Vol 1 - Operation Maintenance Manual

OPEN 180K NITROGEN UNIT
SERIAL NUMBER J15177001
ASSET No. 12220042
VOLUME 1 – OPERATION AND MAINTENANCE

OP 999
Halliburton Open 180K Nitrogen Unit
Operation and Maintenance – Volume 1
CONTENTS
1.0 Introduction
1.1. General Use

1.2. Unit Introduction
1.3. NOV Hydra Rig UK Terms & Conditions
2.0 Safety
2.1. Liquid Nitrogen

2.1.1. Exposure to Cool Temperatures
2.1.2. Personnel Equipment
2.1.3. Liquid to Gas Expansion
2.2. Gaseous Nitrogen
2.3. Operating Safety
2.4. Safety Precaution
2.5. Rules and Regulations

2.5.1. Daily activities
2.5.2. Transport/Installation
2.6. Atex
2.7. General Safety

2.7.1. Warning Icons
2.7.2. Restriction Icons
2.7.3. Responsibilities
2.8. General Safety Instructions

2.8.1. Chemical hazards/Hot surfaces
-Responsibilities
2.8.2. Noise hazards
-Responsibilities
2.8.3. Respiratory hazards
-Responsibilities
2.8.4. Eye hazards
-Responsibilities
2.8.5. Electrical hazards
-Responsibilities
2.8.6. Mechanical hazards
-Responsibilities
Halliburton Asset No. 12220042 Page 1 of 4

Open 180K Nitrogen Unit J15177001
OP 999
2.8.7. Lubricant Hazards

-Handling
2.9. Injury Treatment
2.9.1. Injured or trapped body parts
2.9.2. Inhalation problems
2.9.3. Burns
2.9.4. Acid spills
2.9.5. Eye damage
2.10. Lift Safety

2.10.1. General
2.10.2. Specific Safety Precautions
2.10.3. Technical Specifications
3.0 Definitions of Terms
3.1. Definition of Technical Terms
4.0 System Outline
4.1. Scope of Supply

4.2. Description of Major Components
4.2.1. Instrumentation and Controls
4.2.2. Cryogenic Piping
4.2.3. Special Features
4.2.4. Painting/Corrosion Protection
4.2.5. Documentation and Manuals
4.2.6. Testing
4.3. General Description
4.4. Component Actions
4.5. Controls and Indicators
4.5.1. Engine Control and Indicators
4.5.2. Nitrogen Pumping Controls and Indicators
4.5.3. Heat Load Controls
4.5.4. Boost Pump Controls
4.5.5. Engine Controls
4.6. Circuit Description
4.6.1. Water Circuit
4.6.2. Hydraulic Circuit
4.6.3. Nitrogen Circuit
4.6.4. High Nitrogen Overpressure Shutdown

OP 999
4.7. SOS 3g Engine Protection System (where applicable)

4.7.1. Technical Data
4.7.2. System Outline
4.7.3. Shutdown Operation
4.7.4. Stopping the Engine
4.7.5. Safety Over-temperature or Low Oil Pressure Shutdown
4.7.6. Safety Over-speed Shutdown
4.7.7. Emergency Shutdown
4.7.8. Reset after Shutdown
4.8. Pump Speed v Nitrogen Flow
5.0 Operating, Start-up & Stopping Procedures -
5.1. Introduction
5.2. Before Starting Engine
5.3. Inter Unit Connection
5.4. Start-up and Operating Procedures
5.5. Stopping the System
5.6. Engine Safety System Shutdowns
5.7. Final Rig Down
6.0 Maintenance and Troubleshooting
6.1. Introduction
6.2. Inspection
6.3. Unit Maintenance
6.4. Unit Cleaning
6.5. Compressor Maintenance
6.6. Maintenance Drive Belts
6.7. Maintenance Safety Valves
6.8. Maintenance Lifting Equipment
6.9. Maintenance Frame
6.10. Maintenance Hydraulics
6.11. Maintenance Pneumatics
6.12. Maintenance Electrical System
6.13. Engine Maintenance
6.14. Nitrogen Unit Troubleshooting Guide
6.15. Hydraulic Troubleshooting
6.16. SOS 3g System Maintenance
6.17. Oils & Filters

OP 999
7.0 Drawings & Schematics
7.1. Schematic Coolant N2 CAT 3406 Open Frame 2NE090398

7.2. Schematic Hydraulic 180K CAT 3406 2NE090346
7.3. Schematic Nitrogen Open Frame CAT 3406 2NE090348
7.4. Schematic Pneumatic 180K Open Frame CAT 3406 2NE090245
7.5. Schematic Fuel Caterpillar 3406 2CD190020
7.6. Schematic Electric 180K CAT 3406 MC11 2NB090013
7.7. Control Panel Assembly - 2NS020075
8.0 Parts Identification
8.1. Parts Identification & Function Hydraulic

8.2. Parts Identification & Function Coolant
8.3. Parts Identification & Function Pneumatic
8.4. Parts Identification & Function Nitrogen
9.0 Hose Registers
9.1. Panel Hose Register

9.2. Unit Hose Register
10.0 Unit Safety
10.1. LOLER & PUWER

10.2. Design Safety
10.3. Critical Component Catastrophic Failure Analysis
10.4. Essential Safety Requirement Checklist

ASSET No. 12220042
SECTION 1.0 – INTRODUCTION

OP999
1.0 INTRODUCTION
1.1 General Use
NOV Hydra Rig UK equipment is engineered for simple operation and maintenance. This
equipment manual provides the operator with the information necessary to learn the
fundamentals of successful operation. Study this manual carefully before making any
attempt to operate the equipment. Pay special attention to any safety instructions. During
the operation or maintenance of this equipment, personnel safety should always be of the
utmost importance.
The equipment is designed and all components are carefully specified to provide maximum
performance and safety. Maintenance schedules outlined in this manual should be
considered as minimum requirements to maintain satisfactory performance. Maintenance
schedules should be followed as closely as possible. In the unlikely event of equipment
failure or decreased performance, maintenance personnel will find valuable
troubleshooting, circuit analysis and component information throughout the manual.
The abilities of operators or maintenance personnel to understand and use the system
schematics are vital when troubleshooting this equipment. Before operating, adjusting, or
replacing any components, be certain that the ramifications and consequences of those
actions are clearly understood by ensuring that the appropriate precautions are taken.
If problems cannot be readily resolved, it is strongly recommended that you contact NOV
Hydra Rig UK Service department. NOV Hydra Rig UK stands behind all equipment and is
willing and able to provide replacement parts and field service upon request.
NOV Hydra Rig UK

Excalibur Road
Beacon Park
Gorleston
Great Yarmouth
Norfolk, NR31 7RQ
UNITED KINGDOM
Tel: 00 44 (0) 1493 666200

Fax: 00 44 (0) 1493 666249
Web: www.hydrarig.com

OP999
1.2 Introduction
The Halliburton Zone 2 180K Nitrogen pumping and vaporising system has the following
identifications:
Halliburton Hydra Rig UK Description

Asset No. Job No.
12220042 J15177001 N2 Unit
A skid mounted liquid nitrogen pumping and vaporizing system, to come complete as
described in the scope of supply.
The unit is designed and constructed for operations onshore and offshore and the final
assembly and design to be approved by D. N. V. This will include equipment designed to
meet, but not limited to, the requirements of D.N.V. 2.7-1, PED, C.E. marking and Zone 2
compliance.
Performance Specifications
Maximum working pressure: 690 Bar/10,000 psig

Hydrostatic test pressure: 1035 Bar/15,000 psig
Maximum flow rate: 4700 NM3/Hr180, 000 scf/h
Design max flow rate temperature: 20° C/70ºF
Maximum simultaneous flow and pressure: 4700 NM3/Hr/180,000 scf/h
at 690 Bar/10,000 psig
Gross Weight: 10,500KG
Fuel Capacity: 375 Litres/100 US Galls.
Design ambient temperature: 50°C
Design environment: Offshore/Marine/Desert
Skid Dimensions
(ISO shipping compatible height and width)
Length: 4,572mm/180”
Width: 2,438mm/ 96”
Height: 2,600mm/102"

NATIONAL OILWELL VARCO, L.P. AND ITS AFFILIATES
TERMS AND CONDITIONS FOR THE PROVISION OF EQUIPMENT, PARTS, SERVICES OR RENTAL
1. ACCEPTANCE Cooperation. Buyer shall cooperate with Seller, and at the request of Seller, Buyer shall use its best
Orders or other requests, whether oral or written, for the supply or sale of machinery or equipment efforts to supply to Seller such information (including documentary information) in connection with its
(“Equipment”), or for the supply or sale of spare or replacement parts (“Parts”), or for the provision of activities as may be required by Seller for any of the following purposes:
services (“Services”), or for the rental of machinery or equipment (“Rental”) to be provided by National a) To enable Seller to comply with the lawful demand or requirement for such information by
Oilwell Varco, L.P., on behalf of itself and its divisions and subsidiaries, or by its affiliates (“Seller”) to any appropriate government authority or to ensure that all requirements of the applicable
its customers (each a “Buyer”) (the “Order(s)”) are subject to Seller’s written acceptance by an law are being complied with;
authorized representative of Seller and any Orders so accepted will be governed by (a) the terms and b) To enable Seller to conduct, defend, negotiate or settle any claim arising out of, or in
conditions stated in these Terms and Conditions for provision of Equipment, Parts, Services or Rental connection with, such activities, whether or not such claim shall have become the subject
(the “Terms and Conditions”); (b) the written proposal submitted by Seller to Buyer (“Proposal”), if any; of arbitration or judicial proceedings;
(c) the written order acknowledgment issued by Seller to Buyer (“Acknowledgment”), if any; and, (d) c) To enable Seller to make any application (including, but without limitation, any claim for
any change orders identified as such and agreed to in writing by Seller (the Order, Terms and any allowances or relief) or representation in connection with, or to contest any
Conditions, Proposal, Acknowledgment, and any such change order, and any such additional terms as assessment on, or liability of Seller to any taxes, duties, levies, charges and contributions
agreed to in writing by an authorized representative of Seller collectively referred to herein as the (and any interest or penalties thereon); or
“Agreement”). Buyer’s submission of a purchase order (or other similar document) shall be deemed to d) To secure for Seller any beneficial tax treatment and legally minimize any tax obligations
be an express acceptance of these Terms and Conditions notwithstanding language in Buyer’s in connection with this Agreement.
purchase order (or other similar document) inconsistent herewith, and any inconsistent language in Seller’s request for such information and documents shall allow Buyer a reasonable time to prepare,
Buyer’s purchase order (or other similar document) is hereby rejected. Buyer’s purchase order (or provide and submit that information requested. The obligations set forth above shall exist for a period of
other similar document) is incorporated in this Agreement, only to the extent of specifying the nature six (6) years commencing with the date of agreement by Buyer of Seller's final statement of account
and description of the Equipment, Parts, Services or Rental and then only to the extent consistent with under the Agreement, and the Buyer shall retain and shall procure any subcontractor hereunder to
the Proposal or Acknowledgment. In the event of any conflict between a Proposal and an retain, all information and documents in connection with its activities under or pursuant to the
Acknowledgement, the Acknowledgment shall prevail. Agreement as shall enable the Buyer to comply with the above obligations.
2. PRICES 4. PAYMENT TERMS

