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Inspection and Maintenance Safety

12.1 Safety DANGER Loss of consciousness and suffocation due to nitrogen Evaporating nitrogen displaces oxygen in the breathing air and leads to loss of consciousness and death due to suffocation without prior physical warning signs.  Prevent nitrogen from escaping  Ensure a sufficient fresh air supply  Carry a warning device WARNING Automatic start-up  Make sure that the machine is switched off  Make sure that the machine is not accidentally switched on WARNING Danger due to pressurized components Components and media of the hydraulics, pneumatics, cooling system and functional circuits are pressurized. They can penetrate the skin, body and eyes.  Switch all systems an circuits into a depressurised state and discharge before you begin work.  Wear personal protective equipment. WARNING Cryogenic burns due to extremely cold media Contact with extremely cold media leads to cyrogenic burning of the skin, eyes with a risk of blinding and the respiratory tract.  Avoid any contact  Do not touch piping, lines or containers  Wear specialist personal protective equipment when handling extremely cold media

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Inspection and Maintenance Safety

WARNING Poisoning due to swallowing or intake of aerosol Consumables, operating materials and process materials may be toxic if swallowed or inhaled.  Avoid direct or indirect contact  Do not breathe in vapours  Wear personal protective equipment. CAUTION Head injuries in the working area Machine components and assemblies can protrude into the working area and thus come into contact with you.  Work with caution and pay attention to components that protrude into the working area  Wear personal protective equipment. CAUTION Risk of falling in the machine room You may stumble over components, pipes and lines. Working areas can be slippery.  Please enter these areas with caution and ensure firm support when you move around in them  Clean working areas  Keep working paths free CAUTION Sensitization Breathing in aerosols and skin contact with consumables, operating and process materials leads to sensitization.  Avoid any direct or indirect contact  Wear personal protective equipment.  Immediately change contaminated clothing  Clean and rinse any affected skin parts

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Inspection and Maintenance Nitrogen skid

CAUTION Burns due to hot surfaces Touching hot surfaces leads to burns and adverse reactions.  Switch off the machine and allow it to cool down.  Wear personal protective equipment.

12.2 Truck All information about inspection and maintenance can be found in the manual of the truck. The operator of the system must adjust the inspection and maintenance intervals to the present operating conditions if necessary. Read and follow the operating instructions / maintenance instructions of the manufacturer of such components. The documents can be found in the Chapter Supplier Documentation.

12.3 Nitrogen skid The values indicated are indicative and are dependent on the individual operating conditions. The operator of the system must adjust the inspection and maintenance intervals to the present operating conditions if necessary. Also read and follow the operating instructions / maintenance instructions of the manufacturer of such supplied components. The documents can be found in the Chapter 15.2 Supplier Documentation.

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Inspection and Maintenance Nitrogen skid

12.3.1 Before each operation Maintenance activities / inspection Table 30: Nitrogen skid – before each operation

Interval

Before each operation

Activity

W020

Check

Check external tank

W020

Check

Check frost and ice formation

W020

Check

Check overpressure valve

W020

Check

Dents or other damages visible

W020

Check

Check gauge function

W020

Check

Operation of the valves

W020

Check

Check safety valves

W020

Check

Check overpressure valves

W020

Check

Check relief valves

W020

Check

Check connection hoses

Required for the maintenance Small auxiliary materials

No tools, auxiliary aids or third persons are required.

Implementation of the maintenance / inspection DANGER Loss of consciousness and suffocation due to nitrogen Evaporating nitrogen displaces oxygen in the breathing air and leads to loss of consciousness and death due to suffocation without prior physical warning signs.  Prevent nitrogen from escaping  Ensure a sufficient fresh air supply  Carry a oxygen deficiency warning device

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Inspection and Maintenance Nitrogen skid

WARNING Cryogenic burns due to extremely cold media Contact with extremely cold media leads to cyrogenic burning of the skin, eyes, with a risk of blinding, and the respiratory tract.  Avoid any contact  Do not touch piping, lines or containers  Wear specialist personal protective equipment when handling extremely cold media 1. 2.

The external tank must not show any signs of moisture. The external tank must not show any signs of frost formation 3. Ice and frost formation on direct-flow pipelines is normal. All other ice and frost formations must be immediately reported to a responsible person. 4. Check the overpressure valve. There must be no emerging gas. Any escaping gas indicates an internal leak and must be immediately reported to a responsible person. 5. Check the tank for dents or other damages that may indicate a possible fault or hazard. 6. Check the gauges for function. Immediate replacement measures should be initiated if the gauges do not function. 7. Check that the valves open, operate and can be closed again. Immediate replacement measures should be initiated if the valves do not function correctly. 8. Check the safety valves. These must be free of ice, contamination or other obstacles. Immediate replacement measures should be initiated if the safety valves are not in proper working order. 9. Overpressure valves may vent at regular intervals under normal operating conditions. Continuous venting indicates damage and must be immediately reported to a responsible person. 10. Relief valves must not leak at low nominal pressure. 11. Connection hoses or lines may not exhibit any thread damage or other damages.

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Inspection and Maintenance Pump unit

12. Connection hoses or lines must be kept free from contamination, oil, grease and water. Repairs to cryogenic containers may only be carried out by personnel who are trained and certified to do so. Any unauthorized repairs will terminate the operating licence or certification.

12.3.2 Inspection after 2.5 years The tank must be subjected to a periodic inspection every 2.5 years. This includes a leakage test and a check of all service equipment. The inspection methods used can be determined by the component authority or the testing organization commissioned.

12.3.3 Inspection after 5 years The tank must be subjected to a periodic test and inspection every 5 years. The internal and external tank must be pressure tested separately in this instance, including a completely new risk assessment and certification. The operator is responsible for carrying out inspections (after 2.5 years, after 5 years). The certification for the nitrogen tank / the nitrogen skid shall be voided if these inspections are not carried out. Operation of the nitrogen pump with a non-certified nitrogen tank is prohibited.

12.4 Pump unit 12.4.1 Drive motor The values indicated are indicative and are dependent on the individual operating conditions. The operator of the system must adjust the inspection and maintenance intervals to the current operating conditions if necessary.

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Inspection and Maintenance Pump unit

Also read and follow the operating instructions / maintenance instructions of the manufacturer of such components. The documents can be found in the Chapter Supplier Documentation. Daily maintenance Daily / before each operation

Table 31: Drive motor maintenance – daily

Interval

Activity

W020

Check

Check motor oil and coolant level

W020

Check

General visual inspections

W020

Check

Check air filter contamination display

W020

Check

Check dust discharge valve

W020

Check

Check fuel filter / water separator pan

W020

Check

Check connection hoses

As required As required

Table 32: Drive motor maintenance – as required

Interval

Activity

W000

Change

Replace air filter inserts

W000

Vent

Vent the fuel system

W000

Change

Replace three-phase alternator and fan belts

W000

Check

Check fuses

W000

Check

Check air compressors (if present)

W000

Check

Check rear PTO (if present)

W000

Change

Replace air pre-filter inserts, if the contamination display shows a negative pressure of 625 mm (25 in.) Water column indication

After the first 100 operating hours

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Table 33: Drive motor maintenance – after 100 OH

Interval B040

After the first 100 OH

Activity Change

Change the oil and filters for the first time after a maximum of 100 operating hours during the running-in period of the motor

Every 500 operating hours Table 34: Drive motor maintenance – every 500 OH

Interval

Every 500 Oh

Activity

B060

Check

Service fire extinguisher

B060

Check

Service the battery

B060

Change

Change the motor oil

B060

Change

Replace motor oil filter

B060

Check

Check foam filter of the water pumps-water drainage bore

B060

Change

Replace fuel filter

B060

Clean

Clean water separator

B060

Check

Check motor speed

B060

Check

Check the attachment parts of the motor

B060

Clean

Clean the ventilation hose and ventilation valve of the crankcase

B060

Check

Check air intake hose, connections and system

B060

Check

Check motor ground connection

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Inspection and Maintenance Pump unit

Interval

Activity

B060

Check

Check automatic belt tensioner and belt wear

B060

Check

Check the cooling system

B060

Adjust; check

Carry out a coolant analysis; add supplemental coolant additives (SCAs) if necessary

B060

Check

Pressure test of the cooling system

Every 2000 operating hours Every 2000 Oh

Table 35: Drive motor maintenance – every 2000 OH

Interval

Activity

B100

Check

Check crankshaft vibration dampers

B100

Check

Flush and refill cooling system

B100

Check

Check the thermostats

Every 2500 operating hours Every 2500 Oh

Table 36: Drive motor maintenance – every 2500 OH

Interval B110

Activity Adjust; check

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Adjust the motor valve clearance and pretension of the electronic injector unit

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Inspection and Maintenance Heating circuit

12.5 Heating circuit 12.5.1 Exhaust gas heat exchanger The values indicated are indicative and are dependent on the individual operating conditions. The operator of the machine must adjust the inspection and maintenance intervals to the current operating conditions if necessary. Also read and follow the operating instructions / maintenance instructions of the manufacturer of such components. The documents can be found in the Chapter Supplier Documentation.