Prices of Equipment, Parts, Services or Rental shall be as stated in the Proposal or Acknowledgment, Unless alternate payment terms are specified and agreed to by Seller in writing, all charges, including
or if there is no Proposal or Acknowledgment, as otherwise agreed to in writing by Seller. Unless applicable packing and transportation costs, billed by Seller are payable within net 30 days of the date
otherwise specified, all prices contained in a Proposal are valid for thirty (30) days from date of issue of of invoice. Seller reserves the right to modify or withdraw credit terms at any time without notice.
the Proposal. All price quotations are EXW Seller's premises (INCOTERMS 2010), or as agreed per Unless otherwise specified, all payments are due in the currency specified in Seller's Proposal,
the Proposal or Acknowledgement and are subject to change without notice. Seller bears no Acknowledgment and/or invoice. Interest shall be due from Buyer to Seller on overdue accounts at the
responsibility for any consular fees, fees for legalizing invoices, certificates of origin, stamping bills of maximum rate allowed by law. When partial shipments are made, the goods will be invoiced as
lading, or other charges required by the laws of any country of destination, or any fines, penalties or shipped and each invoice will be treated as a separate account and be payable accordingly. Payment
interest imposed due to incorrect declarations. Charges will be added for factory preparation and for goods is due whether or not technical documentation and/or any third party certifications are
packaging for shipment. Minimum freight and invoice charges in effect at the time of the Order shall complete at the time of shipment. Seller shall be entitled to recover all reasonable attorneys’ fees and
apply. If by reason of any act of government, the cost to Seller of performing its obligations hereunder other costs incurred in the collection of overdue accounts. Seller reserves the right, where a genuine
is increased, such increase shall be added to the quoted price. doubt exists as to Buyer’s financial position or if Buyer is in default of any payment obligation, to
suspend delivery or performance of any Agreement or any part thereof without liability and without
3. TAXES prejudice to, and without limitation of, any other remedy available to Seller until Buyer cures the default
Transaction Taxes. In addition to the charges due under this Agreement, the Buyer shall be responsible or satisfactory security for payment has been provided. Seller shall have the option to extend the
for, and shall protect, indemnify, defend and save harmless Seller from and against the reporting, filing delivery date by a time at least equal to the period of such suspension. In the event of Rental, should
and payment of any taxes, duties, charges, licenses, or fees (and any related fines, penalties or interest Buyer default in meeting any of the terms hereunder for any reason, Seller has the right to retrieve all
and the like) imposed directly on Buyer as a result of this Agreement and all liabilities, costs, and Rentals as detailed in the Proposal and also to collect rental payments due. If Buyer elects to exercise
associated expenses (including lawyers’ and experts’ fees) which may be incurred in connection a purchase option for Rental equipment, rental charges will be incurred and will be invoiced until the
therewith. Such taxes, duties, charges, licenses, or fees include but are not limited to any local, state, later of; (i) the end of the agreed rental period; or (ii) 30 days prior to the receipt of total purchase price
federal, foreign, or international sales, use, value added tax (”VAT”), goods and services tax (“GST”), and all other rental amounts due.
rental, import, export, personal property, stamp, excise and like taxes and duties. If Seller pays any
such tax, Buyer shall, within thirty (30) days of Seller’s demand, reimburse Seller for the tax including 5. DELIVERY
interest, fines, and penalties, paid by the Seller. It shall be Buyer’s sole obligation after payment to Unless otherwise agreed to by Seller in writing, delivery terms shall be EXW Seller’s premises
Seller to challenge the applicability of any tax. (INCOTERMS 2010), except to the extent modified by these Terms and Conditions. Where goods are
to be supplied from stock, such supply is subject to availability of stocks at the date of delivery. Partial
Notwithstanding the foregoing, the Buyer shall provide Seller with a copy of all exporting documents shipments may be made as agreed to by Buyer and Seller. Stated delivery dates are approximate only
and any other documents reasonably requested by Seller to prove or substantiate to the appropriate and cannot be guaranteed. Seller shall have no liability for damages arising out of the failure to keep a
tax authorities the goods were timely exported. projected delivery date, irrespective of the length of the delay. In the event Buyer is unable to accept
delivery of goods when tendered, Seller may, at its option, arrange for storage of the goods at Buyer’s
Withholding Taxes. If Buyer is required by any appropriate government department or agency to sole risk and Buyer shall be liable to Seller for the reasonable cost of such storage. This provision is
withhold compensation due Seller to satisfy any obligation of Seller for taxes due, Buyer shall give at without prejudice to any other rights which Seller may have with respect to Buyer's failure to take
least 30 days’ notice to Seller that Buyer will withhold. Buyer agrees to pay on a timely basis the delivery of goods, which includes the right to invoice Buyer for the goods. Buyer agrees that title to the
amounts so withheld over to the appropriate government department or agency, on behalf of Seller, stored goods will transfer to Buyer upon invoicing notwithstanding Buyer's inability to accept delivery
and to provide Seller with any tax receipts (originals, if possible) or other reliable evidence of payment and that Buyer assumes all risk of loss or damage to the goods from the date title passes to Buyer.
issued by such government department or agency within 30 days of the date required for withholding. Buyer is responsible for all shipping costs from Seller’s premises to the location as designated by the
Buyer shall not withhold compensation due Seller if Seller produces evidence, acceptable to Buyer, that Buyer. All shipping costs for the return of goods from the location specified by Buyer to Seller’s
Seller is not subject to the withholding of such taxes. Buyer agrees that it shall not unreasonably premises shall also be for Buyer’s account.
withhold such acceptance. Buyer shall reimburse Seller for any taxes withheld for which receipts or
other reliable evidence substantiating the remittance of taxes to the appropriate government 6. FORCE MAJEURE
department or agency are not provided to Seller. Buyer's obligation to deliver to Seller tax receipts or If either party is unable by reason of Force Majeure to carry out any of its obligations under this
other reliable evidence issued by the taxing authority shall not apply if Buyer establishes to the Agreement, other than the obligations to pay money when due and indemnification obligations
reasonable satisfaction of Seller that the appropriate government department or agency does not assumed hereunder, then on such party giving notice and particulars in writing to the other party within
provide such documentation. Notwithstanding the above, if Buyer is required to pay any such taxes or a reasonable time after the occurrence of the cause relied upon, such obligations shall be suspended.
amounts that Buyer believes is directly attributable to Seller, Buyer shall first provide notice to Seller “Force Majeure” shall include acts of God, laws and regulations, government action, war, civil
and give Seller an opportunity to intervene to protect its interest before Buyer makes any payment. disturbances, strikes and labor problems, delays of vendors, carriers, lightening, fire, flood, washout,
storm, breakage or accident to equipment or machinery, shortage of raw materials, and any other
Protest Rights. If the Buyer receives any demand or request for payment of any levies, charges, taxes causes that are not reasonably within the control of the party so affected. Seller shall be paid its
or contributions for which it would seek indemnity or reimbursement from Seller, Buyer shall promptly applicable standby rate, if any, during any such Force Majeure event.
and timely notify the Seller in writing of such demand or request. “Promptly and timely” as used in this
sub clause means that Buyer must notify Seller so that Seller has enough time and a reasonable 7. CANCELLATION
opportunity to appeal, protest or litigate the levies, charges, taxes or contributions in an appropriate Orders placed by Buyer and accepted by Seller may be canceled only with the consent of Seller and
venue. To the extent that Buyer fails to give prompt and timely notice, Seller has no obligation to, and will subject Buyer to cancellation charges. All of Seller’s documents, drawings and like information
will not, reimburse Buyer for these levies, charges, taxes or contributions. At Seller’s request and cost, shall be returned to Seller upon Buyer’s request for cancellation. No Orders may be canceled
Buyer shall initiate an appeal, protest or litigation in Buyer’s own name if Buyer is the only party that subsequent to delivery or shipment, whichever occurs earlier. As estimated actual damages, Buyer
can legally initiate this appeal, protest or litigation. The Buyer shall allow the Seller to control the agrees to pay Seller the greater of Seller's actual costs incurred prior to cancellation plus a reasonable
response to such demand or request and the Buyer shall use its best efforts to appeal against such profit, or the following minimum cancellation charges:
demand or request. If Buyer is required to pay any levies, charges, taxes or contributions in order to a) 20% of Agreement value if canceled 30 or more days prior to the original
pursue an appeal, protest or litigation, Seller shall reimburse Buyer for that amount promptly upon delivery/shipment date;
receipt of a written request from Buyer. Seller shall not be responsible for any compromise made by b) 50% of the Agreement value if canceled thereafter; or
Buyer without Seller’s prior written consent. c) 100% of the value of any non-standard items (which are items not built for stock or built
to customer specifications).
In the event of Rental, minimum rental charges as stated in the Proposal will apply. Buyer shall verify
the amount of the cancellation charges prior to canceling an order.
Page 1 of 3 NOV Terms and Conditions for the Provision of Equipment, Parts, Services or Rental AAR 7/25/2011
months from date of purchase.
8. TITLE AND RISK OF LOSS
For purchased goods, ownership and risk of loss pass to Buyer upon the earlier of (a) Seller's delivery 12. LIABILITIES, RELEASES AND INDEMNIFICATION
of the goods, or (b) invoicing by Seller for the goods where Buyer is unable to accept delivery on the For purpose of this Article12, the following definitions shall apply:
scheduled date. Seller retains a security interest in the goods until the purchase price has been paid, “Seller Group” shall mean (i) Seller, its parent, subsidiary or related companies, (ii) its and their
and Buyer agrees to perform upon request all acts required to secure Seller's interest. Seller accepts working interest owners, co-lessees, co-owners, partners, joint venturers, if any, and their respective
no responsibility for any damage, shortage or loss in transit. Seller will attempt to pack or prepare all parents, subsidiary or related companies and (iii) the officers, directors, employees, consultants, agents
shipments so that they will not break, rust or deteriorate in shipment, but Seller does not guarantee and invitees of all of the foregoing.
against such damage. Claims for any damage, shortage or loss in transit must be made by Buyer on
the carrier. “Buyer Group” shall mean (i) Buyer, its parent, subsidiary or related companies, (ii) its and their
working interest owners, co-lessees, co-owners, partners, joint venturers, if any, and their respective
In the event of Rental, Buyer assumes all risk and liability whether or not covered by insurance, for loss parents, subsidiary or related companies and (iii) the officers, directors, employees, consultants, agents
or damage to the Rental machinery or equipment. Risk and liability passes to Buyer upon delivery by and invitees of all of the foregoing.
Seller. Title to Rental machinery or equipment shall remain with Seller at all times. Buyer acquires no
ownership, title or property rights to the Rental machinery or equipment except the right to use the “Claims” shall mean all claims, demands, causes of action, liabilities, damages, judgments, fines,
Rental machinery or equipment subject to the terms of this Agreement. penalties, awards, losses, costs, expenses (including, without limitation, attorneys’ fees and costs of
litigation) of any kind or character arising out of, or related to, the performance of or subject matter of
9. LIMITED WARRANTY this Agreement (including, without limitation, property loss or damage, personal or bodily injury,
New Equipment/Parts. In the case of the purchase of new Equipment/Parts, and solely for the benefit sickness, disease or death, loss of services and/or wages, or loss of consortium or society).
of the original user, Seller warrants, for a period of eighteen (18) months from delivery or twelve (12)
months from installation, whichever is earlier, that new Equipment/Parts of its own manufacture shall a) Seller shall release, indemnify, defend and hold Buyer Group harmless from and against
conform to the material and technical specifications set forth in the Agreement. Goods manufactured by any and all Claims in respect of personal or bodily injury to, sickness, disease or death of
others are sold "as is" except to the extent the manufacturer honors any applicable warranty made by any member of Seller Group or Seller Group’s subcontractors or their employees, agents
the manufacturer. Secondhand goods are sold "as is". If the new Equipment/Parts fail to conform with or invitees, and all Claims in respect of damage to or loss or destruction of property
such specifications upon inspection by Seller, Seller will, at its option and as Buyer’s sole remedy, owned, leased, rented or hired by any member of Seller Group or Seller Group’s
either repair or replace such defective Equipment/Parts with the type originally furnished. subcontractors or their employees, agents or invitees.
b) Buyer shall release, indemnify, defend and hold Seller Group harmless from and against
Remanufactured to “As New” Equipment/Parts. Seller warrants to Buyer, that for a period of six (6) any and all Claims in respect of personal or bodily injury to, sickness, disease or death of
months from the date of delivery by Seller or installation of the Equipment/Parts, whichever is earlier, any member of Buyer Group or Buyer Group’s other contractors or their employees,
that reconditioned to “as new” Equipment/Parts will be free from defects in material and workmanship. agents or invitees, and all Claims in respect of damage to or loss or destruction of
If the reconditioned to “as new” Equipment/Parts fail to conform with such warranty upon inspection by property owned, leased, rented or hired by any member of Buyer Group or Buyer
Seller, Seller will, at its option and as Buyer’s sole remedy, either repair or replace such defective Group’s other contractors or their employees, agents or invitees.
Equipment/Parts with the type originally furnished. c) Each party covenants and agrees to support the mutual indemnity obligations contained
in Paragraphs (a) and (b) above, by carrying equal amounts of insurance (or qualified
Overhauled Equipment/Parts. Seller warrants that for a period of four (4) months from the date of self insurance) in an amount not less than U.S. $5,000,000.00.
delivery by Seller or three (3) months from installation, whichever is earlier, that overhauled d) Notwithstanding anything contained in this Agreement to the contrary, in all instances
Equipment/Parts will be free from defects in workmanship. If the overhauled Equipment/Parts fail to where Seller is providing Services at a well site, Buyer, to the maximum extent permitted
conform with such warranty upon inspection by Seller, Seller will, at its option and as Buyer’s sole under applicable law, shall release, indemnify, defend and hold Seller Group and Seller
remedy, either repair or replace such defective Equipment/Parts with the type originally furnished. This Group subcontractors harmless from and against any and all Claims asserted by or in
warranty expressly assumes that parts normally considered consumables (including, but not limited to favor of any person or party, including Seller Group, Buyer Group or any other person or
rubber goods, seals (rubber, polymer and/or metallic) and/or bearings, are replaced during overhaul. If party, resulting from: (i) loss of or damage to any well or hole (including but not limited to
Buyer requests that such parts not be replaced, Seller hereby disclaims any warranty for said the costs of re-drill), (ii) blowout, fire, explosion, cratering or any uncontrolled well
overhauled Equipment/Parts. condition (including but not limited to the costs to control a wild well and the removal of
debris), (iii) damage to any reservoir, geological formation or underground strata or the
Service. Seller warrants that the Services to be provided pursuant to this Agreement shall conform to loss of oil, water or gas therefrom, (iv) pollution or contamination of any kind (other than
the material aspects of the specifications set forth in the Agreement. Seller shall re-perform that part of surface spillage of fuels, lubricants, rig sewage or garbage, to the extent attributable to
the non-conforming Services, provided Seller is notified by Buyer prior to Seller’s departure from the the negligence of Seller Group, including but not limited to the cost of control, removal
worksite. and clean-up, or (v) damage to, or escape of any substance from, any pipeline, vessel or
storage facility.
Rental. Seller warrants that the Rental equipment to be provided pursuant to this Agreement shall e) NOTWITHSTANDING ANYTHING CONTAINED IN THIS AGREEMENT TO THE
conform to the material aspects of the specifications set forth in the Agreement. Provided Seller is CONTRARY, NEITHER PARTY SHALL BE LIABLE TO THE OTHER AND EACH
notified by Buyer prior to Seller’s departure from the worksite, Seller shall repair or replace non- PARTY RELEASES THE OTHER FOR ANY INDIRECT, SPECIAL, PUNITIVE,
conforming Rental equipment. In the event of failure or other non-performance of Seller’s Rental EXEMPLARY OR CONSEQUENTIAL DAMAGES OR LOSSES (WHETHER
equipment’s contributing to loss of hole, rental rates will apply during re-drill to equivalent TD. FORESEEABLE AT THE DATE OF THIS AGREEMENT, INCLUDING WITHOUT
LIMITATION, DAMAGES FOR LOST PRODUCTION, LOST REVENUE, LOST
Seller’s warranty obligations hereunder shall not apply if non-conformity or failure was caused by (a) PRODUCT, LOST PROFIT, LOST BUSINESS OR BUSINESS OPPORTUNITIES.
Buyer’s failure to properly store or maintain the equipment or parts; (b) the unauthorized modification, f) Seller’s total liability for all claims, damages, causes of action, demands, judgments,
repair or service of the equipment or parts by Buyer; (c) utilization of replacement parts not fines, penalties, awards, losses, costs and expenses (including attorney’s fees and cost
manufactured by Seller; or (d) use or handling of the equipment by Buyer in a manner inconsistent with of litigation) shall be limited to and shall not exceed the value of the Equipment, Parts,
Seller’s recommendations. Further, Seller’s warranty obligations under this Article 9 shall terminate if Services or Rental purchased under the Agreement.
(a) Buyer fails to perform its obligations under this or any other Agreement between the parties, or (b) if g) THE EXCLUSIONS OF LIABILITY, RELEASES AND INDEMNITIES SET FORTH IN
Buyer fails to pay any charges due Seller. Any third party warranties provided on equipment or parts PARAGRAPHS A. THROUGH F. OF THIS ARTICLE 12 SHALL APPLY TO ANY
not manufactured by Seller are assigned to Buyer, without recourse, at the time of delivery, provided CLAIM(S), LOSSES OR DAMAGES WITHOUT REGARD TO THE CAUSE(S)
such warranties are assignable. THEREOF, INCLUDING BUT NOT LIMITED TO PRE-EXISTING CONDITIONS,
WHETHER SUCH CONDITIONS BE PATENT OR LATENT, THE UNSEAWORTHINESS
THIS ARTICLE 9 SETS FORTH BUYER’S SOLE REMEDY AND SELLER’S EXCLUSIVE OF ANY VESSEL OR VESSELS, IMPERFECTION OF MATERIAL, DEFECT OR
OBLIGATION WITH REGARD TO NON-CONFORMING EQUIPMENT, PARTS, SERVICES OR FAILURE OF PRODUCTS OR EQUIPMENT, BREACH OF REPRESENTATION OR
RENTAL. EXCEPT AS OTHERWISE EXPRESSLY PROVIDED PURSUANT TO THE PROVISIONS WARRANTY (EXPRESS OR IMPLIED), ULTRAHAZARDOUS ACTIVITY, STRICT
OF THIS ARTICLE 9, SELLER MAKES NO OTHER WARRANTIES OR REPRESENTATIONS OF LIABILITY, TORT, BREACH OF CONTRACT, BREACH OF DUTY (STATUTORY OR
ANY KIND, EXPRESS OR IMPLIED, AND SELLER DISCLAIMS THE IMPLIED WARRANTIES OF OTHERWISE), BREACH OF ANY SAFETY REQUIREMENT OR REGULATION, OR
MERCHANTIBILITY AND FITNESS FOR A PARTICULAR PURPOSE. THE NEGLIGENCE OR OTHER LEGAL FAULT OR RESPONSIBILITY OF ANY
PERSON (INCLUDING THE INDEMNIFIED OR RELEASED PARTY), WHETHER SUCH
10. CHANGES NEGLIGENCE BE SOLE, JOINT OR CONCURRENT, ACTIVE OR PASSIVE.
Seller expressly reserves the right to change, discontinue or modify the design and manufacture of its h) Redress under the indemnity provisions set forth in this Article 12 shall be the exclusive
products without obligation to furnish, retrofit or install products previously or subsequently sold. remedy(ies) available to the parties hereto for the matters, claims, damages and losses
covered by such provisions.
11. RETURN OF MAKE TO STOCK GOODS
With Seller’s written approval, unused, incorrectly shipped or “Made to Stock” goods ordered 13. INSURANCE
incorrectly, in new condition and of current manufacture and catalog specifications may be returned by Upon written request, each party shall furnish to the other party certificates of insurance evidencing the
Buyer for credit (subject to a restocking fee), provided written request is received within one (1) year fact that the adequate insurance to support each party’s obligations hereunder has been secured. To
after the purchase date. Non-standard goods are not returnable for credit and such goods shall only be the extent of each party’s release and indemnity obligations expressly assumed by each party
accepted for return with the prior written agreement of Seller. Requests for return of goods must show hereunder, each party agrees that all such insurance policies shall, (a) be primary to the other party’s
the original purchase order number, invoice number, description of material, and date of purchase. insurance; (b) include the other party, its parent, subsidiary and affiliated or related companies, and its
Return of goods does not relieve Buyer of the obligation to make payment against Seller’s invoice, and and their respective officers, directors, employees, consultants and agents as additional insured; and,
any credit or refund allowed will be issued following Seller’s receipt of the goods. The credit allowed on (c) be endorsed to waive subrogation against the other party, its parent, subsidiary and affiliated or
returned goods, if any, is a merchandise credit and is applicable only against future purchases of Seller related companies, and its and their respective officers, directors, employees, consultants and agents.
goods. The credit given will be solely in Seller's discretion and may be based on the original or a
subsequently adjusted price. A charge will be assessed to clean-up, refinish and restock the goods, if 14. GOVERNING LAW
applicable. No rubber or electronic products or components may be returned for credit after six (6) Except for Equipment, Parts, Services or Rental provided, or to be provided, by Seller in North or South
America (the “America’s”), this Agreement shall be governed by and interpreted in accordance with the such information; (e) which is developed by the party receiving the Confidential Information as
laws of England and Wales, excluding conflicts and choice of law principles. All disputes arising out of evidenced by documentation, independently of the Confidential Information; or, (f) which is required to
or in connection with this Agreement shall be finally settled under the Rules of Arbitration of the be disclosed by the party receiving the Confidential Information pursuant to an order of a court of
International Chamber of Commerce by one or more arbitrators appointed in accordance with said competent jurisdiction or other governmental agency having the power to order such disclosure,
rules. Arbitration shall be held in London, England and shall be conducted in the English language. provided that the party receiving the Confidential Information uses its best efforts to provide timely
notice to the party disclosing the Confidential Information of such order to permit such party an
For Equipment, Parts, Services or Rental provided, or to be provided, by Seller in the America’s, this opportunity to contest such order. In the event that Seller owns copyrights to, patents to or has filed
Agreement shall be governed by and interpreted in accordance with the substantive laws of the State of patent applications on, any technology related to the Equipment, Parts, Services or Rental furnished by
Texas, excluding conflicts and choice of law principles. Any dispute, action or proceeding arising out of Seller hereunder, and if Seller makes any improvements on such technology, then Seller shall own all
or relating to this Agreement must be brought in a state or federal court sitting in Harris County, Texas, such improvements, including drawings, specifications, patterns, calculations, technical information and
and each of the parties hereby agrees to irrevocably submit itself to the exclusive jurisdiction of each other documents.
such court in any such action or proceeding and waives any objection it may now or hereafter have to
venue or convenience of forum. 18. INDEPENDENT CONTRACTOR
It is expressly understood that Seller is an independent contractor, and that neither Seller nor its
Seller retains the right to arbitrate any all disputes that may arise in connection with the provision of the principle, partners, employees or subcontractors are servants, agents or employees of Buyer. In all
Equipment, Parts, Services or Rental. cases where Seller’s employees (defined to include Seller’s and its subcontractors, direct, borrowed,
special, or statutory employees) are covered by the Louisiana Worker’s Compensation Act. La. R.S.
15. OWNERSHIP AND PATENT INDEMNITY 23:102 et seg., Seller and Buyer agreed that all Equipment, Parts, Services or Rental provided by
All software used in connection with the Equipment, Parts, Services or Rental, either purchased or Seller and Seller’s employees pursuant to this Agreement are an integral part of and are essential to
rented from Seller, is copyrighted and owned by Seller and licensed to Buyer. Seller warrants that the the ability of Buyer to generate Buyer’s goods, products, and services for the purpose of La. R.S.
use or sale of Equipment or Parts hereunder will not infringe patents of others by reason of the use or 23:106(A) (1). Furthermore, Seller and Buyer agree that Buyer is the statutory employer of all of
sale of such Equipment or Parts per se, and hereby agrees to hold Buyer harmless against judgment Seller’s employees for the purpose of La. R.S. 23:1061(A) (3).
for damages for infringement of any such patent, provided that Buyer shall promptly notify Seller in
writing upon receipt of any claim for infringement, or upon the filing of any such suit for infringement, 19. ADDITIONAL RENTAL TERMS AND CONDITIONS
whichever first occurs, and shall afford Seller full opportunity, at Seller’s option and expense, to answer Unless otherwise indicated, the rental rates contained in Seller’s Proposal are on a per day basis and
such claim or threat of suit, assume the control of the defense of such suit, and settle or compromise such rates shall apply to each piece of equipment or part rented. Seller represents that it has fully
same in any way Seller sees fit. Seller does not warrant that such Equipment or Parts: (a) will not inspected the Rental equipment and parts as detailed in the Agreement and that said equipment and
infringe any such patent when not of Seller's manufacture, or specially made, in whole or in part, to the parts are in good condition and repair, and are fully acceptable for use as specified in the Agreement.
Buyer’s design specifications; or (b) if used or sold in combination with other materials or apparatus or Furthermore, Seller represents that the Rental equipment and parts are not subject to any
used in the practice of processes, will not, as a result of such combination or use, infringe any such encumbrances or liens, and that Seller has full title to the equipment and parts, and thus, Seller is
patent, and Seller shall not be liable and does not indemnify Buyer for damages or losses of any nature authorized to enter into and execute this Agreement.
whatsoever resulting from actual or alleged patent infringement arising pursuant to (a) and (b) above.
THIS ARTICLE STATES THE ENTIRE RESPONSIBILITY OF SELLER CONCERNING PATENT Buyer represents that it shall use the Rental equipment and parts in a careful and proper manner and
INFRINGEMENT. shall comply with all laws, ordinances and regulations relating to the possession, use and maintenance
of the equipment and parts in accordance with Seller's approved procedures. In the event the parties
16. REGULATORY COMPLIANCE agree that the Buyer shall operate the Rental equipment and parts, Buyer further represents that the
By acceptance of delivery under this Agreement, Buyer warrants it has complied with all applicable Rental equipment and parts will be operated by skilled employees trained in the use of the Rental
governmental, statutory and regulatory requirements and will furnish Seller with such documents as equipment and parts. Buyer shall keep the Rental equipment and parts free and clear of all liens and
may be required. Seller warrants and certifies that in the performance of this Agreement, it will comply encumbrances arising in connection with Buyer’s operations and/or use of the Rental equipment and
with all applicable statutes, rules, regulations and orders in effect at the time of Agreement execution, parts. Buyer, at its sole cost, shall provide and maintain insurance against the loss, theft, damage or
including laws and regulations pertaining to labor, wages, hours and other conditions of employment, destruction of the Rental equipment and parts. The coverage shall be in an amount not less than the
and applicable price ceilings if any. Seller will not provide any certification or other documentation nor new replacement price of the Rental equipment and parts. NOV shall provide equipment and parts
agree to any contract provision or otherwise act in any manner which may cause Seller to be in prices at execution of this Agreement.
violation of applicable United States law, including but not limited to the Export Administration Act of
1979 and regulations issued pursuant thereto. No provision in this Agreement shall be interpreted At the expiration of the applicable rental term, Buyer will at its sole cost return the Rental equipment to
or applied which would require any party to do or refrain from doing any act which would the facility designated by Seller, in working condition (reasonable wear and tear excepted). Upon
constitute a violation of, or result in a loss of economic benefit under, any anti-boycott receipt of the returned Rental equipment, Seller will service and inspect the Rental equipment. In the
including but not limited to any such law of the United States. All Orders shall be conditional upon event Seller determines that the Rental equipment is materially damaged or not in working condition
granting of export licenses or import permits which may be required. Buyer shall obtain at its own risk (reasonable wear and tear excepted), any service work required to bring the Rental equipment to good
any required export license and import permits and Buyer shall remain liable to accept and pay for working condition will be charged back to the Buyer. Such charges may include service, inspection,
material if licenses are not granted or are revoked. and spare parts.
17. CONFIDENTIAL INFORMATION 20. GENERAL

Each party recognizes and acknowledges that it shall maintain all data, information, disclosures, Failure of Buyer or Seller to enforce any of the terms and conditions of this Agreement shall not prevent
documents, drawings, specifications, patterns, calculations, technical information and other documents a subsequent enforcement of such terms and conditions or be deemed a waiver of any subsequent
(collectively, "Confidential Information") obtained from the other party in strict confidence. However, breach. Should any provisions of this Agreement, or portion thereof, be unenforceable or in conflict
nothing hereinabove contained shall deprive the party receiving the Confidential Information of the right with applicable governing country, state, province, or local laws, then the validity of the remaining
to use or disclose any information: (a) which is, at the time of disclosure, known to the trade or public; provisions, and portions thereof, shall not be affected by such unenforceability or conflict, and this
(b) which becomes at a later date known to the trade or the public through no fault of the party Agreement shall be construed as if such provision supersedes all prior oral or written agreements or
receiving the Confidential Information and then only after said later date; (c) which is possessed by the representations. Buyer acknowledges that it hast not relied on any representations other than those
party receiving the Confidential Information, as evidenced by such party’s written records, before contained in this Agreement. This Agreement shall not be varied, supplemented, qualified, or
receipt thereof from the party disclosing the Confidential Information; (d) which is disclosed to the party interpreted by any prior course of dealing between the parties or by any usage of trade and may only
receiving the Confidential Information in good faith by a third party who has an independent right to be amended by an agreement executed by an authorized representative of each party.
ASSET No. 12220042
SECTION 2.0 – GENERAL SAFETY

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2.0 SAFETY
2.1 Liquid Nitrogen
The hazards associated with liquid nitrogen are exposure to the cold temperatures which
can cause severe skin burns, over pressurisation due to expansion of small amounts of
liquid vaporising into large volumes of gas in inadequately vented equipment and
asphyxiation due to displacement of oxygen in the air in confined work areas.
(Asphyxiation is dealt with in the next section on gaseous nitrogen).
Bodily contact with liquid nitrogen is of major importance but a well-ventilated working
environment is even more essential. Nitrogen is odourless, colourless, and tasteless. The
human senses cannot detect it within the air. Without proper ventilation nitrogen can
expand, displacing enough oxygen in the working atmosphere to cause dizziness,
unconsciousness or even death when inhaled. Always store liquid nitrogen containers in
well-ventilated facilities or outdoors.
2.1.1 Exposure to Cool Temperatures
At this extreme temperature, liquid nitrogen can produce an effect on the skin
similar to a burn.
When spilled on a surface, it tends to cover it completely and therefore cools a

large area. The vapours from these liquids are also extremely cold and can also
produce burns.
Delicate tissues, such as those of the eye, can be damaged by an exposure to these
cold gases which is too brief to affect the skin of the face or the hands.
Never allow any unprotected part of the body to touch the uninsulated pipes or
vessels containing liquid nitrogen; the extremely cold material may stick fast and
tear the flesh when you attempt to withdraw it. Even non-metallic materials are
dangerous to touch at low temperatures. In addition to the hazards of frost bite or
flesh sticking to cold materials, objects that are soft and pliable at room
temperatures, such as rubber or plastics, are easily broken because they become
hard and brittle at these extremely low temperatures.
Carbon steels become brittle at low temperatures and may easily fracture when
stressed.

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2.1.2 Personnel Equipment
Personnel should be thoroughly familiar with the material’s properties and safety
considerations if they must be in the area where liquid nitrogen is being used.
Loose fitting gloves of impermeable material should be worn when handling
anything that comes into contact with cold liquids and vapour or whenever the
possibility of exposure to liquid nitrogen spill exists. (Customer personnel, under
normal circumstances, will not be exposed to the hazards of cold temperatures).
2.1.3 Liquid to Gas Expansion
One volume of liquid nitrogen at one atmosphere vaporises to 695.5 volumes of

nitrogen gas at 70°F and one atmosphere. Liquid nitrogen cannot be indefinitely
maintained as a liquid even in well-insulated containers. Any liquid or even cold
vapour trapped between valves has the potential to cause an excessive pressure
build up to the point of violent rupture of container or piping, hence the use of
reliable pressure relief devices is mandatory.

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2.2 Gaseous Nitrogen
The inherent hazard of nitrogen is in a pressurised system where the potential energy of
the containment will on release, accidental or otherwise, be cause for concern.
Nitrogen, although non-toxic, can constitute an asphyxiation hazard through the

displacement of oxygen in the atmosphere. The potential for this type of hazard is
significant, because of the widespread use of nitrogen as a purging or blanketing gas in
chemical, metallurgical and other industrial operations and because neither nitrogen gas
nor oxygen depletion are detected by the normal human senses.
Unless adequate precautions are taken, persons can be exposed to oxygen deficient
atmospheres if they enter equipment or areas which have contained, or have been purged
with, nitrogen.
Atmospheres containing less than 10% oxygen can produce permanent brain damage or
death.
The danger of nitrogen displacing oxygen in the atmosphere within the vicinity of
operations must be brought to the attention of all personnel involved in the opening up of
plant/equipment/pipelines etc. that have been inerted or where liquid nitrogen is being
used.
Initial symptoms of asphyxiation include nausea and vomiting, breathing becomes slow,
deep and difficult, and then becomes noisy with frothing at the mouth, and then finally
stops. Casualty’s colour will be flushed at first, becoming blue especially at the head, neck,
face and lips. The casualty will gradually lose consciousness.
Persons exposed to such atmospheres and suffering from the above symptoms may be
unable to help themselves or warn others of their predicament. The symptoms are an
inadequate warning of the hazard.
Breathing a pure nitrogen atmosphere will produce immediate loss of consciousness and
almost immediate death.

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2.3 Operating Safety
When pumping at LOW and HIGH discharge pressure the operator should remember the
unit is capable of producing pressures up to 10,000 PSIG. The following safety procedures
should be taken and observed.
1. Inspection of all piping and valves to insure pressure rating and integrity.
2. All pumping lines are restrained in case of joint or connection failure.
3. Restrict personnel access to system and line area. Warning signs and barriers
should be employed.
4. All system safety devices should be inspected and in known working order.
5. System and related piping should be pressure tested prior to commencement of

pumping operations.
These are few examples and are not intended to be considered the only safety measures
employed or required for safe pumping operations. It is the responsibility of the system
operator to insure his and others safety.

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2.4 Safety Precaution
The following are general safety precautions. These precautions are not related to any
specific procedures and do not appear repeatedly in this publication. Personnel must
understand and apply these precautions during all phases of operation and maintenance of
this equipment. Specific precautions will be included in the text for certain potentially
hazardous operations in the form of WARNING or CAUTION statements. Some of the
warnings appear in the text of this publication but are presented here for emphasis.
Qualified Personnel – Only qualified personnel should be authorised to operate and

perform maintenance on this equipment.
Protective Equipment – Personnel operating and performing maintenance on this

equipment should wear suitable protective clothing and equipment.
Safety Practices – Overall good safety practices should be adhered to at all times when
starting up, operating, shutdown, and maintenance of this equipment. It is the equipment
owner’s operator’s responsibility to establish good safety practices, personnel training, and
enforce observance of safety practices.
Unit Operation – Personnel should not operate the unit unless they are thoroughly familiar
with the equipment manual, all unit operating controls, and functions. Reading the
equipment manual does not qualify any individual to operate this equipment.
Unauthorised Personnel – Keep unauthorised personnel away from the unit when
operating, servicing, or performing maintenance.
High Pressure – Ensure pressure in piping connected to the unit has been bled to zero (0)
pressure before attempting to disconnect any component.
Unauthorised Maintenance – Do not attempt unauthorised disassembly or maintenance of

components. Some components (e.g. accumulators) store fluid under pressure. Contact
Hydra Rig UK for further information.
Lifting – Equipment used in lifting and moving items from the unit must be of sufficient
rating to handle the weights involved.
Compressed Air Usage – Use of compressed air can create an environment of propelled
foreign particles. Air pressure should be reduced to less than 30 PSIG and used with
effective chip guarding and personal protective equipment. Never direct compressed air to
the body or towards other people.
Moving Parts – Keep hands, hair, clothing, jewellery, rags, and tools away from moving
parts when the unit is in operation.

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Visibility – Do not attempt to operate equipment with obstructed visibility. Always ensure
suitable lighting provisions are available.
Pre-Start – Before starting the unit ensure that all operating controls are in the proper
position (e.g. off, on, neutral).
Work Areas – Keep work areas clean and clear of obstructions, hand tools and other
objects when operating the unit.
Transporting the Unit – Ensure all components are secured before transporting the unit to
another location.

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2.5 Rules and Regulations
2.5.1. Daily Activities
Read and understand this manual before operating NOV HydraRig UK equipment.
Use this manual as a guide for system operation in conjunction with common sense
and operator experience.
While working with NOV HydraRig UK equipment follow the field’s rules and
regulations
While working with NOV HydraRig UK equipment wear appropriate work clothing
and personal protective equipment as required.
While working with NOV HydraRig UK equipment wear appropriate hearing

protection as required (unit sound level is above 65 dB).
Let only qualified and experienced personnel operate NOV HydraRig UK equipment.
(Please note that rigging up and rigging down is also a part of unit operations.) This
will help prevent damage to the equipment and reduce the possibility of dangerous
situations arising.
Do not restart NOV HydraRig UK equipment after an emergency stop without

verifying that the cause of this stop has been removed or rectified.
The equipment has been designed and built for particular purposes. Do not
attempt to use the equipment for other purposes outside its design scope. This
may lead to damage and/or dangerous situations.

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2.5.2. Transport/Installation
· When lifting the unit by crane, make sure that you cannot get trapped between
the load and a wall, fixed object etc.
· If possible, position yourself so that you are visible to the crane operator. If not,
make sure to have a flagman to give signs to the crane operator.
· Never walk under a hanging load!
· Make sure that lifting gear to be used is sufficiently dimensioned and certified.
· Never leave an “operation-ready” unit unattended.
· Do not operate damaged equipment. This may lead to further damage and/or
dangerous situations.
· Respect and maintain your working environment. Dispose of waste correctly.
· Keep the unit and connected components clean. Accumulated dirt can hamper
unit operations and might jeopardize safety.
· Keep all safety guards in position while operating ASEP equipment. Removal of
any safety guards may lead to accidents.
· When engaged in maintenance and/or performing checks on the unit:
§ First consider your safety and that of others.
§ Make sure that the equipment is switched off completely and use a decal or
similar to prevent unauthorized starting during maintenance or check up.
§ Never work on a hydraulic and/or pneumatic system under pressure.
Always relieve the system to prevent dangerous situations.
§ Never attempt to move heavy parts without aid of a mechanical device
§ Do not allow heavy objects to rest in an unstable position.
§ Use the right tools for the task..

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2.6. ATEX (if applicable)
With the engine certified according to ATEX regulations apply the following: The diesel
engine, including driven parts, has been manufactured and assessed according to ATEX. All
driven parts have been tagged with a unique identification number. ONLY trained
personnel may service the assembly.
Failure to follow this may impair suitability for Zone 2. In its explosion safe version the unit
is suitable for use in gas hazardous classified locations however limited to Group II Zone 2
(acc. IEC) or Class I Division 2 (acc. NEC). Hereto the unit is designated amongst other as
Ex ia IIB T4.
The design and manufacturing has been based on European Directive nr. 94/9/EC following
conformity assessment procedure relating to internal control of production according
Annex VIII of the Directive. The construction is documented in a confidential Technical
Construction File held at the offices of NOV HydraRig UK. Let only qualified `EX` personnel
trained to a level as described in IEC 60079-14 and IEC 60079-17 perform maintenance on
NOV HydraRig UK equipment.
Maintenance should also be performed with the right tools and under controlled
circumstances. Performing maintenance under the proper conditions will prevent damage
to the equipment and prevent dangerous situations arising.
Maintenance can be described as and is not limited to: installing and removing parts from
the unit filling up the fluid levels on the unit trouble shooting any malfunctions that may
occur on the unit before, during and after operations calibrating and adjusting setting on
the units hydraulic, pneumatic, mechanical, electrical and diesel systems.
Parts that have not been approved or supplied by NOV HydraRig UK cannot be relied upon
to be of the correct material strength, correct dimensions, finish or quality.
NOV HydraRig UK cannot be held responsible for any damage arising from the use of such
parts and guarantee claims may be refused.

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2.7. General Safety
High voltage (up to 480VAC 3-phase), mechanical, chemical, thermal, Radiation,

noise and stored energy hazards are present in NOV HydraRig UK systems.
Therefore, pay special attention to safety when operating and maintaining each
system, including:
· Meet all applicable codes, laws and regulations.

· Read and understand each item in this manual.
· Follow the operator and maintenance procedures exactly.
· Perform all testing procedures exactly as specified.
· Ensure that only trained and qualified personnel are allowed to work on the
system.
· Ensure that adequate safety equipment is installed (fire extinguishers, escape
routes, shut off valves, etc.), and that personnel are trained to use the
equipment.
· Always use the correct tools for the job.
· Take recommended precautions - never take short cuts.
· Follow the procedures and advice in this manual closely.
· Never work alone if there is a possibility of an accident.
· Wear safety shoes where necessary.

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2.7.1. Warning Icons
WARNING
For conditions that may result in injury to personnel
operating the system.
CAUTION
For conditions that may cause damage to the equipment or
interfere with the normal processing and ruin the product.
CORROSIVE
Liquids or adhesive that can cause injury to the operator,
and can damage the machine.
DANGEROUS ELECTRICITY
The machine, or parts of the machine are under high
voltage.
EARTH CONNECTION
This icon indicates that this equipment requires an earth
connection. Always make sure this connection is in place
before and after maintenance.
EXPLOSIVE
Substances may explode – be extremely careful when
handling or disposing of these materials.
FLAMMABLE
Substances are flammable.

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ENTRAPMENT
Do not place any part of your body between any units that
can close.
HOT SURFACE
Do not touch object, this may cause serious burns.
MOVING MACHINERY
Make sure no body-parts, clothing or jewelry can get
caught in the machinery.
AUTOMATICALLY STARTING & STOPPING MACHINES

Keep your distance.
LOW TEMPERATURES
Do not touch any cold surface, may result in serious injury.

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2.7.2. Restriction Icons
PROTECTION FROM UV LIGHT

Always wear LASER-goggles or UV-
goggles to prevent eye damage.
CLEANING
Clean your hands after this procedure.
BREATHING PROTECTION
Wear a full respiratory mask if working
with toxic vapors.
EAR PROTECTION
Wear ear protection during this
procedure.
WEAR PROTECTIVE GLOVES

Always wear latex gloves to protect your
skin when performing this procedure.
WEAR PROTECTIVE HELMET

Always wear a helmet to protect your
head when performing this procedure.
WEAR PROTECTIVE SHOES

Always wear protective shoes to protect
your ankles and feet when performing
this procedure.

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2.7.3. Responsibilities
Supervisor
1. Posts appropriate warning and restriction logos for materials of a hazardous

nature (poisonous, toxic, flammable, carcinogenic, biological hazard,
radioactive, etc.) or hazardous conditions (high voltage, slippery when wet,
welding arcs, etc.).
Employee
1. Conducts themselves in the manner (safe procedures, protective

equipment, clothing, etc.) as called for by the hazard warning/restriction
logos and training.
2. Assists the supervisor in recognition of any potentially hazardous condition
that may need identification by hazard warning/restriction logos.
Local Health Authority
1. Periodically surveys all operations to ensure proper identification of

hazardous areas or conditions by use of warning logos and immediately
notifies supervisor of any lack of, or improper markings.
2. Assists the supervisor in defining proper identification, and acceptable
location of logos in compliance with existing local regulations.

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2.8 General Safety Instructions
2.8.1. Chemical Hazards/Hot Surfaces
Protective clothing will be provided whenever it is necessary by

reason of hazards, processes or environmental conditions. The
company requires that protective clothing be used when chemical
hazards, radiological hazards, hot surfaces, or mechanical irritants
are encountered in a manner capable of causing injury or
impairment through absorption or physical contact.
2.8.1.1. Responsibilities
Supervisor
1. Immediately identifies to the Local Health Authority all protective

clothing new employees must receive.
2. Ensures all employees use and maintain protective clothing as
needed to provide effective protection against identified hazards.
Employee
1. Uses and maintains all protective clothing issued and when

necessary suggests additional protection.
1. Identifies and prescribes the local regulations for use of protective

clothing for work tasks and associated hazards.

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2.8.2. Noise Hazards
All employees must be protected against the detrimental effects

of excessive noise exposure. Feasible administrative or
engineering controls must be utilized when employees are
subjected to excessive sound levels. If such controls fail to
reduce sound below acceptable levels, personal protective
equipment must be used to reduce exposures to within
permissible levels. Hearing protectors shall be made available to
all employees exposed at or above the action level. These
protectors shall be capable of attenuating noise levels to at least
a time-weighted average of 90 dBA for all employees and 85 dBA
for employees who have experienced a standard threshold shift
(STS).
Supervisor
1. Maintains an awareness of the approximate noise levels in work
places for which he/she is responsible.
2. Requests a survey from the Local Health Authority when a change in
equipment or procedure may increase employee exposure to noise.
3. Ensures that all employees are aware of the requirements for
hearing protection in any area that has been identified as having
levels which exceed permissible exposure limits.
4. Ensures that appropriate protective devices are worn and that any
other control measures are observed.
Employee
1. Complies with the recommendations of the Local Health Authority
and supervisor for controlling noise exposure.
2. Makes proper use of the hearing protection devices provided by the
Health and Safety Branch.
3. Reports any suspected change in noise levels of equipment to the
Local Health Authority so that a survey can be made.
4. Participates in audiometric testing or other hearing conservation
programs as required by company policy.

1. Performs noise surveys in all areas as required.
2. Identifies those areas where hearing protection is required and
establishes total daily permissible exposure times.
3. Approves all hearing protection devices used by employees. Provides
instruction on the proper use, care, and maintenance of these
devices.

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2.8.3. Respiratory Hazards
All employees must be protected from exposure to airborne

radioactive, chemical, or biological contamination by installing,
implementing, or instituting feasible engineering or
administrative controls. If these controls do not prove feasible,
appropriate respiratory protection must be used.
2.8.3.1 Responsibilities
Supervisor
1. Ensures that all employees who wear respiratory protective devices

are thoroughly trained in their use.
2. Provides employees with the respiratory protection appropriate for
the operation, and ensures the use of such devices.
3. Identifies potentially hazardous conditions and immediately notifies
the Local Health Authority for corrective action.
Employee
1. Uses respiratory protective equipment as instructed and required

under hazardous agent protocols.
2. Stores respirator properly to prevent damage and inspects prior to
each use.
3. Reports any malfunction of respiratory protective equipment to the
immediate supervisor.
1. Periodically inspects all respiratory protective devices stored for

operation procedures and emergency use.

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2.8.4. Eye Hazards
Always use protective eye and face equipment where

machines or operations present hazards of glare, flying
objects, chemicals, radiation or any combination thereof.
Protection is specifically required around welding or Ultra-
violet (UV) equipment.
Supervisor
1. Must emphasize the need and importance of wearing eye

protection.
2. Must ensure that all employees under his/her direction have and
wear eye protection.
3. Makes sure visitors to laboratory areas wear eye protection.
4. Suggests areas requiring posting concerning required eye protection
to the Local Health Authority.
Employee
1. Uses correct eye protection as designated by supervisor and Local

Health Authority at appropriate times and for appropriately
designated tasks.
2. Conforms to Local Health Authority policy on eye care and uses good
safe laboratory practices.
1. Determines areas that will be designated as eye hazard areas.

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2.8.5. Electrical Hazards
Always treat all circuits as if they are live until you have
personally disconnected the power.
Keep your clothing, hands and feet dry at all times.
Do not wear rings, watches, metal-rimmed glasses or jewelry

when working around electrical circuits.
Supervisor
1. All work hazards must be anticipated and all safeguards utilized.