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Daily maintenance Table 37: Exhaust gas heat exchanger maintenance – daily

Interval W020

Daily

Activity Check

Check all flange and pipe connections and rectify leakages

Monthly maintenance Table 38: Exhaust gas heat exchanger maintenance – monthly

Interval

Monthly

Activity

W050

Check

Check all flange and pipe connections and rectify leakages

W050

Check

Check safety equipment (pressure and temperature limiter, safety valves, flow controller or water level limiter) for functionality

W050

Check

Check inner side of the hot tube plate (water side) via endoscope socket or discharge opening for formation of deposits

W050

Clean

Clean the water side if deposits have formed (chemically)

W050

Check

Check values of the circuit water (see circuit water requirements)

W050

Check; clean Check the water side for sludge formation and flush if necessary

W050

Check; clean Check heating surfaces on the exhaust gas side for coatings or deposits and clean if necessary

W050

Check

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Check steam traps for correct function

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Maintenance every 6 months Every 6 months

Table 39: Exhaust gas heat exchanger maintenance – every 6 months

Interval

Activity

W070

Check

Temperature displays functional test via comparison measurement

W070

Check

Value check on the water side; values must comply with the requirements for the properties and condition of the circuit water

W070

Check

Check formation of deposits and sludge on the water side via endoscope socket

12.5.2 Plate heat exchanger The values indicated are indicative and are dependent on the individual operating conditions. The operator of the machine must adjust the inspection and maintenance intervals to the current operating conditions if necessary. Also read and follow the operating instructions / maintenance instructions of the manufacturer of such components. The documents can be found in the Chapter Supplier Documentation.

As required As required

Table 40: Plate heat exchanger – as required

Interval W000

Activity Clean

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Flush plate heat exchanger (with chemicals should it be necessary) to eliminate calcium deposits and encrustations

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Inspection and Maintenance Heating circuit

Required for the maintenance

Acid-based cleaning agents

Phosphoric acid  Concentration max. 2%  Temperature max. 20 °C  Exposure time approx. 1 hour

or

Lye-based cleaning agents

Caustic soda  Concentration max. 4%  Temperature 85 °C  Exposure time 24 hours

Implementation of the maintenance If there is contamination or formation of deposits in the flow gaps due to the water or media quality, then the plate heat exchanger must be rinsed out. This takes place – if possible – in reverse flow, i.e. against the actual direction of flow. Only carry out all cleaning work with chloride-free or lowchloride water of low hardness and then flush with plenty of water until the acid is completely rinsed off the plate heat exchanger and the adjacent pipelines. If chemicals are used for cleaning, then these may not affect the materials of the plate heat exchanger nor the lines or components or the machine. The plate heat exchanger will be destroyed if these notes aren't observed. The safety regulations and recommendation of the cleaning agent manufacturer must be strictly observed in this instance.

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Decommissioning Safety

13 Decommissioning Information about how to definitively decommission the machine, to dismantle the machine and to dispose of the machine can be found in this chapter.

13.1 Safety DANGER Fatal injuries due to falling machines / machine parts / loads  Never place yourself under raised loads.  Do not enter danger zones or swivelling ranges and immediately leave these as quickly as possible.  Communicate with crane drivers or accompanying persons.  Wear personal protective equipment. DANGER Loss of consciousness and suffocation due to nitrogen Evaporating nitrogen displaces oxygen in the breathing air and leads to loss of consciousness and death due to suffocation without prior physical warning signs.  Prevent nitrogen from escaping  Ensure a sufficient fresh air supply  Carry a warning device WARNING Vehicles in motion  Never move within vehicle or transport routes without addressing the drivers of vehicles or cranes or draw clear attention to yourself.  Wear a high visibility vest so that you are easily recognisable.

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WARNING Poisoning due to swallowing or intake of aerosol Consumables, operating materials and process materials may be toxic if swallowed or inhaled.  Avoid direct or indirect contact  Do not breathe in vapours  Wear personal protective equipment. WARNING Danger due to pressurized components Components and media of the hydraulics, pneumatics, cooling system and function circuits are pressurized. They can penetrate the skin, body and eyes.  Switch all systems and circuits into a depressurised state and discharge before you begin work.  Wear personal protective equipment. WARNING Squeezing / crushing of body and limbs  Never position your moving body or parts thereof between machines / vehicles if these are moving towards each other.  Keep a sufficient safety distance.  Wear personal protective equipment. CAUTION Sensitization due to skin contact or intake of aerosol    

Avoid any direct or indirect contact Wear personal protective equipment. Immediately change contaminated clothing Clean and rinse any affected skin parts

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Decommissioning Disassembly

CAUTION Spinal damage Lifting and carrying heavy loads leads to spinal damage.  Use technical aids and hoisting gear ATTENTION Environmental damage Improper or reckless handling of environmentally hazardous substances can result in serious environmental damages.  Ensure careful handling of the hazardous substances with environmental awareness.  Read the information and observe the Material Safety Data Sheets

13.2 Disassembly Disassembly must only be performed by specialist personnel. The national provisions for the disassembly of machines must be observed (operational approvals, deposition equipment, etc.) Before you begin with the disassembly     

Turn off electronic circuits Depressurize the hydraulic circuits Depressurize the pneumatic circuits Depressurize the process circuits Ensure sufficiently sized containers to collect liquids.

Empty all containers and pipes (residual emptying) of fuel, oils, hydraulic oils, cooling liquids and other processing materials. Collect materials separately in the containers provided especially for them. Residual amounts of nitrogen in containers and lines must be vaporized in compliance with the relevant safety regulations. Make sure that the nitrogen can not accumulate in hollows or sink into drainage systems. Rinse the containers, lines and components before disassembly if necessary. Carrying out unclean disassembly and break-

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Decommissioning Disposal

down procedures such as cutting, separating and sawing can lead to fires or explosions. Secure components and assemblies before removing connections. Lift heavy machine parts using appropriate means and lifting equipment. Observe national safety and environmental requirements

13.3 Disposal Dispose of hazardous or contaminated substances in the designated collection points. Separate recyclable material in accordance with the valid provisions and recycling targets.

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Additional Documents Manufacturer’s Certificate

14 Additional Documents 14.1 Manufacturer’s Certificate 14.1.1 Device pass The Device pass of the manufacturer for the Nitrogen Pumping Unit machine can be found in it’s original translation, English and Russian language, and in paper format in the main documentation under chapter 01 Unit / 1.1 Passport. The Device pass of the manufacturer for the Nitrogen Pumping Unit machine can be found as an electronic document – in the form of a PDF file – on the CD supplied and can be accessed via this link: Open documents folder

14.1.2 Certificate of Conformity The Certificate of Conformity of the manufacturer for the Nitrogen Pumping Unit machine can be found in it’s original translation, English and Russian language and in paper format in the main documentation under chapter 01 Unit / 1.4 Certificates. The Certificate of Conformity of the manufacturer for the Nitrogen Pumping Unit machine can be found as an electronic document – in the form of a PDF file – on the CD supplied and can be accessed via this link: Open documents folder

14.1.3 Certificate of Origin The Certificate of Origin of the manufacturer for the Nitrogen Pumping Unit machine can be found in it’s original translation, English and Russian language and in paper format in the main documentation under chapter 01 Unit / 1.4 Certificates.

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The Certificate of Origin of the manufacturer for the Nitrogen Pumping Unit machine can be found as an electronic document – in the form of a PDF file – on the CD supplied and can be accessed via this link: Open documents folder

14.1.4 Certificate of Warranty The Certificate of Warranty of the manufacturer for the Nitrogen Pumping Unit machine can be found in it’s original translation, English and Russian language and in paper format in the main documentation under chapter 01 Unit / 1.4 Certificates. The Certificate of Warranty of the manufacturer for the Nitrogen Pumping Unit machine can be found as an electronic document – in the form of a PDF file – on the CD supplied and can be accessed via this link: Open documents folder

14.1.5 Full Application Test The machine has been set-up, calibrated and tested on a test stand upon commissioning by employees of the manufacturer. The results can be found in their original translation, English and Russian language and in paper format in the main documentation under chapter 01 Unit / 1.3 Test report. The Full Application Test (FAT) of the manufacturer can be found as an electronic document – in the form of a PDF file – on the CD supplied and can be accessed via this link: Open documents folder

14.2 Machine Structure 14.2.1 Overall drawing The Overall drawing of the manufacturer for the Nitrogen Pumping Unit machine can be found in it’s original translation,

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Additional Documents Hydraulics

English and Russian language and in paper format in the main documentation under chapter 01 Unit / 1.2 drawings. The Overall drawing of the manufacturer for the Nitrogen Pumping Unit machine can be found as an electronic document – in the form of a PDF file – on the CD supplied and can be accessed via this link: Open documents folder

14.2.2 Construction BOM The Construction BOM of the manufacturer for the Nitrogen Pumping Unit machine can be found in it’s original translation, English and Russian language and in paper format in the main documentation under chapter 01 Unit / 1.2 Drawings. The Construction BOM of the manufacturer for the Nitrogen Pumping Unit machine can be found as an electronic document – in the form of a PDF file – on the CD supplied and can be accessed via this link: Open documents folder

14.3 Hydraulics 14.3.1 Hydraulic plan The Hydraulic plan of the manufacturer for the Nitrogen Pumping Unit machine can be found in it’s original translation, English and Russian language and in paper format in the main documentation under chapter 04_Hydraulic System\4.1 Hydraulic System Diagram. The Hydraulic plan of the manufacturer for the Nitrogen Pumping Unit machine can be found as an electronic document – in the form of a PDF file – on the CD supplied and can be accessed via this link: Open documents folder