2. Ensures that all employees are properly trained and instructed in the
safe operation of electrical equipment and aware of all hazards
associated with the use of these electrical devices.
3. Initiates any necessary administrative action required to enforce
safety practices.
Employee
1. Follows the company’s electrical safety policies and procedures and

instructions of responsible supervisor and/or Local Health Authority.
2. Brings to the attention of the supervisor and/or Local Health
Authority potential hazardous situations such as discrepancies
between instruction, procedures, policies and manual, faulty
equipment, misapplication of device, etc.
3. Electrical equipment known to be malfunctioning must be repaired
or replaced before use. The repair must be initiated as soon as
possible after the malfunction is noted.
1. Assists supervisors in defining hazardous operations, designating

safe practices and selecting proper application of devices.
2. When necessary, obtains from the principle supervisor, standard
operating procedure for electrical equipment and devices in use.
3. Reviews and approves standard operating procedures.
4. Evaluates potential electrical hazards during facility inspections to
insure compliance with local policy and other safety guidelines.

OP999
2.8.6. Mechanical Hazards
Always use spare parts of a type and part number recommended

by NOV HydraRig UK.
Always replace all parts when adjusting or replacing equipment.
Do not wear rings, watches, jewelry, ties or loose sleeves when

working around moving mechanical parts.
Securely tuck all long hair under a cap when working around
moving mechanical parts.
Supervisor
1. All work hazards must be anticipated and all safeguards utilized.
2. Ensures that all employees are properly trained and instructed in the
safe operation of mechanical equipment and aware of all hazards
associated with the use of these devices.
3. Initiates any necessary administrative action required to enforce
safety practices.
Employee
1. Follows the company’s mechanical safety policies and procedures
and instructions of responsible supervisor and/or Local Health
Authority.
2. Brings to the attention of the supervisor and/or Local Health
Authority potential hazardous situations such as discrepancies
between instruction, procedures, policies and manual, faulty
equipment, misapplication of device, etc.
3. Mechanical equipment known to be malfunctioning must be
repaired or replaced before use. The repair must be initiated as soon
as possible after the malfunction is noted.

1. Assists supervisors in defining hazardous operations, designating
safe practices and selecting proper application of devices.
2. When necessary, obtains from the principle supervisor, standard
operating procedure for mechanical equipment and devices in use.
3. Reviews and approves standard operating procedures.
4. Evaluates potential mechanical hazards during facility inspections to
ensure compliance with local policy and other safety guidelines.

OP999
2.8.7 Lubricants Hazards
Always wear appropriate hand protection when handling oils and

ensure good hygiene practices are observed thereafter.
CAUTION
It is illegal to pollute drains, sewers or the ground. Clean up all split fluids and/or
lubricants. Used fluids and/or disposed of in accordance with local regulations.
Use authorised waste disposal sites. All waste products should be disposed of in
accordance with all the relevant regulations. The collection and disposal of used
oil should be in accordance with any local regulations. Never pour used engine oil
into the sewers, drains or on the ground.
Handling
New Oil-There is no special precautions needed for the handling or use of new oil,
beside the normal care and hygiene practices.
Used Oil-Used engine crankcase lubricants contain harmful contaminants.
Here are precautions to protect your health when handling used engine oil:
1) Avoid prolonged, excessive or repeated skin contact with used oil

2) Apply a barrier cream to the skin before handling used oil
3) Note the following when removing engine oil from skin:
· wash your skin thoroughly with soap and water
· using a nail brush will help
· Use special hand cleaners to help clean dirty hands
· never use petrol, diesel fuel, or paraffin for washing
4) Avoid contact with oil soaked clothing.
5) Don’t keep oily rags in pockets.
6) Wash dirty clothing before re-use.
7) Throw away oil-soaked shoes.

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First aid-Oil
Eyes
In the case of eye contact flush with water for 15 minutes. If irritation persists, get
medical attention.
Swallowing
If oil is swallowed do not induce vomiting. Get medical advice.
Skin
In the case of excessive skin contact, wash with soap and water.
Spillage
Absorb on sand or a locally approved brand of absorbent granules. Scrape up and
remove to a chemical disposal area.
Fires
Extinguish with carbon dioxide, dry chemical or foam. Fire fighters should use self-
contained breathing apparatus.

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2.9. Injury Treatment
If you require medical treatment for any problems arising from incorrect use of NOV
HydraRig UK equipment, please read the following headings.
2.9.1. Injured or Trapped Body Parts
1. Notify your colleagues that you require treatment for injury and/or
assistance to release a trapped body part.
2. Make sure any injury is correctly treated.
2.9.2. Inhalation Problems
1. Immediately exit the work area.

2. Signal your foreman or work colleagues that you have problems breathing
and that the work area is possibly contaminated with fumes.
2.9.3. Burns
1. Immediately apply water to the burned area.

2. Notify your colleagues or foreman that you require treatment for burns.
2.9.4. Acid Spills
1. Immediately apply water to the skin area contaminated with acid spill (use a
shower if available).
2. Notify your colleagues or foreman that you require treatment for acid
burns.
2.9.5. Eye Damage
1. Signal your foreman or work colleagues that you have eye damage and
indicate the cause.
2. If the eye damage is caused by contaminating spray, rinse your eye(s) with
an eye bath filled with water.

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2.10. Lifting Safety
2.10.1 General
· While working with equipment follow the field's rules and regulations.
· When lifting the unit by crane or forklift, make sure that you cannot get trapped
between the load and a wall or a fixed object, etc.
· If possible, position yourself so that you are visible to the crane operator. If not,
make sure a flag man is available to give signs to the crane operator.
· Never walk under hanging load!
· Make sure that lifting gear to be used is sufficiently dimensioned.
· All lifting equipment used with this equipment must have the correct
certification and be marked accordingly. The lifting equipment may only be used
by instructed personnel.
· Before each lift it must be checked that the shackles are mounted in a correct
manor.
· The equipment must be checked yearly for deformation and wear.
2.10.2 Specific Safety Precautions
· Before lifting the unit ensure:

§ all hydraulic hoses are disconnected and connectors are cleaned and
capped.
§ all cables are properly stowed.
§ all hatches, doors or lids are closed and locked.
2.10.3 Technical Specifications

· 4 point lifting, lifting angle 45°
· side entry bottom forklift pockets
· dimensions (LxWxH) 4572mm x 2438mm x .2600mm
· weight
§ Payload = 1,000 kgs
§ Tare = 9,500 kgs
§ Gross = 10,500 kgs

ASSET No. 12220042
SECTION 3.0 – DEFINITION OF TERMS

OP 999
Operation & Maintenance - Volume 1
3.0 DEFINITIONS OF TECHNICAL TERMS
NOTE Definitions listed relate to the context in which these terms are used in this manual. A
more general definition of terms is given in the “Glossary of Terms for Fluid Power NFPA
Recommended Standard T2.70.1”.
ABSOLUTE – A measure having as its zero point or base the complete absence of the entity being
measured.
ABSOLUTE PRESSURE – The pressure above zero absolute, i.e., the sum of atmospheric and gage
pressure. In vacuum related work it is usually expressed in millimetres of mercury (mm Hg).
ACCUMULATOR – A container in which fluid is stored under pressure as a source of fluid power.
ACTUATOR – A device for converting hydraulic energy into mechanical energy. A motor or
cylinder.
AERATION – Air in the hydraulic fluid. Excessive aeration causes the fluid to appear milky and
components to operate erratically because of the compressibility of the air trapped in the fluid.
AMPLIFIER – A device for amplifying the error signal sufficiently to cause actuation of the stroke
control. Several types of servo amplifiers are used at the present time: electronic (DC, AC, phase
sensitive, and magnetic) and mechanical.
AMPLITUDE OF SOUND – The loudness of a sound.
ANNULAR AREA – A ring shaped area - often refers to the net effective area of the rod side of a
cylinder piston, i.e., the piston area minus the cross-sectional area of the rod.
ATMOSPHERE (ONE) – A pressure measure equal to 14.7 psi.
ATMOSPHERIC PRESSURE – Pressure exerted by the atmosphere at any specific location. (Sea
level pressure is approximately 14.7 pounds per square inch absolute).
BACK CONNECTED – A condition where pipe connections are on normally unexposed surfaces of
hydraulic equipment. (Gasket mounted units are back connected).
BACK PRESSURE – A pressure in series. Usually refers to pressure existing on the discharge side of
a load. It adds to the pressure required to move the load.
BAFFLE – A device, usually a plate, installed in a reservoir to separate the pump inlet from return
lines.

OP 999
BLEED-OFF – To divert a specific controllable portion of pump delivery directly to reservoir.
BREATHER – A device which permits air to move in and out of a container or component to
maintain atmospheric pressure.
BY-PASS – A secondary passage for fluid flow.
CARTRIDGE
1. The replaceable element of a fluid filter.
2. The pumping unit from a vane pump composed of the rotor, ring, vanes and one or both
side plates.
CAVITATION – A localised gaseous condition within a liquid stream which occurs where the
pressure is reduced to the vapour pressure.
CHAMBER – A compartment within a hydraulic unit. May contain elements to aid in operation or
control of a unit. Examples: spring chamber, drain chamber, etc.
CHARGE (supercharge)
1. To replenish a hydraulic system above atmospheric pressure.
2. To fill an accumulator with fluid under pressure (see pre-charge pressure).
CHARGE PRESSURE – The pressure at which replenishing fluid is forced into the hydraulic system
(above atmospheric pressure).
CHECK VALVE – A valve which permits flow of fluid in one direction only.
CHOKE – A restriction, the length of which is large with respect to its cross-sectional dimension.
CIRCUIT – An arrangement of components interconnected to perform a specific function within a

system.
CLOSED CENTRE VALVE – One in which all ports are blocked in the centre or neutral position.
CLOSED CENTRE CIRCUIT – One in which flow through the system is blocked in neutral and
pressure is maintained at the maximum pressure control setting.
CLOSED LOOP – A system in which the output of one or more elements is compared to some other
signal to provide an actuating signal to control the output of the loop.

OP 999
COMMAND SIGNAL (or input signal) – An external signal to which the servo must respond.
COMPENSATOR CONTROL – A displacement control for variable pumps and motors which alters
displacement in response to pressure changes in the system as related to its adjusted pressure
setting.
COMPONENT – A single hydraulic unit.
COMPRESSIBILITY – The change in volume of a unit volume of a fluid when it is subjected to a unit
change in pressure.
CONTROL – A device used to regulate the function of a unit (see Hydraulic Control, Manual
Control, Mechanical Control, and Compensator Control).
COOLER – A heat exchanger used to remove heat from the hydraulic fluid.
COUNTERBALANCE VALVE – A pressure control valve which maintains back pressure to prevent a
load from falling.
CRACKING PRESSURE – The pressure at which a pressure actuated valve begins to pass fluid.
CUSHION – A device sometimes built into the ends of a hydraulic cylinder which restricts the flow
of fluid at the outlet port, thereby arresting the motion of the piston rod.
CYLINDER – A device which converts fluid power into linear mechanical force and motion. It
usually consists of a movable element such as a piston and piston rod, plunger rod, plunger ram,
operating within a cylindrical bore.
DEADBAND – The region or band of no response where an error signal will not cause a
corresponding actuation of the controlled variable.
DECOMPRESSION – The slow release of confined fluid to gradually reduce pressure on the fluid.
DELIVERY – The volume of fluid discharged by a pump in a given time, usually expressed in gallons
per minute (gpm).
DE-VENT – To close the vent connection of a pressure control valve permitting the valve to
function at its adjusted pressure setting.
DIFFERENTIAL CURRENT – The algebraic summation of the current in the torque motor; measured
in MA (milliamperes).

OP 999
DIFFERENTIAL CYLINDER – Any cylinder in which the two opposed piston areas are not equal.
DIRECTIONAL VALVE – A valve which selectively directs or prevents fluid flow to desired channels.
DISPLACEMENT – The quantity of fluid which can pass through a pump, motor or cylinder in a
single revolution or stroke.
DITHER – A low amplitude, relatively high frequency periodic electrical signal, sometimes
superimposed on the servo valve input to improve system resolution. Dither is expressed by the
dither frequency (Hz) and the peak-to-peak dither current amplitude (ma).
DOUBLE ACTING CYLINDER – A cylinder in which fluid force can be applied to the movable element
in either direction.
DRAIN – A passage in, or a line from, a hydraulic component which returns leakage fluid
independently to reservoir or to a vented manifold.
EFFICIENCY – The ratio of output to input. Volumetric efficiency of a pump is the actual output in
gpm divided by the theoretical or design output. The overall efficiency of a hydraulic system is the
output power divided by the input power. Efficiency is usually expressed as a percent.
ELECTRO-HYDRAULIC SERVO VALVE - A directional type valve which receives a variable or

controlled electrical signal and which controls or meters hydraulic flow.
ENERGY – The ability or capacity to do work. Measured in units of work.
ENCLOSURE – A rectangle drawn around a graphical component or components to indicate the

limits of an assembly.
ERROR (signal) – The signal which is the algebraic summation of an input signal and a feedback
signal.
FEEDBACK (or feedback signal) – The output signal from a feedback element.
FEEDBACK LOOP – Any closed circuit consisting of one or more forward elements and one or more
feedback elements.
FILTER – A device whose primary function is the retention by a porous media of insoluble
contaminants from a fluid.
FLOODED – A condition where the pump inlet is charged by placing the reservoir oil level above
the pump inlet port.

OP 999
FLOW CONTROL VALVE – A valve which controls the rate of oil flow.
FLOW RATE – The volume, mass, or weight of a fluid passing through any conductor per unit of
time.
FLUID
1. A liquid or gas.
2. A liquid that is specially compounded for use as a power-transmitting medium in a
hydraulic system.
FOLLOW VALVE – A control valve which ports oil to an actuator so the resulting output motion is
proportional to the input motion to the valve.
FORCE – Any push or pull measured in unit weight. In hydraulics, total force is expressed by the
product P (force per unit area) and the area of the surface on which the pressure is applied. F = P
x A.
FOUR-WAY VALVE – A directional valve having four flow paths.
FREQUENCY – The number of times an action occurs in a unit of time. Frequency is the basis of all
sound. A pump or motor’s basic frequency is equal to its speed in revolutions per second
multiplied by the number of pumping chambers.
FRONT CONNECTED – A condition wherein piping connections are on normally exposed surfaces of
hydraulic components.
FULL FLOW – In a filter, the condition where all the fluid must pass through the filter element or
medium.
GAUGE PRESSURE – A pressure scale which ignores atmospheric pressure. Its zero point is 14.7 psi
absolute.
HEAD – The height of a column or body of fluid above a given point expressed in linear unit. Head
is often used to indicate gage pressure. Pressure is equal to the height times the density of the
fluid.
HEAT – The form of energy that has the capacity to create warmth or to increase the temperature
of a substance. Any energy that is wasted or used to overcome friction is converted to heat. Heat
is measured in calories or British Thermal Units (BTU’s). One
BTU is the amount of heat required to raise the temperature of one pound of water one degree
Fahrenheit.
HEAT EXCHANGER – A device which transfers heat through a conducting wall from one fluid to
another.

OP 999
HORSEPOWER (HP) – The power required to lift 550 pounds one foot in one second or 33,000
pounds one foot in one minute. A horsepower is equal to 746 watts or to 42.4 British Thermal
Units per minute.
HYDRAULIC BALANCE – A condition of equally opposed hydraulic forces acting on a part in a

hydraulic component.
HYDRAULIC CONTROL – A control which is actuated by hydraulically induced forces.
HYDRAULICS – Engineering science pertaining to liquid pressure and flow.
HYDRODYNAMICS – Engineering science pertaining to the energy of liquid flow and pressure.
HYDROSTATICS – Engineering science pertaining to the energy of liquids at rest.
KINETIC ENERGY – Energy that a substance or body has by virtue of its mass (weight) and velocity.
LAMINAR (FLOW) – A condition where the fluid particles move in continuous parallel paths.
Streamline flow.
LEVERAGE – A gain in output force over input force by sacrificing the distance moved. Mechanical
advantage or force multiplication.
LIFT – The height a body or column of fluid is raised; for instance, from the reservoir to the pump
inlet. Lift is sometimes used to express a negative pressure or vacuum. The opposite of head.
LINE – A tube, pipe or hose which acts as a conductor of hydraulic fluid.
LINEAR ACTUATOR – A device for converting hydraulic energy into linear motion - a cylinder or
ram.
MANIFOLD – A fluid conductor which provides multiple connection ports.
MANUAL CONTROL – A control actuated by the operator, regardless of the means of actuation.
Example: Lever or foot pedal control for directional valves.
MANUAL OVERRIDE – A means of manually actuating an automatically-controlled device.
MAXIMUM PRESSURE VALVE – See relief valve.
MECHANICAL CONTROL – Any control actuated by linkages, gears, screws, cams or other
mechanical elements.

OP 999
METER – To regulate the amount or rate of fluid flow.
METER-IN – To regulate the amount of fluid flow into an actuator or system.
METER-OUT – To regulate the flow of the discharge fluid from an actuator or system.
MICRON – One millionth of a meter or about .00004 inch.
MICRON RATING – The size of the particles a filter will remove.
MOTOR – A device which converts hydraulic fluid power into mechanical force and motion. It
usually provides rotary mechanical motion.
OPEN CENTRE CIRCUIT – One in which pump delivery flows freely through the system and back to
the reservoir in neutral.
OPEN CENTRE VALVE – One in which all ports are interconnected and open to each other in the
centre or neutral position.
ORIFICE – A restriction, the length of which is small in respect to its cross-sectional dimensions.
PASSAGE – A machined or cored fluid conducting path which lies within or passes through a
component.
PILOT PRESSURE – Auxiliary pressure used to actuate or control hydraulic components.
PILOT VALVE – An auxiliary valve used to control the operation of another valve. The controlling
stage of a 2-stage valve.
PISTON – A cylindrically shaped part which fits within a cylinder and transmits or receives motion
by means of a connecting rod.
PLUNGER – A cylindrically shaped part which has only one diameter and is used to transmit thrust.
A ram.
POPPET – That part of certain valves which prevents flow when it closes against a seat.
PORT – An internal or external terminus of a passage in a component.
POSITIVE DISPLACEMENT – A characteristic of a pump or motor which has the inlet positively
sealed from the outlet so that fluid cannot recirculate in the component.
POTENTIOMETER – A control element in the servo system which measures and controls electrical
potential.

OP 999
POWER – Work per unit of time. Measured in horsepower (hp) or watts.
POWER PACK – An integral power supply unit usually containing a pump, reservoir, relief valve and
directional control.
PRECHARGE PRESSURE – The pressure of compressed gas in an accumulator prior to the admission
of liquid.
PRESSURE – Force per unit area; usually expressed in pounds per square inch (psi).
PRESSURE DROP – The difference in pressure between any two points of a system or a
component.
PRESSURE LINE – The line carrying the fluid from the pump outlet to the pressurised port of the
actuator.
PRESSURE OVERRIDE – The difference between the cracking pressure of a valve and the pressure
reached when the valve is passing full flow.
PRESSURE PLATE – A side plate in a vane pump or motor cartridge on the pressure port side.
PRESSURE REDUCING VALVE – A valve which limits the maximum pressure at its outlet regardless
of the inlet pressure.
PRESSURE SWITCH – An electric switch operated by fluid pressure.
PROPORTIONAL FLOW – In a filter, the condition where part of the flow passes through the filter
element in proportion to pressure drop.
PUMP – A device which converts mechanical force and motion into hydraulic fluid power.
RAM – A single-acting cylinder with a single diameter plunger rather than a piston and rod. The
plunger in a ram-type cylinder.
RECIPROCATION – Back-and-forth straight line motion or oscillation.
REGENERATIVE CIRCUIT – A piping arrangement for a differential type cylinder in which discharge
fluid from the rod end combines with pump delivery to be directed into the head end.
RELIEF VALVE – A pressure operated valve which by-passes pump delivery to the reservoir, limiting
system pressure to a predetermined maximum value.
REPLENISH – To add fluid to maintain a full hydraulic system.