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14.3.2 Hydraulics BOM The Hydraulics BOM of the manufacturer for the Nitrogen Pumping Unit machine can be found in it’s original translation, English and Russian language and in paper format in the main documentation under chapter 04_Hydraulic System\4.2 Hydraulic System Parts List. The Hydraulics BOM of the manufacturer for the Nitrogen Pumping Unit machine can be found as an electronic document – in the form of a PDF file – on the CD supplied and can be accessed via this link: Open documents folder

14.4 Electronics 14.4.1 Electronics plan The Electronics plan of the manufacturer for the Nitrogen Pumping Unit machine can be found in it’s original translation, English and Russian language and in paper format in the main documentation under chapter 05_Electric System\5.1 Electrical System Diagram. The Electronics plan of the manufacturer for the Nitrogen Pumping Unit machine can be found as an electronic document – in the form of a PDF file – on the CD supplied and can be accessed via this link: Open documents folder

14.4.2 Electronics BOM The Electronics BOM of the manufacturer for the Nitrogen Pumping Unit machine can be found in it’s original translation, English and Russian language and in paper format in the main documentation under chapter 05_Electric System\5.1 Electrical System Parts List. The Electronics BOM of the manufacturer for the Nitrogen Pumping Unit machine can be found as an electronic document

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Additional Documents Flow chart

– in the form of a PDF file – on the CD supplied and can be accessed via this link: Open documents folder

14.5 Flow chart 14.5.1 Heat recovery circuit The flow chart for the Heat recovery circuit of the Nitrogen Pumping Unit machine can be found in it’s original translation, English and Russian language and in paper format in the main documentation under chapter 07_Heating circuit\7.1 Heat Recocery Circuit Diagram. The flow chart for the Heat recovery circuit of the Nitrogen Pumping Unit machine can be found as an electronic document – in the form of a PDF file – on the CD supplied and can be accessed via this link: Open documents folder

14.5.2 Heat recovery circuit BOM The Heat recovery circuit BOM of the manufacturer for the Nitrogen Pumping Unit machine can be found in it’s original translation, English and Russian language and in paper format in the main documentation under chapter 07_Heating circuit\7.2 Heat Recovery Circuit Parts List. The Heat recovery circuit BOM of the manufacturer for the Nitrogen Pumping Unit machine can be found as an electronic document – in the form of a PDF file – on the CD supplied and can be accessed via this link: Open documents folder

14.5.3 Nitrogen circuit The flow chart for the Nitrogen circuit of the Nitrogen Pumping Unit machine can be found in it’s original translation, English and Russian language and in paper format in the main

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Additional Documents Flow chart

documentation under chapter 03_Flow System\3.1_Flow System Diagram. The flow chart for the Nitrogen circuit of the Nitrogen Pumping Unit machine can be found as an electronic document – in the form of a PDF file – on the CD supplied and can be accessed via this link: Open documents folder

14.5.4 Nitrogen circuit BOM The Nitrogen circuit BOM of the manufacturer for the Nitrogen Pumping Unit machine can be found in it’s original translation, English and Russian language and in paper format in the main documentation under chapter 03_Flow System\3.2_Flow System Parts List. The Nitrogen circuit BOM of the manufacturer for the Nitrogen Pumping Unit machine can be found as an electronic document – in the form of a PDF file – on the CD supplied and can be accessed via this link: Open documents folder

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Supplier Documentation N2 pump, drive

15 Supplier Documentation 15.1 Truck The operating instructions / service manual of the supplier for the Truck can be found in their original, English version and in paper format in the main documentation under chapter 2 Main Parts / 2.1 Chassis. The operating instructions / service manual of the supplier for the Truck can be found as an electronic document – in the form of a PDF file – on the CD supplied. If the media is inserted into a CD ROM drive, then the instructions can be opened using this link: Open supplier documentation for the Truck English, Russian

15.2 Nitrogen Tank Skid The operating instructions / service manual of the supplier for the Nitrogen Tank Skid can be found in their original, English version and in paper format in the main documentation under chapter 02_Main Parts\2.2_2000 Gallon Tank. The operating instructions / service manual of the supplier for the Nitrogen Tank Skid can be found as an electronic document – in the form of a PDF file – on the CD supplied. If the media is inserted into a CD ROM drive, then the instructions can be opened using this link: Open supplier documentation for the Nitrogen Tank Skid

15.3 N2 pump, drive 15.3.1 Drive motor The operating instructions / service manual of the manufacturer for the component Drive motor can be found in their original

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Supplier Documentation N2 pump, drive

version and in paper format in the main documentation under chapter 02_Main Parts\2.3_Deck Engine. These documents can also be found as an electronic document – in the form of a PDF file – on the CD supplied. If the media is inserted into a CD ROM drive, then the documentation can be opened using this link: Open supplier documentation for the Drive motor.

15.3.2 Pump distributor gearbox The operating instructions / service manual of the manufacturer for the component Pump distributor gearbox can be found in their original version and in paper format in the main documentation under chapter 04_Hydraulic System\4.3 Hydraulic System Parts Manual\4.3.4 Hydraulic Pump Drive. These documents can also be found as an electronic document – in the form of a PDF file – on the CD supplied. If the media is inserted into a CD ROM drive, then the documentation can be opened using this link: Open supplier documentation for the Pump distributor gearbox.

15.3.3 Hydraulic pump S90 The operating instructions / service manual of the manufacturer for the component Hydraulic pump S90 can be found in their original version and in paper format in the main documentation under chapter 04_Hydraulic System\4.3 Hydraulic System Parts Manual\4.3.1 Hydraulic Pump. These documents can also be found as an electronic document – in the form of a PDF file – on the CD supplied. If the media is inserted into a CD ROM drive, then the documentation can be opened using this link: Open supplier documentation for the Hydraulic pump S90.

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Supplier Documentation N2 pump, water circuit

15.3.4 Hydraulic pump S45 The operating instructions / service manual of the manufacturer for the component Hydraulic pump S45 can be found in their original version and in paper format in the main documentation under chapter 04_Hydraulic System\4.3 Hydraulic System Parts Manual\4.3.1 Hydraulic Pump. These documents can also be found as an electronic document – in the form of a PDF file – on the CD supplied. If the media is inserted into a CD ROM drive, then the documentation can be opened using this link: Open supplier documentation for the Hydraulic pump S45:

15.4 N2 pump, water circuit 15.4.1 Circulation pump The operating instructions / service manual of the manufacturer for the component Circulation pump can be found in their original version and in paper format in the main documentation under chapter 07_Heating circuit\7.3 Heat Recovery Circuit Parts Manual\7.3.5 Segmental Pump. These documents can also be found as an electronic document – in the form of a PDF file – on the CD supplied. If the media is inserted into a CD ROM drive, then the documentation can be opened using this link: Open supplier documentation for the Circulation pump.

15.4.2 Charge air cooler heat exchanger The operating instructions / service manual of the manufacturer for the component Charge air cooler heat exchanger can be found in their original version and in paper format in the main documentation under chapter 07_Heating circuit\7.3 Heat Recovery Circuit Parts Manual\7.3.2 Hydraulic Oil Cooler.

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Supplier Documentation N2 pump, water circuit

These documents can also be found as an electronic document – in the form of a PDF file – on the CD supplied. If the media is inserted into a CD ROM drive, then the documentation can be opened using this link: Open supplier documentation for the Charge air cooler heat exchanger.

15.4.3 Plate heat exchanger The operating instructions / service manual of the manufacturer for the component Plate heat exchanger can be found in their original version and in paper format in the main documentation under chapter 07_Heating circuit\7.3 Heat Recovery Circuit Parts Manual\7.3.3 Brazend Plate Heat Exchangers. These documents can also be found as an electronic document – in the form of a PDF file – on the CD supplied. If the media is inserted into a CD ROM drive, then the documentation can be opened using this link: Open supplier documentation for the Plate heat exchanger.

15.4.4 Exhaust gas heat exchanger The operating instructions / service manual of the manufacturer for the component Exhaust gas heat exchanger can be found in their original version and in paper format in the main documentation under chapter 07_Heating circuit\7.3 Heat Recovery Circuit Parts Manual\7.3.1 Exhaust Gas Heat Exchanger. These documents can also be found as an electronic document – in the form of a PDF file – on the CD supplied. If the media is inserted into a CD ROM drive, then the documentation can be opened using this link: Open supplier documentation for the Exhaust gas heat exchanger.

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Supplier Documentation N2 pump, nitrogen circuit

15.5 N2 pump, nitrogen circuit 15.5.1 Booster pump The operating instructions / service manual of the manufacturer for the component Booster pump can be found in their original version and in paper format in the main documentation under chapter 03_Flow System\3.3_Flow System Parts Manual. These documents can also be found as an electronic document – in the form of a PDF file – on the CD supplied. If the media is inserted into a CD ROM drive, then the documentation can be opened using this link: Open supplier documentation for the Booster pump

15.5.2 Triplex pump The operating instructions / service manual of the manufacturer for the component Triplex pump can be found in their original version and in paper format in the main documentation under chapter 03_Flow System\3.3_Flow System Parts Manual. These documents can also be found as an electronic document – in the form of a PDF file – on the CD supplied. If the media is inserted into a CD ROM drive, then the documentation can be opened using this link: Open supplier documentation for the Triplex pump.