OP 999
RESERVOIR – A container for storage of liquid in a fluid power system.
RESTRICTION – A reduced cross-sectional area in a line or passage which produces a pressure

drop.
RETURN LINE – A line used to carry exhaust fluid from the actuator back to sump.
REVERSING VALVE – A four-way directional valve used to reverse a double-acting cylinder or

reversible motor.
ROTARY ACTUATOR – A device for converting hydraulic energy into rotary motion - a hydraulic
motor.
SEQUENCE
1. The order of a series of operations or movements.

2. To divert flow to accomplish a subsequent operation or movement.
SEQUENCE VALVE – A pressure operated valve which, at its setting, diverts flow to a secondary line
while holding a predetermined minimum pressure in the primary line.
SERVO MECHANISM (servo) – A mechanism subjected to the action of a controlling device which
will operate as if it were directly actuated by the controlling device, but capable of supplying
power output many times that of the controlling device, this power being derived from an external
and independent source.
SERVO VALVE
1. A valve which modulates output as a function of an input command.

2. A follow valve.
SIGNAL – A command or indication of a desired position or velocity.
SINGLE ACTING CYLINDER – A cylinder in which hydraulic energy can produce thrust or motion in
only one direction. (May be mechanical or gravity returned).
SLIP – Internal leakage of hydraulic fluid.
SPOOL – A term loosely applied to almost any moving cylindrically shaped part of a hydraulic
component which moves to direct flow through the component.
STRAINER – A coarse filter.
STREAMLINE FLOW – (see laminar flow).

OP 999
STROKE
1. The length of travel of a piston or plunger.

2. To change the displacement of a variable displacement pump or motor.
SUB-PLATE – An auxiliary mounting for a hydraulic component providing a means of connecting

piping to the component.
SUCTION LINE – The hydraulic line connecting the pump inlet to the reservoir or sump.
SUMP – A reservoir.
SUPERCHARGE – (see charge).
SURGE – A transient rise of pressure or flow.
SWASH PLATE – A stationary canted plate in an axial type piston pump which causes the pistons to
reciprocate as the cylinder barrel rotates.
SYNCHRO – A rotary electromagnetic device generally used as an AC feedback signal generator

which indicates position. It can also be used as a reference signal generator.
TACHOMETER (AC) (DC) – A device which generates an AC or DC signal proportional to the speed
at which it is rotated and the polarity of which is dependent on the direction of rotation of the
rotor.
TANK – The reservoir or sump.
THROTTLE – To permit passing of a restricted flow. May control flow rate or create a deliberate
pressure drop.
TORQUE – A rotary thrust. The turning effort of a fluid motor usually expressed in inch pounds.
TORQUE CONVERTER – A rotary fluid coupling that is capable of multiplying torque.
TORQUE MOTOR – A type of electromechanical transducer having rotary motion used in the input
stages of servo valves.
TRANSDUCER (or feedback transducer) – An element which measures the results at the load and
sends a signal back to the amplifier.
TURBULENT FLOW (TURBULENCE) – A condition where the fluid particles move in random paths
rather than in continuous parallel paths.

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TURBINE – A rotary device that is actuated by the impact of a moving fluid against blades or vanes.
TWO-WAY VALVE – A directional control valve with two flow paths.
UNLOAD – To release flow (usually directly to the reservoir), to prevent pressure being imposed
on the system or portion of the system.
UNLOADING VALVE – A valve which by-passes flow to tank when a set pressure is maintained on
its pilot port.
VACUUM – Pressure less than atmospheric pressure. It is usually expressed in inches of mercury
(in. Hg) as referred to the existing atmospheric pressure.
VALVE – A device which controls fluid flow direction, pressure, or flow rate.
VELOCITY
1. The speed of flow through a hydraulic line. Expressed in feet per second (fps) or inches per
second (ips).
2. The speed of a rotating component measured in revolutions per minute (rpm).
VENT
1. To permit opening of a pressure control valve by opening its pilot port (vent connection) to
atmospheric pressure.
2. An air breathing device on a fluid reservoir.
VISCOSITY – A measure of the internal friction or the resistance of a fluid to flow.
VISCOSITY INDEX – A measure of the viscosity-temperature characteristics of a fluid as referred to

that of two arbitrary reference fluids.
VOLUME
1. The size of a space or chamber in cubic units.

2. Loosely applied to the output of a pump in gallons per minute (gpm).
WOBBLE PLATE – A rotating canted plate in an axial type piston pump which pushes the pistons
into their bores as it “wobbles”.
WORK – Exerting a force through a definite distance. Work is measured in units of force multiplied
by distance. For example, pound-foot.

ASSET No. 12220042
SECTION 4.0 – SYSTEM OUTLINE

OP999
Operation & Maintenance – Volume 1
4.0 SYSTEM OUTLINE
4.1 Scope of Supply
Hydraulic pump power and liquid nitrogen vaporizing heat are supplied via a diesel power
pack. The system converts waste engine heat used in the nitrogen vaporizing.
During normal operation liquid nitrogen flows from a storage vessel through the
centrifugal charge pump where the suction pressure to the triplex pump is boosted to
meet the required inlet conditions. The liquid nitrogen is then pressurized by the
reciprocating pistons of the triplex pump to the required downstream pressure. The high
pressure liquid then flows through the nitrogen / water heat exchanger where it is
vaporized and the gaseous nitrogen temperature is raised to a minimum of 20 degrees
Celsius.
The heat balance between the hydraulically loaded engine and the nitrogen vaporization
circuit is obtained by transferring the heat through a plate heat exchanger. The engine
water temperature is maintained in all conditions by thermostatically controlling the water
flow either back to the engine water pump or to an air blast radiator.
4.2 Description of the Major Components
Skid and Frame designed to BS EN 12079, DNV certifications note 2.7-1. Upper frame
manufactured from 100 x 100mm box section steel. Base section includes ISO twist lock
blocks set on STD ISO 10’ x 8’ container size. 350mm x 150mm on 2000mmm centres
forklift pockets are integral to the base skid
Power Unit: CAT 3406C DITA Turbocharged and after cooled - 490 BHP at 2100 rpm.
Engine conforms to BP 200 requirements for the protection of Diesel engines working in 3G
T3 (Zone 2) areas. Engine meets Tier 1 for emissions for land based and off-shore
operation. Engine Zone 2 protection equipment includes, exhaust gas heat exchanger, air
inlet shut down valve and engine protection system with exhaust flame traps.
· Galvanized steel radiator

· All engine coolant pipework stainless steel.
· Engine air inlet and engine exhaust pipework stainless steel.
· Zone 2 certified stainless steel spark arresting exhaust silencer.
Engine loading is achieved using a Denison hydraulic vane pump, the applied load is
controlled by remote activation of the sequence valve.

OP999
Closed loop: This system uses separate hydraulic pumps for triplex drive and heat load. A
closed loop piston pump drives the triplex and a large double vane pump provides the heat
load. This allows the heat load to be applied independently to the operation of the triplex.
The triplex pump drive is obtained using a Denison P14 variable flow high pressure piston
hydraulic pump.
The Triplex pump power end: A Hydra Rig model number NP 200 complete with integral
reduction drive and Rexroth hydraulic drive motor.
NOV Hydra Rig UK designed and built 1 5/8” cold end pumps D.N.V. approved, 10,000 psi
working pressure, 180,000 scf/h flow.
NOV Hydra Rig UK designed and built 1 1/2” x 2 1/2” x 6” centrifugal charge pump.
NOV Hydra Rig UK designed and built high pressure vaporizer, used to convert the waste
heat obtained from the power pack and hydraulic circuits to useful heat for liquid nitrogen
conversion.
Non slip material on all ladder rungs and a harness point at the top of each ladder.
Sealed internal floor to catch spillages.
4.2.1 Instrumentation and Controls
A local panel contains all the instrumentation and controls to ensure compliance to
the standards applicable to meet Zone 2 and CE marking regulations.
The control panel and enclosure constructed from stainless steel and the panel sub
divided by circuits to allow for ease of operation of all the valves and controls. The
gauges to read in both psi and bar for pressure and Celsius and Fahrenheit for
temperature.
The panel includes the following gauges and safety features:
· Engine controls; start, stop, emergency stop, engine rpm/hour meter, oil
pressure, water pressure, air pressure, water temperature, engine speed
control.
· Nitrogen hp pump and discharge system; hydraulic pressure, hydraulic charge

pressure, MC11 digital rate/totalizer display, nitrogen discharge temperature,
discharge control valve, pump speed control, lubricating oil pressure and
temperature, hydraulic oil temperature.

OP999
· Vaporizer circuit temperature.
· Shut down indicators for high exhaust temperature, high water temperature,
low oil pressure, over-speed and discharge overpressure.
Fuel and Air Shut down Valves to close automatically on:
· Engine over speed

· Emergency stop
· High exhaust temperature (max 200deg. C)
· High coolant temperature
· Low oil pressure (engine)
· Low air system pressure.
4.2.2 Cryogenic Piping
All the cryogenic piping of either type 316 or 304 stainless steel. Piping installed
with sufficient flexibility to avoid damage during cool down or transportation. The
system and cryogenic valves conform to the requirements of the PED directive.
4.2.3 Special Features
· Cryogenic long stem ball valves for the liquid nitrogen circuit.
· Stainless Steel fuel and hydraulic tanks.
· Tempering line around the nitrogen vaporizer to control the gaseous
nitrogen discharge temperature.
· Stainless steel floor in all areas exposed to possible cryogenic spillage.
· High pressure safety shut down system.
· Discharge relief valve set at 11,000 psi and a gas line check valve for unit
protection.
· The control panel mounted on the end of the skid assembly.
· Engine equipped with an air start system.
· Cryogenic suction, boost pump bypass and return fittings 1-1/2 “CGA.
· Vent valves on LN2 inlets
· Hydraulically operated discharge valve 2 x 1 valve with a “Danfoss” actuator.
· OPP vent connection point ( ¼” BSP male with cap)
· Slings provided.
· Stainless steel nuts and bolts where possible.
· Tool box, large enough to store boost pump, cold ends, fuel filters, vee belts
and other small spares.

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4.2.4 Painting/Corrosion Protection
· Shot blasting, priming and finish painting to customer specifications.

· All fluid tanks clearly marked as to contents.
· Hoses ends and fittings coated with rust preventing wax.
· PVC cover complete with unit weight and asset number provided.
4.2.5 Documentation and Manuals
Two off operating and maintenance manuals in accordance with DNV complete
with schematics, parts lists and trouble shooting procedures. Two off separate
quality manuals to be supplied containing all records applicable to both the FAT
document and the requirements for D.N.V. and C.E. Marking.
4.2.6 Testing
The equipment furnished field tested and in field ready condition. The Customer
Acceptance testing performed with the customer representative witnessing. A pre-
test performed before the customer acceptance test. Customer shall provide a
minimum of 2 tanks of LN2 for testing, or NOV Hydra Rig to supply and to recharge.
Testing carried out to meet your customer acceptance testing requirements and
incorporates the following:
· 1/2 hour at full rate and 1,500 psi back pressure and showing a minimum of
20 degree C discharge temperature.
· 1 hour at full rate and 10,000 psi back pressure.
· Chart recording taken on the above tests.
· Start up and testing data taken and recorded in a test report.
· Customer representative to include a customer test report.
The following supplied prior to the unit release note being issued:
· Hydrostatic test reports on all pressure equipment to be supplied to the

customer representative for inspection.
· Report on the corrective action taken on any deficiencies identified during
the testing.

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4.3 General Description
The system comprises the following components whose actions are further described in
4.4.
a. Diesel Engine: Caterpillar 3406C DITA producing 490 HP @ 2100 RPM providing all
necessary power. The engine is fitted with Zone II equipment comprising exhaust
gas heat exchanger, air inlet shutdown valve and engine protection devices.
b. Centrifugal Charge Pump: (boost pump) supplies the main nitrogen triplex pump
with a positive head of liquid nitrogen.
c. Triplex Pump: A positive displacement pump which increases the LN2 pressure to a
maximum operating pressure of 10,000 PSIG; consisting of the following:
i. COLD END(s): The reciprocating positive displacement pistons that draw in

low pressure LN2. Cold Ends are attached to and driven by the warm end
ii. WARM END(s): The mechanical drive and plunger section of the triplex
pump assembly.
The Warm End drives the attached Cold Ends.
d. LN2 Vaporiser: This part of the system converts the liquid nitrogen to a gas by
absorbing heat from the coolant loop circuit.
e. Controls and Indicators: Consisting of a control panel to display and control:

Nitrogen discharge, Coolant Circuit, LN2 Charge Pump, Lube Oil, Engine Controls
and safety shut downs. Valving is provided throughout the unit to bleed, direct and
block nitrogen flow as required.
f. Coolant Loop Circuit: Water/Glycol system that collects unit generated heat for LN2
vaporisation.

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4.4 Component Actions
a. Power Unit
Caterpillar 3406C DITA producing 490 HP @ 2100 RPM: Engine speed is controlled
mechanically and governed via manual control cables. Engine power is accessed via
the power take off.
b. Centrifugal Charge Pump
To insure that positive pressure of liquid nitrogen is available for pumping and
vaporisation. The centrifugal charge (boost) pump is used to maintain a pressure of
40-100 PSIG on the suction of the cold end. This is necessary to maintain net
positive suction head across the cold end vent or return pressure. Typically, cold
end(s) require between 30-40 PSIG NPSH to pump efficiently.
c. Triplex Pump
The triplex pump cold end(s) receive the liquid nitrogen at a pressure of 40-100
PSIG. The three positive displacement cold end chambers are capable of
pressurising the liquid nitrogen to a maximum pressure of 10,000 PSIG.
d. Heat Exchanger
There are three basic types of heat exchangers utilised, shell and tube heat
exchanger, plate heat exchanger and air blast exchanger, all function virtually the
same. A heat exchanger normally has two or three isolated fluid paths. As two
different temperature fluids flow through these paths, the higher temperature fluid
gives up heat to lower temperature fluid.
e. LN2 Vaporiser
i. The vaporiser is the heart of the vaporisation system. The vaporiser is a

specially designed heat exchanger consisting of an exchanger filled with a
wrapped tubing bundle to pass the LN2. The coolant loop fluid floods the
exchanger and flows around the tubing at a pressure of 80-150 PSIG. When
the LN2 (-196°C) circulates through the tubes of the tubing bundle, the LN2
gains heat as required from the water circuit. Typically the gaseous
temperature is controlled at 20°C. This discharge gas is normally measured
in SCFM (Standard Cubic Feet per Minute). The coolant loop temperature is
manually controlled to maintain a steady input to the vaporiser between
50°C-70°C. The heat is generated in the coolant loop and is acquired from
two separate sources as listed below:

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Waste heat generated by the hydraulic system. (Via a heat exchanger.)

Waste heat from the engine cooling system. (Via a heat exchanger.)
ii. Hydraulic heat exchanger. The coolant fluid will absorb additional heat from
the hydraulic oil. In cold weather a reverse heat exchange is possible, i.e.
the coolant loop exchanges heat into the hydraulic oil. This is desirable in
cold weather because it allows a more rapid unit warm up allowing
operations to start sooner.
iii Engine Cooling System: The engine water cooling system produces a large
percentage of the heat required to warm up the vaporisation coolant circuit.
The amount varies depending upon the horsepower draw or engine load.

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4.5 Controls and Indicators
Most of the controls and indicators needed to control the system are contained on the
engine control panel and nitrogen control panel. The following is a brief description of the
panel control areas and their purpose as shown in the following diagram.
4.5.1 Engine Control and Indicators

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4.5.2 Nitrogen Pumping Controls and Indicators
2 & 27.Flow Rate – indicates customer requirements in either cubic metre or feet
per hour of nitrogen gas discharge.
3. GN2 Discharge Pressure Gauge – indicates the pressure of gas nitrogen at

discharge.
4. Triplex Lube Oil Pressure Gauge – provides information of oil pressure in

the lubrication system for the power end.
11. GN2 Discharge Temperature Gauge – indicates the gas nitrogen

temperature.
12. Triplex Lube Oil Temperature Gauge – provides information on lubrication

system for the power end.
12. Hydraulic Oil Temperature Gauge – indicates temperature of hydraulic oil.
14. LN2 Pressure Gauge – indicates the nitrogen pressure.
15. Push to Activate – safety button has to be operated before discharge valve
can be operated.
23. Triplex Speed Adjust – adjusts speed of triplex pump.
26. GN2 Discharge Valve (Open/Closed) - utilises Activate button (15) & valve
(26) which must be depressed for the discharge control valve to operate this
is a two handed operation to prevent accidental operation of the valve.
29. Nitrogen Over Pressure Indicator– indicates nitrogen gas discharge pressure
above maximum system pressure.
29 GN2 Discharge Valve Indicator – indicates whether discharge valve is in the

open or closed position.

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4.5.3 Heat Load Controls
5. Heat Load Pressure Gauge – indicates heat load. (hydraulic pressure)
11. Coolant Temperature Gauge – indicates the temperature of the coolant

water.
19, 20. Hydraulic Load Control – controls the load on hydraulic system.
4.5.4 Boost Pump Controls
9. Boost Pump Pressure Gauge – indicates pressure from the boost pump
10. Hydraulic Pressure Gauge – indicates hydraulic pressure driving the boost
pump.
21. Boost Pump Speed Control – adjusts the speed of the boost pump by
controlling the hydraulic pressure.

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4.5.5 Engine Controls
4. Engine Oil Pressure Gauge – provides information on engine oil pressure.
6. System Hydraulic Pressure Gauge – indicates triplex drive motor pressure.
7. Charge Pressure Gauge – indicates P14 charge pressure.
8. Air Pressure Gauge – indicates system air pressure.
12. Engine Water Temperature Gauge – indicates engine water temperature.
13. Exhaust Temperature Gauge – indicates exhaust temperature.
15. Permissive Override – press and hold until oil pressure rises and stabilises.
Use in-conjunction with air starter.
16. Engine Stop – push button to normal to stop engine.
17. Air Start – push button which operates engine air starter motor to start
engine.
18. Emergency Stop – kills system operation instantly.
22. High Water Temperature – illuminates when engine water temperature

exceeds safety limit.
22. High Exhaust Temperature – illuminates when engine exhaust temperature

exceeds safety limit.
22. Low Oil Pressure – illuminates when engine oil pressure drops below safety
limit.
24, 28. Throttle – increase/decrease engine rpm.
25. Engine RPM – indicates RPM of engine

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4.6 Circuit Description
Refer to the General Arrangement and Control Panel drawings respectively for an overview
of the system.
4.6.1 Water Circuits
There are two water circuits. The first is an internal circuit for the engine. The
second is the main circuit which absorbs the heat from the various sources and
vaporises the liquid nitrogen. Both circuits will be described starting from the
water pump in the direction of flow.
a. Engine Water Circuit
The engine water pump takes water from the circuit, and after passing it
through the engine and the exhaust gas cooler, passes it through the shell
and tube where the heat is transferred to the nitrogen vaporiser water
circuit. The water then returns to the suction of the engine water pump. If
this returning water is above 65°C it is diverted by a thermostat, through a
radiator to dissipate the excess heat.
b. Nitrogen Vaporiser Water Circuit
A centrifugal water pump pushes water through a nitrogen vapour pot

where heat is transferred to the nitrogen. The water then passes through
the shell heat exchanger, where heat is transferred from the hydraulic oil
then through a plate hex when heat is transferred from engine circuit before
returning to the water pump.
A panel mount temperature gauge monitors temperature at the inlet to the

vaporiser pot.
4.6.2 Hydraulic Circuit
There are three hydraulic pumps mounted via a splitter box to the rear of the
engine, a Denison P14 closed loop mounted on the centre pad, a Denison T6EDC
mounted on the left hand pad and a Tandem Gear Pump and single vane pump
mounted on the right hand pad.
a. The Denison P14 closed loop variable displacement pump supplies hydraulic
pressure to drive the cryogenic power end, via a gearbox and hydraulic
motor. The speed of the power end is controlled hydraulically by a pressure
relief valve which controls the angle of ‘swash’, i.e. changes the output of
the pump.

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b. The Denison T6EDC triple segment pump mounted on the left hand pad
provides the following:. It consists of three sections:-
i. The first two segments are utilised to provide heat loading.
ii. The third segment provides hydraulic pressure to the hydraulic

motor driving the water pump.
c. The Tandem Gear pump consists of one double segment which drives the
following:
i. Hydraulic power to the boost pump hydraulic motor.
ii. Second segment supplies triplex lube oil.
d. The single vane pump provides system flushing by circulating the hydraulic
tank.
4.6.3 Nitrogen Circuit
Nitrogen enters the system from a tank hose through a valve and a Y strainer into
the nitrogen centrifugal boost pump. From the centrifugal pump it is pumped
either through a low pressure vent to atmosphere or into the jacketed ends of the
cold ends where some of the liquid is forced into the pistons and some passes out
of the cold ends to tank return. The liquid that enters the piston chambers is
pressured to discharge pressure and pumped to the nitrogen vaporiser where it is
vaporised from a high pressure liquid to a high pressure gas. The gas flow
continues through a high-pressure check valve, a plug valve and on to the
customer. Instrumentation includes, centrifugal discharge pressure, centrifugal
hydraulic pressure, gas discharge pressure and gas discharge temperature. A
pressure switch stops the pump on overpressure.
4.6.4 High Nitrogen Overpressure Shutdown
The overpressure trip operates by dumping the oil from the servo supply to the
tank allowing the pump to return to zero swash.

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4.7 SOS 3g Engine Protection System (where applicable)
4.7.1 Technical Data
Equipment Operating ambient - -20 to +50°C
Heat to coolant from Gas Cooler - At continuous load 203 KW
Coolant Capacity - Cooler body 45Lt

Cooler Plenum Box 15Lt
Duplex 6Lt approx.
Component dry Weights - Gas Cooler body 330Kg

Gas Cooler Plenum Box 110Kg
Outlet Box 47Kg
Gas Cooler Adapter 12Kg
Exhaust Flame Traps 24.5 Kg ea
Torque Settings - Cooler to Plenum Joint (no gasket) 65N-M

Cooler adapter fixings (no gasket) 50N-M
Exhaust Flame Trap (no gasket) 35N-M
Duplex (gasket joints) 45N-M
Induction Manifold 45N-M
4.7.2 System Outline
The 3g Made Safe system works with the standard engine as a bolt on accessory
that more than meets the engine shutdown requirements of EN 1834-1:2008.
3g Made Safe holds positive advantages over alternative available systems in its
ability to interface easily as a fully functional stand alone unit, with no downside
effects on the functionality of the engine and its installation and maintenance.
Key Components:
* Gas Cooler.
* Duplex Exhaust.
* Air Inlet Flame Trap.

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4.7.3 Shutdown Operation
The engine electronic fuel system will shut down on the actuation on any one of the
following:
* High Exhaust Gas Temperature (200 deg C)

* High Coolant Temperature (100 deg C)
* Engine Overspeed (10% over max engine no load speed)
* Low engine lube oil pressure. (10 PSI falling)
* The emergency stop will be rigged in pneumatically to actuate the induction
air valve and the fuel shutoff directly. Any number may be fitted.
The following automatic shutdowns have indicators mounted in the engine control
panel:
Low oil pressure

High water temperature
High Exhaust temperature
4.7.4 Stopping the Engine
1. Standard shutdowns not involving hazardous conditions will be performed

by pressing the Engine Stop button.
2. Emergency shutdown is achieved by pressing the Emergency Stop button.
3. Automatic shutdown is by:
Engine over speed

Emergency stop
High exhaust temperature (max 200deg. C)
High coolant temperature
Low oil pressure (engine)
Low air system pressure
4.7.5 Safety Over-temperature or Low Oil Pressure Shutdown
Over temperature inputs and low lubricating oil pressure are monitored, e.g.
water and exhaust and if they go above their pre-set temperature, the engine will
be shutdown by removing the fuel supply.

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4.7.6 Safety Over-speed Shutdown
The safety system is calibrated to the engine’s normal maximum speed. If this
figure is subsequently exceeded by 10%, the engine will be shutdown by closing the
air inlet valve and removing the fuel supply.
4.7.7 Emergency Shutdown
The emergency stop is activated via the red mushroom shaped button on the
Engine control panel. The system operates by closing the engine air intake flap and
Disabling the engine ignition circuit.
4.7.8 Reset after Shutdown
In the event of the system being shutdown via the emergency shutdown button or
any of the components identified in 4.5 then the system can be restarted after fault
has been identified and corrected.

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4.8 Pump Speed v Nitrogen Flow

NITROGEN SYSTEM
Working Pressure Maximum 10,000 PSIG (690 Bar)

Flow Rate (Maximum) 180,000 SCFH
Temperature Operation (Minimum) -20°F(-29°C)
Temperature Operation (Maximum) 120°F(49°C)
Liquid Nitrogen Pump NOV Hydra Rig UK
Cold End DNV Approved Bore 1.625
Stroke 1.375in.
Maximum Speed 1000rpm
Vaporiser Pot Hydra Rig 180K
Capacity 3000 SCFM
PUMP SPEED vs. NITROGEN FLOW – 1.625 COLD END
PUMP SPEED (RPM) NITROGEN FLOW (SCFM)
100 300
150 450
200 600
250 750
300 900
350 1050
400 1200
450 1350
500 1500
550 1650
600 1800
650 1950
700 2100
750 2250
800 2400
850 2550
900 2700
950 2850
1000 3000
NOTE: OUTPUTS ARE APPROXIMATE AND BASED ON PUMP VOLUMETRIC

EFFICIENCY OF 87%

ASSET No. 12220042
SECTION 5.0 – OPERATING, START UP

AND STOPPING PROCEDURE
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5.0 OPERATING, START UP AND STOPPING PROCEDURE
NOTE:
REFER TO THE OPERATIONS MANUAL IN VOLUME 2 OF THE DIESEL ENGINE FOR FULL
DETAILS ON BEFORE STARTING AND STOPPING THE CATERPILLAR 3406C DITA ENGINE ON
THIS UNIT.
5.1 Introduction
This section contains the ‘before starting engine’, ‘starting engine’ and ‘stopping engine’
guidelines. Only competent, suitably qualified personnel who have a good understanding
regarding the operation of a Nitrogen Pumping Unit should be authorised to perform such
an operation on this system.
5.2 Before Starting Engine
5.2.1 Check the following fluid levels to insure levels are full or at safe working levels.
The engine and lube oil tank oils are per recommendations of suppliers in support
documents supplied with this manual. Coolant is to be 50/50 Ethylene
Glycol/water.
a Engine – dip stick.
b. Triplex Pump Lube Tank – sight

glass.

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c. Hydraulic Oil Tank – sight glass
d. Engine Coolant Level – radiator

header tank.

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e. Vaporiser Circuit Water Level –

sight glass.
f. Check fuel system supply –

sight glass.
g. Check fuel isolation valve is open.

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h. Check starter lube contains sufficient oil.
i. Check regulated air lubricator contains sufficient oil and is in the open position.
Isolation valve
j. Check triplex gearbox oil level dipstick.

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k. Check engine drive gearbox oil level.

Gearbox breather /
filler point.
Gearbox level plug.

Remove this plug if gear
oil seeps out, level is ok.
If no oil seeps out, top up
at filler point/breather.
5.2.2 Check nitrogen liquid level. Make certain tank contains sufficient liquid to cool
down the nitrogen system. Tank should be filled to the full tri-cock level.
5.2.3 Ensure that the following controls are set to the minimum adjustment.
a. Engine Throttle.
NOTE:
Push button on throttle control to

ensure the throttle is in the idle
position.
b. Boost Pump Control.
NOTE:
Ensure that the Boost pump control is

wound out fully Anti-clockwise.

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c. Triplex Control
NOTE:
Ensure that the Triplex control is

wound out fully Anti-clockwise.
d. Heat load Control
NOTE:
Ensure that the Heat load control is

wound out fully Anti-clockwise and the
gauge reads ‘zero’.
5.2.4 Check that BOTH hydraulic suction filters are in the ‘OPEN’ position. This allows
hydraulic fluid to the pump supply.
O Closed position, lead screw out.
P Open position, lead screw in.
WARNING:
NEVER OPERATE THE UNIT WITH THE SUCTION FILTERS IN
THE CLOSED POSITION.

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5.3 Inter-Unit Connections
5.3.1 Rig up two hoses from the nitrogen

tank supply to the nitrogen unit.
Inlet Return Line
5.3.2 Rig up these two hoses to the

nitrogen unit from the nitrogen tank.
Return Line Inlet
5.3.3 Vent the tank down to atmospheric

pressure to cool the liquid.
5.3.4 Rig up high pressure treating iron.

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5.3.5 Connect the rig air supply and charge

the air tank ensuring that the bleeding
valve on the air tank is in the close
position.
Rig Air Supply set up
Air Tank Bleeding Valve

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5.4 Start-up and Operating Procedures
5.4.1 Ensure the throttle control to the idle position.
5.4.2 Press and Hold the permissive override

button.
5.4.3 Whilst holding in the permissive override

button. Press the Air Start button.
5.4.4 Release the air start button when engine fires

up.
5.4.5 Keep pressing the permissive override button

until the low oil pressure, high water and high
exhaust temperature indicators turn green.

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· Ensure engine oil pressure increases.
· Ensure charge pressure increases.

(approx 220 psi)
· Ensure lube oil pressure increases.

(approx 25 -40 psi)
Note: Stop engine immediately and investigate if

any of the above fail to build pressure.
5.4.6 Allow the system to warm up until water temperature is a minimum of 60°C (140°F).
5.4.7 Pressure the nitrogen tank to about 2 BAR (30 PSI).
5.4.8 Open the return and inlet valves on the

unit.
Return Line Inlet

‘OPEN VALVE’ ‘OPEN VALVE’

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5.4.9 Open the tank valves.
5.4.1 Open the metering valve (Globe Valve).

0
NOTE.
Open up the valve to catch prime and

adjust accordingly.
5.4.1 Open the low pressure vent valve to allow nitrogen to cool down boost pump
1 and cold ends.

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5.4.1 Turn in the pilot relief valve (boost pump control) to spin the centrifugal boost
2 pump slowly, in short bursts after it becomes frosted. DO NOT SPIN
EXCESSIVELY. This prevents pump from freezing.
NOTE
During the pumping operation it is important that the control panel gauges be
monitored to ensure that all components are functioning properly.
5.4.1 Increase engine to about 1800 RPM.

3
5.4.1 Open high-pressure bleed valve and tempering valve.

4

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5.4.1 Ensure cold ends are completely cooled

5
5.4.1 Open rapid cool down re-circulating

6 valve by pulling out the handle.
5.4.1 Spin the centrifugal boost pump until pump picks up prime, pressure rises to 60 –
7 80 PSI.
5.4.1 Close the low pressure vent valve.

8
5.4.1 Slowly close rapid cool down re-

9 circulating valve by pushing the handle
in.
NOTE
If pump does not pick up prime, or loses prime, repeat procedure 5.4.11 – 19.
5.4.2 Ensure high pressure discharge plug valve is open.

0
5.4.2 Ensure that boost pump pressure is 60-80 PSI.

1

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5.4.2 Adjust engine speed to 2100 RPM.

2
5.4.2 Adjust the pump speed to achieve desired rate.

3
5.4.2 Adjust pump speed control to start main pump turning.

4
IMPORTANT
Close bleed valve and tempering valve to start pumping nitrogen to customer.
5.4.2 Use the load control valve to maintain a discharge temperature of 21ºC or 70ºF.
5 Increasing the load will increase the heat input into the water circuit and
consequently increase nitrogen discharge temperature. To decrease the nitrogen
temperature, decrease the load. If cooler discharge temperatures are required,
the tempering valve can be used by bypass the nitrogen vaporiser pot and allow
liquid nitrogen to enter the discharge nitrogen gas.
NOTE:
The globe metering valve is controlling the amount of liquid returning to tank.

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5.5 Stopping the System
5.5.1 Turn off heat-load.
5.5.2 Turn off the pump speed control to stop the

Triplex pump.
5.5.3 Turn off the boost pump supply.
5.5.4 Stop the centrifugal by turning out the LN2 control centrifugal valve.
5.5.5 Bring the engine back to idle and allow the engine to cool at idle for 10 to 15
minutes depending on environment.
5.5.6 Close in the nitrogen tank valves. Gently crack the vent valve to vent nitrogen.
5.5.7 Open all N2 vent valves on unit.
5.5.8 After engine idle period and engine has cooled then push the engine stop button.
WARNING
DO NOT OPEN HOSE DRAIN VALVE TO DRAIN NITROGEN AFTER
PUMPING. EXPANDING VAPOUR CAN DISPLACE OXYGEN CAUSING
ASPHYXIATION AND DEATH.

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5.6 Engine Safety System Shutdown
5.6.1 The engine will shutdown under the following conditions:
· Engine over speed

· High exhaust temperature (max 200deg. C)
· High coolant temperature
· Low oil pressure (engine)
· Low air system pressure
· No Fuel
5.6.2. In the Event of an Emergency, immediately operate the

EMERGENCY STOP BUTTON.
5.7 Final Rig Down
5.7.1 Open vent valves making sure the pressure is vented.
5.7.2 Break off nitrogen hoses.
5.7.3 Ensure that valves on nitrogen inlets are closed and the caps are replaced.
NOTE
If water gets in, it will accumulate in the Y strainer and be blown through into the nitrogen
centrifugal on the next job. This will almost certainly freeze the centrifugal seal and it will
tear when the centrifugal is spun.

ASSET No. 12220042
SECTION 6.0 – MAINTENANCE & TROUBLESHOOTING

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6.0 MAINTENANCE AND TROUBLESHOOTING
NOTE: REFER TO THE OPERATIONS MANUAL OF THE DIESEL ENGINE FOR ALL MAINTENANCE
AND TROUBLESHOOTING ON THIS UNIT.
6.1 Introduction
This section contains Inspection, Maintenance, Cleaning, and Troubleshooting. Only qualified
Personnel shall be authorised to perform maintenance on this system.
6.2 Inspection
6.2.1 Periodic inspection should be performed as presented in maintenance – see 6.3.

Operator and maintenance personnel must be aware of any discrepancies and these shall
be corrected before the system is put into operation. During these inspections, check the
following:
a. CLEANLINESS. Inspect all nitrogen components for cleanliness. Remove all forms of
foreign material and contaminants from equipment. Special attention should be given to
couplings to ensure that no contamination or foreign materials can enter the nitrogen
system.
b. CORROSION. Inspect entire nitrogen system for any forms of corrosion. Clean and
inspect corrosion area. Repair as required. Take preventative measures to inhibit future
corrosion.
c. WELDMENTS. Inspect all welded parts for evidence of cracked or broken welds.
Determine cause and take measures to prevent future failures. Repair as required.
d. GLASS. Inspect all glass components for cracks or breaks. Rework and repair as required.
e. VALVES. Check all valves for general condition, missing parts, and signs of leakage.
Operations of the system, inspect valves for ease of operation and positive seating. Note
problem areas and make repairs as soon as conditions permit.
f. LEAKAGE. Inspect all fittings and tubing for looseness and signs of leakage. Repair as
required
g. HOSES. Inspect hoses for excessive wear. Inspect fitting for wear or physical damage.
Remove and repair as required
h. ATTACHING HARDWARE. Inspect entire system for loose or missing hardware (E.g. nuts,
bolts, etc.) Repair and re-torque as required.
Halliburton Asset No: 12220042 Page 1 of 18

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6.3 Unit Maintenance
The following schedules are guidelines only. The frequency of any particular maintenance or
service is dependant on the operational conditions, environment, and age or condition of the
system.
6.3.1 Daily (Before start up)

a. Check the following fluid levels:
i. Triplex pump lube. Oil tank level

ii. Engine oil and coolant.
iii. Hydraulic reservoir.
iv. Hydraulic pump drive splitter box.
b. Drain any condensation from pneumatic (air) and hydraulic reservoirs.
c. Check that all hydraulic suction valves on the hydraulic tank are open.
6.3.2 Daily (After shut down)

a. Fill diesel, hydraulic and lubrication reservoirs. Maintaining full reservoirs
prevents condensation from forming.
b. Check all high-pressure plumbing attaching hardware (e.g. nuts) for

tightness.
c. Check all hydraulic and lubrication lines for leaks.
d. Check coolant circuit for leaks.
e. Check engine and pump drive belts.
6.3.3 Weekly (every 75hrs of operation)

a. Drain and clean all drip pans.
b. Check all critical bolted connections for tightness. Include but do not limit
to the following:
i. High and low pressure plumbing supports.

ii. All major components mounting bolts.
iii. Drive shaft mounting and guard bolts.
c. Refer to engine operators’ manual for scheduled maintenance and

procedures for the engine.

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6.3.4 Bi-Weekly (every 150 hrs of operation)

a. Drain and replace engine oil and filters (refer to engine operator's manual
for procedures.)
b. Check and replace, if necessary, engine fuel filters. (Refer to engine

operator's manual for procedures).
c. Check air intake connections for tightness. Check rubber seals and ducts for
deterioration which could cause leaks.
6.3.5 Monthly (every 300 hrs of operation)

a. Perform monthly maintenance.
b. Drain hydraulic and lubrication tanks and clean thoroughly with a suitable
solvent. Replace fluids with new clean fluid.
c. Replace engine air filters element.
d. Check engine drive belts for tension and deterioration.
e. Remove, clean or replace air compressor intake filter as required.
6.3.6 Semi-Annually (every 1000 hr. of operation)

a. Perform monthly maintenance.
b. Drain hydraulic and lubrication tanks and clean thoroughly with a suitable
solvent. Replace fluids with new clean fluids.
c. Replace all filters.
d. Check suction hoses for deterioration and replace as necessary.
e. Check all hose and clamps on hydraulic, lubricating and coolant circuits.
Replace, repair or tighten as required.
f. Drain coolant fluids in vaporiser coolant circuit and flush with clean water.
Replace coolant fluids with 50 per cent ethylene glycol mixture and 50 per
cent clean fresh water.

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6.4 Unit Cleaning
Cleaning precautions related to cleaning the system and its components shall be followed.
Specific precautions which accompany cleaning solutions or solvents shall be followed. The
following precautions are standard to the system and should be observed at all times when
cleaning is required.
a. Wear appropriate safety equipment, when using cleaning solutions, solvents, and
compressed air.
b. Always follow specific warnings that apply to soaps and solvents.
c. Provide adequate ventilation when using solvents. Avoid prolonged breathing of

vapours and contacts to the skin. Know what to do if any personnel become over
exposed to solvents.
d. When using solvents, always keep these items away from a source of flame, sparks
or heat. Do not leave any containers open. These substances can ignite or form
harmful gases when heated.
6.5 Compressor Maintenance
system. For detailed information on the compressor fitted, please refer to the component
manufacturer data contained in Volume 2.