15.5.3 Gearbox The operating instructions / service manual of the manufacturer for the component Gearbox can be found in their original version and in paper format in the main documentation under chapter 02_Main Parts\2.4_Triplexpump. These documents can also be found as an electronic document – in the form of a PDF file – on the CD supplied. If the media is inserted into a CD ROM drive, then the documentation can be opened using this link:

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Open supplier documentation for the Gearbox.

15.5.4 Hydraulic motor The operating instructions / service manual of the manufacturer for the component Hydraulic motor can be found in their original version and in paper format in the main documentation under chapter 04_Hydraulic System\4.3 Hydraulic System Parts Manual\4.3.3 Hydraulic Motor. These documents can also be found as an electronic document – in the form of a PDF file – on the CD supplied. If the media is inserted into a CD ROM drive, then the documentation can be opened using this link: Open supplier documentation for the Hydraulic motor.

15.5.5 Vaporizer The operating instructions / service manual of the manufacturer for the component Vaporizer can be found in their original version and in paper format in the main documentation under chapter 03_Flow System\3.3_Flow System Parts Manual. These documents can also be found as an electronic document – in the form of a PDF file – on the CD supplied. If the media is inserted into a CD ROM drive, then the documentation can be opened using this link: Open supplier documentation for the Vaporizer.

15.5.6 Plug valve The operating instructions / service manual of the manufacturer for the component Plug valve can be found in their original version and in paper format in the main documentation under chapter 03_Flow System\3.3_Flow System Parts Manual\3.3.5 Valves. These documents can also be found as an electronic document – in the form of a PDF file – on the CD supplied.

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Supplier Documentation Control system components

If the media is inserted into a CD ROM drive, then the documentation can be opened using this link: Open supplier documentation for the Plug valve.

15.6 Cabin heating The operating instructions / service manual of the manufacturer for the component Cabin heating can be found in their original version and in paper format in the main documentation under chapter 02_Main Parts\2.1_Chassis. These documents can also be found as an electronic document – in the form of a PDF file – on the CD supplied. If the media is inserted into a CD ROM drive, then the documentation can be opened using this link: Open supplier documentation for the Cabin heating.

15.7 Electric components The operating instructions / service manual of the manufacturer for the component Electric components can be found in their original version and in paper format in the main documentation under chapter 05_Electric System\5.3 Electrical System Parts Manual. These documents can also be found as an electronic document – in the form of a PDF file – on the CD supplied. If the media is inserted into a CD ROM drive, then the documentation can be opened using this link: Open supplier documentation for the Electric components.

15.8 Control system components The operating instructions / service manual of the manufacturer for the component Control system components can be found in their original version and in paper format in the main

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Supplier Documentation Control system components

documentation under chapter 05_Electric System\5.3 Electrical System Parts Manual. These documents can also be found as an electronic document – in the form of a PDF file – on the CD supplied. If the media is inserted into a CD ROM drive, then the documentation can be opened using this link: Open supplier documentation for the Control system components.

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Annex List of Figures

16 Annex 16.1 List of Figures Figure 1: Side Definition ........................................................... 43 Figure 2: Off-road-truck ............................................................ 45 Figure 3: Twistlock ................................................................... 46 Figure 4: Nitrogen skid ............................................................. 47 Figure 5: Container corner with twistlock ................................. 48 Figure 6: N2 pump, frame ........................................................ 49 Figure 7: Container corner with N2 skid twistlock .................... 50 Figure 8: N2 pump, drive ......................................................... 51 Figure 9: Drive motor ............................................................... 52 Figure 10: Pump distributor gearbox ........................................ 53 Figure 11: Hydraulic pump S90 ............................................... 54 Figure 12: Hydraulic pump S45 ............................................... 55 Figure 13: Water circuit circulation pump ................................. 56 Figure 14: Heat exchanger charge air cooler ........................... 57 Figure 15: Lubrication oil heat exchanger ................................ 58 Figure 16: Hydraulic oil heat exchanger .................................. 59 Figure 17: Heat load heat exchanger ....................................... 60 Figure 18: Cooling water heat exchanger ................................ 61 Figure 19: Exhaust gas heat exchanger .................................. 62 Figure 20: Nitrogen circuit ........................................................ 64 Figure 21: Booster pump ......................................................... 65 Figure 22: Triplex assembly ..................................................... 66 Figure 23: Triplex pump ........................................................... 67 Figure 24: Vaporizer ................................................................ 68 Figure 25: Transfer interface .................................................... 69 Figure 26: Position of the auxiliary heater ................................ 70 Figure 27: Webasto storage box .............................................. 70 Figure 28: Auxiliary heater ....................................................... 71 Figure 29: Auxiliary heater switch ............................................ 72 Figure 30: Auxiliary heater manifold ........................................ 72 Figure 31: Auxiliary heater distributor supply ........................... 73 Figure 32: Connections ............................................................ 74 Figure 33: EMERGENCY STOP button ................................... 76 Figure 34: Right EMERGENCY STOP button ......................... 77 Figure 35: Left EMERGENCY STOP button ............................ 78 Figure 36: EMERGENCY STOP panel .................................... 78 Figure 37: Operator workstation .............................................. 79