OP999
6.6 Maintenance Drive Belts
system.
Belt Inspection
6.6.1 Initial Start-up
NOTE.
Belt tension should be checked initially within the first 20 / 40 hours of engine
operation. Check the following fluid levels:
WARNING
Use of standard belts on this engine may cause an explosion which may result in
personal injury or death. Only non-static belts should be used on this engine.
6.6.2 Daily (Before Use)
a. Inspect the belt for any signs of wear.
b. Inspect the belt for any signs of cracks or splits
c. Ensure the belt is not too loose. Refer to operators’ manual for correct
tension.
d. Ensure the belt is not too tight. Refer to operators’ manual for correct
tension.

OP999
6.7 Maintenance Starter Motor
system. For detailed information on the starter motor fitted, please refer to the component
manufacturer data contained in Volume 2.
6.8 Maintenance of Lifting Equipment
system.
Wire Rope Slings
6.8.1 Daily (Before Lift)
Visual Inspection
a. Ensure wire rope slings are clean
b. Ensure the wire rope sling is free from damage
c. Ensure wire rope sling is free from corrosion (protect with non-acidic
lubricants)
d. Examine wire rope sling for illegible markings.
e. Check to ensure the wire rope sling is not distorted.
f. Check wire rope sling fittings are not damage i.e. ferrules, thimbles etc;.
g. Check the wire rope slings wires are not cut or broken.
h. Check the wire rope sling for signs of heat damage or discolouration.
6.8.2 Annually
Proof Load / Certify wire rope slings. Refer to Volume 3 – Certification Databook
for recommended recertification date as detailed by the supplier.

OP999
Shackles
6.8.3 Daily (Before Lift)
Visual Inspection
a. Ensure shackles are clean
b. Ensure the shackle is free from damage
c. Ensure the shackle is free from corrosion (protect with non-acidic lubricants)
d. Examine the shackle for illegible markings.
e. Check to ensure the shackle is not distorted, stretched or body bent.
f. Check the shackle pin is the correct one for the shackle and it is not bent or
damaged and the thread form is complete.
g. Check the shackle for signs of heat damage or discolouration.
6.8.3 Annually
Proof Load/Certify the shackle. Refer to Volume 3 – Certification Databook for

recommended recertification date as detailed by the supplier.

OP999
6.9 Maintenance Frame
6.9.1 General Maintenance
NOTE
This equipment requires periodic safety and maintenance inspections.
The equipment must be thoroughly inspected periodically so as to detect in a timely

manner the possibility of defective, damaged or improperly installed parts.
Frequency of inspection will to a large extent depend upon unit activity and severity
of service and environment but under no circumstances should the interval for the
below listed inspections exceed one month. These inspections should also include
those listed in the daily checklist.
6.9.2 Maintenance Schedule
Subject
Monthly
Weekly
Yearly
Daily
Inspect unit frame for any signs of deformation X

and/or damage. Particular attention should be
paid to areas of potentially high material stress,
lifting eyes, tie-down points and structural
welds.
Re-certification on load test by third party`s X
witnessing (hard stamping on name plate)

OP999
6.10 Maintenance Hydraulics
6.10.1 Replacement Interval

of service and environment but under no circumstances should the interval for the
below listed inspections be exceeded. These inspections should also include those
listed in the daily checklist.
Subject
After first Interval
After first
replacement, according to
100 hours of
every 500 contamination
operation
hours indicator
Suction Filter Element X X X

High Pressure Filter Element X X X
Hydraulic oil 2 years of
Operation
6.11 Maintenance Pneumatic
6.11.1 Servicing Intervals
Subject
If required
Half
Daily Yearly (according to
Yearly
experience)
Lubrication Oil Level X X

OP999
6.12 Maintenance Electrical System
6.12.1 General Maintenance
NOTE
This equipment requires periodic safety and maintenance inspections.

of service but under no circumstances should the interval for the below listed
inspections exceed one month. These inspections should also include those listed
in the daily checklist.
· Items modified or removed and reinstalled by or so recommended by NOV

during installation of the unit (where applicable) is covered in the following
inspection procedures.
· Inspect unit frame for any signs of deformation, damage and leakage Inspect
attaching hardware for security and/or missing items. Particular attention
should be paid to areas of potentially high material stress.
· Inspect electric components (cables, glands) for security, wear and tightness.
· Check that no unauthorized modifications have been made to the unit
NOTE
Use the maintenance schedule to determine action points.

OP999
6.12.2 Maintenance Schedule
Codes Used
1. Check for proper and secure installation

2. Check for visible damage and legibility
3. Check for proper fluid level
4. Check for any structural damage; cracked or broken welds; bent or warped
surfaces; condition of corrosion protection
5. Check for leakage
6. Check for excessive dirt or foreign material
7. Check for proper operation and freedom of movement
8. Check for excessive wear or damage
9. Check for proper tightness and adjustment
10. Drain, clean and refill
11. Check for proper operation while engine is running
12. Check for proper lubrication
13. Check for evidence of scratches, nicks or rust and straightness of rod
14. Check condition of item, replace as necessary
15. Clean or replace
16. Replace
17. Drain or Clean
18. Check continuity/insulation resistance
19. Pressure test
20. Check for proper and secure installation of sub-components
21. Re-certification units electrical system with third party witnessing (hard
stamping on name plate)
Item
3 Monthly
6 Monthly
Monthly
1200hr
Yearly
300hr
600hr
Daily
10hr
Electric cables/earthing/glands/mct 1 4 18
Electric junction boxes 4 20
Tags/decalls/placards 1&2
Complete electrical system 1

OP999
6.13 Engine Maintenance
It is recommended that you follow the manufacturer’s guidelines regarding maintenance

intervals and checks/inspections which can be found in Volume 2.
6.13.1 General Engine Troubleshooting
For a full troubleshooting guide please refer to Volume 2 where you will find the CAT 3406
Manual.

OP999
6.14 Nitrogen Pumping Unit Troubleshooting Guide
TROUBLE PROBABLE CAUSE REMEDY

A. Low flow rate to unit 1. Low tank pressure. 1. Increase tank pressure.
from LN2 tank. 2. Supply valve not fully open. 2. Open valve fully on LN2 tank and skid.
3. Return valve closed or 3. Open valve fully on LN2 tank and skid.
partly closed. 4. Clean or replace strainer.
4. Suction strainer on LN2 5. Clean or replace strainer.
tank clogged. 6. Inspect piping and hoses to insure free
5. Suction strainer on skid flow.
clogged.
6. Clogged piping or transfer
hoses.
B. Frozen valve 1. Moisture in stem packing 1. Thaw valve and dry out packing.
C. Boost pump will not 1. Hydraulic valve closed at 1. Open the valve
turn. boost pump. 2. Turn the shaft coupling with a pipe
2. Locked up from ice wrench. Do not use excessive force. If
formation. pump will not turn then thaw out and dry
3. Suction valve to hydraulic out pump.
pump closed 3. Open valve.
4. Defective hydraulic pump. 4. Disconnect motor supply hose. Plug hose
and cap motor. Test pump pressure if
pump does not build up pressure check
system relief valve. If relief valve is OK,
remove and replace pump.
D. Low flow rate to 1. Low tank pressure. 1. Build pressure on LN2 tank.
pumping skid. 2. One or more valves 2. Check supply and return valves to make
required for liquid supply sure they are fully open.
not fully open. 3. Check for ice or contamination's in LN2
3. Ice or contamination in supply filters/strainers
supply line filters.
E. Frozen valve stem. 1. Moisture in stem packing. 1. Thaw and dry valve packing and packing
gland with dry nitrogen gas.
F. Valve leaking vapor 1. Foreign material or ice on 1. Dissemble valve and repair or replace as
and liquid. valve seat. required.
G. Tank will not build 1. Line to pressure building 1. Clear obstruction and/or open valve.
up pressure. coil obstruction. Ice or 2. Fill tank.
valve closed. 3. Locate leak and repair.
2. Low liquid level.
3. Leak to atmosphere.
H. Excessive tank 1. Defective pressure gauge. 1. Check indicator, replace if necessary.
pressure. 2. Road relief not functioning. 2. Repair or replace road relief as required.
3. Pressure building valve 3. Close valve.
open.

OP999
6.15 Hydraulic Troubleshooting
The following troubleshooting tables are simply checks that field maintenance can make. Any
detailed engine problems should be performed by an authorised engine repair facility. Field
maintenance personnel should be trained by qualified personnel. Field maintenance personnel
should possess a good understanding and working knowledge of the properties and dangers of
power pack equipment before attempting to troubleshoot this unit.
Chart A - Hydraulic Troubleshooting
Refer to pump
Determine
manufacturer’s
hydraulic tank
viscosity effect on
temperature
pump power levels
- Confirm type
of start, air,
- Initiate motor start hydraulic or
sequence electric
- Confirm
engine controls
location
Bring hydraulic
reservoir Hydra Rig UK
temperature to at Service Dept.
least 110°F
Yes
- Confirm suction
valves are open
- Confirm tank
Close.Loop temperature
Charge pressure at
230 psi or above? - Confirm oil
column at sight
No
level gauge
Yes
Hydra Rig UK
Service Dept.
- Proceed with
required operations

OP999
6.16 SOS 3g System Maintenance
6.16.1 Daily
* Exhaust gas flame traps. (If fitted)
Shut the engine down and remove each element, (do not fit dummy units to
run, if an immediate run is required fit spare flame trap elements).
Solvent soak the dirty elements and brush clean, power-hose or ultra-sound
cleaning methods are very effective. (Never poke with mechanical objects)
blow dry with compressed air. Do a mechanical integrity check of the
element and its local surrounding fitting location, if all is well refit.
* Be alert and observe the suitable operation of the Air Shutdown valve on
general start and stop. Don’t forget the air valve is slaved by the run
solenoid so proves the suitability of both components.
6.16.2 Weekly
* Visual check
Visual checks are the first line of defence, at all times during normal
operation of the equipment correct any defective component that is
observed as dangerous or potentially dangerous.
Being non-prejudicial to any visual inspection, in any event make it a weekly

routine to undertake a specific visual routine inspection of the following:
- Check on all components, look for loose components, signs of

mechanical damaged.
- Never permit the on-going operation of your equipment with missing

labelling or instructions.
- Check wiring and pneumatic, induction, and cooling system piping

for good integrity.
- Be critical in your Checking of the joint integrity between the Engine

and the Air shutdown valve, don’t forget the induction Air shutdown
valve is the first line of defence for automatic and emergency
shutdowns.
- Observe any displaced components.
- The integrity of the Alternator drive.

OP999
6.16.3 Monthly
* Component soundness
Undertake a physical check on all the areas mentioned in the weekly visual
check. In this instance, physically check fixing security, cable glanding,
jointing etc.
* Observe any seriously corroded components, replace any wanting

components.
* Check the alternator Belt Tension.
6.16.4 No Time Limitation or as Required

* The internal cleaning of components such as the gas cooler is an important
maintenance event, however, we feel it to be impossible to state any
recommendations as to what interval that is to take place.
The best recommendation we can offer is that the end user observes the
operation of the system, the gas cooler in particular, and when the first
internal cleaning is deemed required, log and schedule this duration as the
next routine clean, be prepared to be flexible.
Components in contact with the exhaust gas such as the Spark Arrestor will
be fitted with a soot/drain box, in the first instance run for six months and
observe the content of the soot box. Adjust this inspection in line with your
observations.
We see no reason to spend valuable time internally cleaning components

such as a duplex flexible. Cleaning such components would only be
necessary if the equipment frequently over temperatures on exhaust gas in
operation.
* Check the integrity of the Battery Power Pack
If the battery is to give a long and useful service it requires attention. The
degree of attention depends on the level of operation of the equipment and
the conditions of the local environment.
Check electrolyte level and specific gravity more regularly if cold no active
situations are evident. Always recharge in a safe area with the lid removed,
make your connection at the bus-bar.

OP999
Never charge the Battery on location and/or still fitted into the equipment.
Always remove the battery with its enclosure from the equipment and place
the whole assembly in a safe area before charging is attempted, also
reference the manufacturers (care for your Battery) instructions.
Always remove the battery enclosure lid before and during the charge
procedure.
* Cooling system integrity is paramount previous checks are mentioned,

however. There is a total dependence here on the equipment’s operational
environment, ensure the cooling system anti-freeze levels are suitable for its
environment.
Some users run all year round with anti-freeze, this is acceptable if the
cooling system is designed to accommodate the difference in performance,
in any event check the concentration in the winter months.
The following troubleshooting tables are simply checks that field

maintenance can make. Any detailed engine problems should be performed
by an authorised engine repair facility. Field maintenance personnel should
be trained by qualified personnel. Field maintenance personnel should
possess a good understanding and working knowledge of the properties and
dangers of nitrogen and high pressure pumping equipment before
attempting to troubleshoot this unit.

OP999
6.17 CATERPILLAR 3406 – OILS AND FILTERS
Typical Unit Filter and Service Intervals
Type Oil Type Manufacturers Filter NOV Hydra Rig Quantity of Services
Number Filter Part Filters on Unit Interval Filters
Number and Oil
Engine Oil Filter
15/40 1R-1808 2VEF00021 1 250 HOURS
Engine Fuel (Filter CAT

9N-2342 2VEF00030 1 250 HOURS
Fuel Primary) 3406
Engine Fuel (Filter CAT
1R-0749 2VEF00022 1 250 HOURS
Fuel Primary) 3406
Triplex Lube Oil 150 HOURS OR 3
MEP 20 CH-070-A25-A 2HFP00002 1
(Element Filter) MONTHS
Hydraulic Oil 150 HOURS OR 3
HV 46 HP0502A10ANP01 2HFR00002 1
(Element Filter) MONTHS
Hydraulic Oil Hydraulic 150 HOURS OR 3
SF5038F1S W-23EF-0019 2
(Suction) Oil HV46 MONTHS
Hydraulic Oil (Return Hydraulic 150 HOURS OR 3
CH-150-A10A HFP00062 2
Filter) Oil HV46 MONTHS
Typical Oil Types Used on Unit
Material Safety Datasheets are available in Volume 2.
Long Description NOV Hydra Rig Part Area Used on Approximate

Number Unit Quantity
Hydraulic Oil HV46200 2RXF00004 Hydraulic Tank 500 Litres
HV46
MEP 20 WO-MEP20/200 2RXF00003 Triplex Lube Pump 25 Litres
15/40 WO-ENDUROL 15W/4 2RXF00008 Engine Oil 40 Litres
EP 80/90 WO-EP 80W/90 200 2RXF00001 Engine Gear Box 7 Litres
EP 80/90 WO-EP 80W/90 200 2RXF00001 Triplex Gear Box 7 Litres

ASSET No. 12220042
SECTION 7.0 – DRAWINGS & SCHEMATICS

REVISIONS
REV. DESCRIPTION ECN # DATE DFTR CHK ENG
A INITIAL RELEASE 12/12/2012
DELETED 2CB270093 AS NO LONGER NEEDED, ITEM NUMBERS REVISED.
B EMERGENCY STOP VALVE 2AVD00011 REPLACED WITH 2AVD00014 AND CABLE 3655 04/04/2013 ZH DM AK
CONTROL VERNIER ALTERED. PANEL FABRICATION CHANGED TO SUIT NEW CUT OUTS.
895
29 26 29 12 14 4 11 12 3 23 2 27
29 2 EA W-20IR-0003 INDICATOR PNEUMATIC RED / GREEN (FROG EYE)

15 28 1 EA 2VXC00002 CABLE CONTROL CLAMP KIT 40 SERIES CLAMP KIT
B
27 2 EA 2NS070024 BRACKET MOUNT MCII FLOW METER FABRICATION
7 26 1 EA W-23VD-0007 SNAPTITE DIRECTIONAL VALVE 1/4" 3-WAY
25 1 EA W-24GR-0006 DIGITAL TACHO C/W HOURMETER + TRIP

11 24 1 EA 2VXC00006 CABLE CONTROL VERNIER 3.50M 40 SERIES CLAMP MOUNT M6
B THREAD
6 23 1 EA W-23VP-0009 VALVE PRESSURE REDUCING
5
22 3 EA W-20IR-0002 PNEUMATIC RELAY
21 1 EA W-23VR-0007 VALVE RELIEF BSP

620 12 19
20 1 EA W-23VR-0027 BOSCH REMOTE RELIEF VALVE
B
20 19 1 EA 2NB070629 MOUNTING PLATE BOSCH VALVE MACHINING
4 18 1 EA 2AVD00014 VALVE 3/2 PALM BUTTON LATCHING EMERGENCY STOP
B
9 17 1 EA W-20VD-0001 START / STOP VALVE (GREEN INSERT)
13 16 1 EA W-20VD-0001 START / STOP VALVE (RED INSERT)
10 15 2 EA W-20VD-0001 START / STOP VALVE (BLACK INSERT)

8 14 1 EA W-24GP-0060 GAUGE PRESS. 0-12000PSI 4.00 PANEL MOUNT
21 13 1 EA W-24GT-0018 GAUGE TEMP. 0-250 DEG C 2.50 PANEL MOUNT
12 3 EA W-24GT-0017 GAUGE TEMP. 0-120 DEG C 2.50 PANEL MOUNT
11 2 EA W-24GT-0016 GAUGE TEMP. 0-120 DEG C 4.00 PANEL MOUNT
10 1 EA W-24GP-0037 GAUGE PRESS. 0-3000PSI 2.50 0.25NPT PANEL MOUNT
9 1 EA W-24GP-0052 GAUGE PRESS. 0-200PSI 4.00 PANEL MOUNT

1 22 15 25 17 16 22 18 24 28 22 7 1 EA W-24GP-0033 GAUGE PRESS. 0-600PSI 2.50 0.25NPT PANEL MOUNT
B B 6 1 EA W-24GP-0040 GAUGE PRESS. 0-6000PSI 2.50 0.25NPT PANEL MOUNT
3 1 EA W-24GP-0063 GAUGE PRESS. 0-12000 PSI 6.00 PANEL MOUNT
2 1 EA 2ITE00020 TOTALIZER FLOWRATE MC-II ATEX/CE VERSION
1 1 EA 2NS020074 CONTROL PANEL ENGRAVING
CONFIDENTIAL-PROPRIETARY
ITM QTY UOM PART NUMBER DESCRIPTION
N/A
THIS DRAWING IS THE PROPERTY OF
N/A HYDRA RIG, INC. AND IS SUBJECT TO LIST OF MATERIALS
RETURN UPON REQUEST. THE DRAWING
INCLUDES CONFIDENTIAL AND PROPRIETARY TOLERANCES SCALE DRAWN
N/A INFORMATION OF HYDRA RIG, INC. AND IS (UNLESS NOTED OTHERWISE) Z HOPKINS
1:5
N/A
LOANED IN CONFIDENCE WITH THE UNDER-
STANDING THAT IT IS NOT TO BE COPIED
OR REPRODUCED WITHOUT EXPRESS WRITTEN
.X ± .040
.XX ± .020
.XXX ± .005
FRACTIONAL
ANGULAR
± 1/16
± 1/2°
125
DATE HydraR g CHECKED
ENGINEER
D McLAUGHLIN
N/A PERMISSION, AND THAT NEITHER THE

SURFACE FINISH 07/12/2012 P DEBBAGE
DRAWING NOR INFORMATION HEREIN BE DESCRIPTION
USED ADVERSELY TO HYDRA RIG, INC. PANEL CONTROL ASSEMBLY Sheet1 of 1
N/A
ALL PATENT RIGHTS ARE RESERVED.
NEXT ASS'Y. DO NOT SCALE DRAWING
THIRD ANGLE
PROJECTION
PRODUCT
NVP
PART NO. 2NS020075 REV
B
ASSET No. 12220042
SECTION 8.0 – PARTS IDENTIFICATION