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Annex List of Figures

Figure 38: Cabin heating ......................................................... 80 Figure 39: Panel overview ....................................................... 82 Figure 40: Panel down overview ............................................. 82 Figure 41: Triplex pump panel field left ................................... 83 Figure 42: Triplex pump panel field middle ............................. 85 Figure 43: Triplex pump panel field right ................................. 86 Figure 44: Heat load panel field .............................................. 87 Figure 45: Boost pump panel field........................................... 89 Figure 46: Motor and system control panel field ..................... 90 Figure 47: Panel detail Volvo Penta ........................................ 92 Figure 48: Readjustments and cool down ............................... 92 Figure 49: Exhaust gas control................................................ 95 Figure 50: Transport Valve .................................................... 101 Figure 51: Valve overview nitrogen tank ............................... 108 Figure 52: Valve list nitrogen tank ......................................... 109 Figure 53: Tank connections ................................................. 112 Figure 54: N2 pump connections .......................................... 113 Figure 55: Pressure reduction valve ...................................... 113 Figure 56: Pressure gauge .................................................... 114 Figure 57:Battery master switch ............................................ 114 Figure 58: Valve N2-Tank vaporizer...................................... 116 Figure 59: N2-Tank pressure gauge ..................................... 117 Figure 60: Cool down boost pump ........................................ 118 Figure 61: Cool down triplex.................................................. 122 Figure 62: Operation with cabin heating ................................ 133

Page 180 of 182

Nitrogen Pumping Unit

Instructions Manual

Version 01, [12.07.2016]

Original translation, English

Annex Table Headings

16.2 Table Headings Table 1: Scope of delivery ......................................................... 9 Table 2: Inspection and Maintenance Intervals ....................... 13 Table 3: Interfaces ................................................................... 18 Table 4: Personnel Qualification .............................................. 30 Table 5: Technical data of the product ..................................... 41 Table 6: Technical data Off-road-truck .................................... 45 Table 7: Technological data of the nitrogen skid ..................... 47 Table 8: Technical data of the N2 pump, frame ....................... 49 Table 9: Technical data of the drive motor ............................... 52 Table 10: Technical data of the pump distributor gearbox ....... 53 Table 11: Technical data of the hydraulic pump S90 ............... 54 Table 12: Technical data of the hydraulic pump S45 ............... 55 Table 13: Technical data of the circulation pump .................... 56 Table 14: Technical data of the heat exchanger charge air cooler ....................................................................................... 57 Table 15: Technical data of the lubrication oil heat exchanger 58 Table 16: Technical data of the hydraulic oil heat exchanger .. 59 Table 17: Technical data, heat load heat exchanger ............... 60 Table 18: Technical data of the exhaust gas heat exchanger.. 62 Table 19: Technical data of the booster pump ......................... 65 Table 20: Technical data of the triplex pump ........................... 67 Table 21: Technical data of the vaporizer ................................ 68 Table 22: Technical data of the plug valve .............................. 69 Table 23: Technical data of Spheros ....................................... 71 Table 24: Technical data of the AH circulation pump............... 71 Table 25: EMERGENCY STOP button .................................... 77 Table 26: Technical data of the cabin heating system ............. 80 Table 27: Cool down boost pump .......................................... 119 Table 28: Exhaust gas heat exchanger troubleshooting ........ 140 Table 29: Faults plate heat exchanger ................................... 143 Table 30: Nitrogen skid – before each operation ................... 150 Table 31: Drive motor maintenance – daily ........................... 153 Table 32: Drive motor maintenance – as required ................. 153 Table 33: Drive motor maintenance – after 100 OH .............. 154 Table 34: Drive motor maintenance – every 500 OH ............. 154 Table 35: Drive motor maintenance – every 2000 OH ........... 155 Table 36: Drive motor maintenance – every 2500 OH ........... 155 Table 37: Exhaust gas heat exchanger maintenance – daily 157 Table 38: Exhaust gas heat exchanger maintenance – monthly ............................................................................................... 157

Instructions Manual

Nitrogen Pumping Unit

Original translation, English

Version 01, [12.07.2016] Page 181 of 182

Annex Table Headings

Table 39: Exhaust gas heat exchanger maintenance – every 6 months................................................................................... 158 Table 40: Plate heat exchanger – as required ...................... 158

Page 182 of 182

Nitrogen Pumping Unit

Instructions Manual

Version 01, [12.07.2016]

Original translation, English