Job Number HALLIBURTON180K NITROGEN UNIT Schematic No.
J15177001 2NE090346
NO. ON
ITEM No. ITEM POSITION/FUNCTION HR PART NO. IHRA REF
SCHEMATIC
H-001 P14 Piston Pump 1 Triplex Motor Pressure W-23PP-0023 001
H-002 Motor Hydraulic Piston 2 Liquid Nitrogen Pump Drive 2HMP00013 001
H-003 Gearbox 3 Pad Inverted 3 Pump Drive Gearbox 2TGP00059 022
H-004 Triple Vane Pump 4 Water Pump Motor Pressure & Heat Load 2HPV00001 002
H-005 Relief Valve 5 Heat Load Pump Relief Valve W-23VR-0040 030
H-006 Relief Valve 6 Heat Load Pump Relief Valve W-23VR-0001 030
H-007 Relief Valve 7 Boost Pump Circuit Relief Valve W-23VR-0003 030
H-008 Pump Gear Hydraulic Tandem 8 Boost Pump & Lube Oil Pump 2HPG00009 169
H-009 Remote Relief Valve 9 Heat Load Control Valve W-23VR-0027 030
H-010 Relief Valve 10 Lube Oil Relief Valve W-23VR-0004 030
H-011 High Pressure Inline Filter 11 Speed Control Valve Filter 2HFP00001 020
H-012 Motor Centrifugal Pump 12 Boost Pump Drive Motor 2HMP00021 001
H-013 H/P Ball Valve 1/2"NPT 13 Boost Pump Motor Isolation Valve W-23VB-0009 004
H-014 Relief Valve 14 Boost Pump Remote Pressure Control W-23VR-0007 033
H-015 Directional Control Valve 15 P14 Compensator Vent Valve W-23VD-0044 032
H-016 Directional Control Valve 15 GN2 Discharge Valve Supply W-23VD-0044 032
H-017 Brazed Plate Heat Exchanger 16 Water Cooled Hydraulic Oil Cooler 2NC040001 034
H-018 Hydraulic Filter 17 Return Oil Filter W-23FHA-0023 020
H-019 Hydraulic Filter 17 Return Oil Filter W-23FHA-0023 020
H-020 Check Valve 18 Triple Vane Pump Charge Pressure Valve W-23VC-0020 008
H-021 Check Valve 1 1/4" BSP LP Flapper Type 19 Triplex Lube Suction W-23VC-0003 008
H-022 Hydraulic Filter 22 Hydraulic Oil Suction Filter W-23FHA-0016 020
H-023 Hydraulic Filter 22 Hydraulic Oil Suction Filter W-23FHA-0016 020
H-024 Hydraulic Filter 23 P14 Servo Oil Filter W-23EF-0040 020
H-025 Pressure Reducing Valve 24 Remote P14 Displacement Control (speed controller) W-23VP-0009 031
H-026 Temperature Gauge 0-120°C 2.50 (back entry) 26 Triplex Lube Oil Temp W-24GT-0017 036
H-027 Filter 27 Triplex Lube Oil Filter W-23FHA-0022 020
H-028 Pump Vane Single 29 Hydraulic Reservoir Oil Circulaing Pump 2HPV00023 002
H-029 Pressure Gauge 0-600 PSI 2.50 0.25NPT (back entry) 30 Panel Mounted P14 Charge Pressure Gauge W-24GP-0033 021
H-030 Valve Check 34 Return Oil Anti-Syphon Valve HVC00005 008
Job Number HALLIBURTON180K NITROGEN UNIT Schematic No.
J15177001 2NE090346
NO. ON
ITEM No. ITEM POSITION/FUNCTION HR PART NO. IHRA REF
SCHEMATIC
H-031 Pressure Gauge 0-100 PSI 2.50 0.25NPT (back entry) 35 Panel Mounted Triplex Lub Oil Pressure Gauge W-24GP-0030 021
H-032 Discharge Valve Actuator 37 GN2 Discharge Valve W-21VP-0010 183
H-033 Pressure Gauge 0-3000 PSI 2.50 0.25NPT (back entry) 38 Panel Mounted Boost Pump Hydraulic Pressure Gauge W-24GP-0037 021
H-034 Pressure Gauge 0-4000 PSI 2.50 0.25NPT (back entry) 39 Panel Mounted Heat Load Pressure Gauge W-24GP-0038 021
H-035 Water Pump c/w Danfoss Motor 40 Pumps Coolant Around Vaporising Circuit W-27PWA-0002 Self Cert
H-036 Pressure Gauge 0-6000 PSI 2.50 0.25NPT (back entry) 41 Panel Mounted P14 System Pressure Gauge W-24GP-0040 021
H-037 Temperature Gauge 0-120°C 2.50 43 Hydraulic Tank Oil Temp W-24GT-0017 036
H-038 Valve Check 2" NPT 44 Triple Pump Prime Valve HVC00008 176
H-039 Relief Valve 45 Water Pump Circuit Relief Valve W-23VR-0002 030
H-040 Gearbox 216:1 47 Triplex Drive Gearbox TPG00129 022
H-041 Directional Valve 0.25NPT 3-Way Snaptite 50 GN2 Discharge Valve Controller W-23VD-0007
Job Number HALLIBURTON 180K NITROGEN UNIT Schematic No.
J15177001 2NE090398
NO. ON
ITEM No. ITEM POSITION / FUNCTION HR PART NO. IHRA REF
SCHEMATIC
C-001 Hydraulic Driven Centrifugal Pump 1 Vaporiser Pot Centrifugal Pump W-27PWA-0002 043
C-002 Vaporiser Pot Assembly 180K 2 LN2 Vaporiser Pot 2LD400002 038
C-003 Pressure Gauge 0-160PSI 2.50 0.25NPT 3 Line/Pump Mount Vaporiser Water Pressure Gauge W-24GP-0031 021
C-004 Temperature Gauge 0-250 C 2.50" 4 Panel Mount Engine Exhaust Temp Gauge W-24GT-0018 036
C-005 Temperature Gauge 0-120 C 4.00" 5 Panel Mounted Coolant Temp Gauge W-24GT-0016 036
C-006 Plate Heat Exchanger Assembly 6 Hydraulic Oil Cooler 2NC040001 034
C-007 Header Tank St/St 7 Vaporiser Circuit Header Tank W-27TH-0008 111
C-008 Thermostatic Valve Assembly 8 Engine Coolant (Radiator Circuit) Thermostat W-27TW-0011 ATEX
C-009 Radiator Jacket Water 9 Engine Coolant Radiator Assembly 2VER00061 035
C-010 Caterpillar Engine 3406 Dita, 490BHP @ 2100RPM 10 Prime Mover (Hydraulic Pump Drive + Heat) 2NA010009 ATEX
C-011 Heat Exchanger Shell & Tube 11 Engine Coolant Heat Exchanger 2HXH00010 034
C-012 Zone 2 Flame Protection Kit 12 Exhaust Gas Cooler (+ Spark Arrestor) 2VEM00007 ATEX
C-013 Duplex (Exhaust) 14 Water Cooled Engine to Manicooler Flexible Joint (incl Item 12) incl. item 12 ATEX
C-014 Drain Valve Brass ¼"NPT 15 Coolant Vent Valve W-26FA-0249 194
C-015 Temperature Gauge 0-120 C 2.50" 17 Panel Mount Engine Water Temp Gauge W-24GT-0017 036
C-016 Anti Static Fan Impeller 18 Radiator Cooling Fan 2VER00060 Self Cert
C-017 Rupture Disc 2" Type SCRD-UT Burst Pressure 14Bar ST/ST 316 19 Vaporiser Circuit Safety Valve 2HXR00001
C-018 Thermowell 0.75"NPT Male ST/ST 21 Temperature Gauge Capiliary Socket 2ITS00001 N/A
J15177001 2NE090245
NO. ON
ITEM No. ITEM POSITION / FUNCTION PART No. IHRA No.
SCHEMATIC
P-001 Start/Stop Valve Black Button 1 Start Valve W-20VD-0001 092
P-002 Start/Stop Valve Black Button 1 Stop Valve W-20VD-0001 092
P-003 Start/Stop Valve Black Button 1 Permissive Start Valve W-20VD-0001 092
P-004 Start/Stop Valve Black Button 1 GN2 Discharge Valve Interlock W-20VD-0001 092
P-005 Valve 3/2 Palm Button Latching Emergency Stop 2 Engine Emergency Stop Valve 2AVD00014 093
P-006 Restrictor Air 4 Control Circuit Air Restrictor W-20REA-0001 094
P-007 Restrictor Air 4 Emergency Stop Circuit Air Restrictor W-20REA-0001 094
P-008 Restrictor Air 4 OPP Point Air Restrictor W-20REA-0001 094
P-009 Solenoid Starter Air 5 Engine Starter Motor Solenoid W-25ASM-0002 101
P-010 Starter Air 150BMP 6 Engine Air Starter Motor 2VEX00217 304
P-011 Lubricator Assembly 1.25 7 Air Starter Lubricator W-20LA-0003 098
P-012 Valve Fuel Shut Off 8 Engine Fuel Stop Valve W-20VFS-0001 085
P-013 Air Receiver Horizontal 200Ltr 9 Air Receiver 2NC060008 013
P-014 Valve Overspeed 10 Engine Overspeed Valve W-20VO-0001 086
P-015 Relay Indicator Pneumatic 11 Low Engine Oil Pressure Indicator W-20IR-0002 091
P-016 Relay Indicator Pneumatic 11 High Exhaust Temperature Indicator W-20IR-0002 091
P-017 Relay Indicator Pneumatic 11 High Engine Coolant Temperature Indicator W-20IR-0002 091
P-018 Manifold Brass 12 Control Air Manifold W-20MA-0001 N/A
P-019 Valve Ball 0.25NPT 14 Rig Air Supply Bleed Down Valve W-23VB-0001 047
P-020 Valve Ball 0.25NPT 14 Air Receiver Drain W-23VB-0001 047
P-021 Relief Valve 0.50" Set @ 150 PSI 15 Air System Safety Relief Valve W-20VR-0001 070
P-022 Gauge Pressure 2.50 0.25NPT 0-160PSI 16 Panel Mounted System Air Pressure Gauge W-24GP-0031 021
P-023 Temperature Valve High Water (96ºC Rising) 17 High Engine Water Temp Shutdown Valve W-20VT-0001 156
P-024 Pressure Valve Low Oil (10psi Falling) 18 Low Engine Oil Pressure Shutdown Valve W-20VP-0001 155
P-025 Valve Ball 1.00 NPT Brass 19 Air Receiver/Rig Supply Isolation Valve W-23VB-0005 047
P-026 Temperature Valve High Exhaust (200ºC Rising) 21 High Exhaust Temperature Shutdown Valve W-20VT-0002 154
P-027 Bendix Governer 22 Compressor Unloader Valve W-20RA-0002 081
P-028 Valve Check 0.50NPT Brass 24 Compressor Protection Check Valve W-20VC-0003 082
P-029 Compressor Engine Driven 25 Engine Mounted Main Air Compressor N/A 014
J15177001 2NE090245
NO. ON
ITEM No. ITEM POSITION / FUNCTION PART No. IHRA No.
SCHEMATIC
P-030 Regulator Filter Air 26 0.50" Externally Mounted System Filter Regulator W-20RA-0001 099
P-031 Valve 3/2 Pilot/Spring 1/4" 27 Engine Stop/Emergency W-20VPD-0010 096
P-032 Cylinder Single Acting 28 Engine Stop Cylinder 2AXC00004 153
P-033 Directional Valve 4/2 32 P14 Pump Servo Pressure Vent W-23VD-0044 166
P-034 Directional Valve 4/2 32 GN2 Discharge Valve Oil Supply W-23VD-0044 166
P-035 Shutdown Switch 0-10,000 PSI 34 GN2 Over Pressure Shutdown Valve 6901 121
P-036 Red/Green (Frog Eye) Indicator 1/8"BSP 35 Panel Mounted Nitrogen Indicator W-20IR-0003 118
P-037 Red/Green (Frog Eye) Indicator 1/8"BSP 35 Panel Mounted Position Indicator W-20IR-0003 118
P-038 Pressure Gauge 0-100 PSI 2.50 36 Engine Oil Pressure Gauge W-24GP-0030 021
P-039 Diecrtional Valve 3/2 Pilot/Pilot G1/4 38 GN2 Discharge Valve indicator Relay 2AVD00009
P-040 Valve 3/2 Roller Spring G1/4 39 GN2 Discharge Valve Open Valve 2AVD00004
P-041 Valve 3/2 Roller Spring G1/4 39 GN2 Discharge Valve Close Valve 2AVD00004
P-042 Air Dryer Bendix AD9 40 Compressor Air Dryer W-20FHA-0005 097
J15177001 2NE090348
NO. ON
SCHEMATIC
N-001 Valve Relief 1/4"NPT x 1/2"BSP SET @ 200 PSI 1 VR1 W-21VR-0007 049
N-009 Valve Relief 9/16"HP 2 GN2 Relief Valve Connected to High Pressure Manifold 2CVR00011 050
N-010 Valve Ball 2.00 Cryo S/Weld 3 Inlet Isolation Valve No.1 W-21VB-0007 047
N-011 Valve Ball 2.00 Cryo S/Weld 3 Inlet Isolation Valve No. 2 W-21VB-0007 047
N-012 Valve Ball 2.00 Cryo S/Weld 3 Boost Pump Bypass W-21VB-0007 047
N-013 Valve Ball 2.00 Cryo S/Weld 3 Boost Pump Inlet Crossover W-21VB-0007 047
N-014 Valve Ball 1.50 Cryo S/Weld 4 Rapid Cooldown Valve W-21VB-0006 047
N-015 Valve Ball 1.50 Cryo S/Weld 4 Return Isolation W-21VB-0006 047
N-016 Valve Ball 1.50 Cryo S/Weld 4 Boost Pump Isolation W-21VB-0006 047
N-017 Valve Ball 0.75 Cryo S/Weld 5 Boost Pump Prime Vent Valve W-21VB-0009 047
N-018 Valve Needle 2-Way 9/16" 6 LN2 Tempering Valve 2CVH00004 150
N-019 Valve Needle 2-Way 9/16" 6 GN2 Vent Valve 2CVH00004 150
N-020 Valve Plug 2" x 1" c/w BRC012 Danfoss Actuator 7 GN2 Discharge Valve Hydraulic Actuator W-21VP-0010 183
N-021 Valve Globe 1.00" St/St S/Weld 8 Back Pressure Globe Valve 2CVG00008 173
N-022 Gauge 0-12000PSI 6" Panel Mount 9 GN2 Discharge Pressure Gauge W-24GP-0063 188
N-023 Valve Check 1.00" St/St S/Weld 10 Between 1" Globe Valve & Return Manifold 2CVC00005 112
N-024 Valve Check 1.00 High Pressure 11 GN2 Check Valve 2CVC00007 051
N-025 Pump Centrifugal 1½ x 2½ x 6 12 LN2 Charge Pump 2LE100002 042
N-026 Strainer 2.00" St/St S/Weld 13 Boost Pump Inlet Filter 2CLS00001 123
N-027 Strainer 2.00" St/St S/Weld 13 Boost Pump Bypass Inlet Filter 2CLS00001 123
N-028 Totalizer Flowrate MC-11 ATEX 14 Pump GN2 Flow Rate/Totalizer 2ITE00020 N/A
N-029 Suction Cryogenic Manifold for Standard 180K Unit 15 LN2 Inlet to Cold Ends 2ND070042 124
J15177001 2NE090348
NO. ON
SCHEMATIC
N-030 Manifold Discharge High Pressure 16 Triplex Discharge Manifold 2ND070037 039
N-031 Gauge 0-12000PSI 6" Panel Mount 17 GN2 Pressure Gauge W-24GP-0060 188
N-032 Pressure Gauge 0-200 PSI 4.00 Panel Mount 19 Panel Mounted Boost Pump Pressure W-24GP-0052 021
N-033 Temperature Gauge 4" 0-120C/248F 20 GN2 Temperature W-24GT-0016 036
N-034 Valve Ball ½" Cryo S/Weld 21 Inlet No. 1 Vent W-21VB-0008 047
N-035 Valve Ball ½" Cryo S/Weld 21 Inlet No. 2 Vent W-21VB-0008 047
N-036 Shutdown High Pressure 0-10,000 PSI 22 GN2 Over Pressure Shutdown Valve 6901 121
N-037 Vaporiser Pot Assembly 180K 29 LN2 Evaporator 2LD400002 038
N-038 Assembly Cold End 1.625 31 Cold End 1 2LD000014 041
N-041 Valve Check 1.5" ST/ST S/Weld 33 Second Inlet Isolating Valve 2CVC00004 179
N-042 Valve Ball Excess Flow 1/4" 39 GN2 Pressure Gauge Damper 2CVB00004 051
N-043 Valve Ball Excess Flow 1/4" 39 LN2 Pressure Gauge Damper 2CVB00004 051
N-044 Valve 2-Way 0.25 Angle 40 GN2 Vent Valve 2CVH00003 190
ASSET No. 12220042
SECTION 9.0 – HOSE REGISTERS

Job Number HALLIBURTON OPEN SKID 180K NITROGEN UNIT WF 168 Iss 3
J15177001 PANEL HOSE REGISTER
LENGTH
ITEM HOSE TYPE/ SIZE HOSE ENDS QTY (inches) HOSE ROUTING DESCRIPTION FROM -TO
P/H 1 ½" 3K ST 90 1 12.5 FROM BRASS RETURN HYDRAULIC MANIFOLD TO PANEL BULKHEAD RETURN
P/H 2 ½" 3K ST 90 1 61.5 RETURN OUT OF HYDRAULIC LOAD CONTROL VALVE TO BRASS RETURN MANIFOLD
P/H 3 ½" 3K ST 90 1 31 HYDRAULIC LOAD PRESSURE FROM BULKHEAD IN PANEL TO HYD LOAD CONTROL VALVE
P/H 4 ½" 3K ST ST 1 37 REGULATED AIR IN FROM PANEL BULKHEAD TO AIR MANIFOLD
P/H 5 ⅜" 3K ST 90 1 44.5 RETURN OUT OF BOOST PUMP CONTROL VALVE TO BRASS RETURN MANIFOLD
P/H 6 ⅜" 3K ST 90 1 40 RETURN OUT OF DISCHARGE CONTROL "OPEN/CLOSE" VALVE TO BRASS RETURN MANIFOLD
P/H 7 ⅜" 3K ST 90 1 19 RETURN OF BOOST PUMP SUN CONTROL VALVE TO PANEL BULKHEAD RETURN
P/H 8 ¼" 3K ST 90 1 20.5 BOOST PUMP HYD PRESSURE FROM PANEL BULKHEAD TO BOOST PUMP CONTROL VALVE
P/H 9 ¼" 3K ST 90 1 26.5 PRESSURE FROM PANEL BULKHEAD TO TRIPLEX CONTROL VALVE "PRESSURE IN" PORT 2
P/H 10 ¼" 3K ST 90 1 20 CONTROLED PRESSURE OUT OF TRIPLEX CONTROL VALVE PORT 1 TO PANEL BULKHEAD
P/H 11 ¼" 3K ST 45 1 26 DISCHARGE CONTROL VALVE "OPEN/CLOSE" PRESSURE FROM PANEL BULKHEAD TO DISCHARGE
- - - - - - CONTROL VALVE PRESSURE IN
P/H 12 ¼" 3K ST ST 1 29 PRESSURE OUT OF DISCHARGE CONTROL VALVE "PORT 1 OPEN" POSITION TO PANEL BULKHEAD
P/H 13 ¼" 3K ST ST 1 27.5 PRESSURE OUT OF DISCHARGE CONTROL VALVE "PORT 2 CLOSED" POSITION TO PANEL BULKHEAD
P/H 14 Microbore ST ST 1 16 PRESSURE OUT OF HYDRAULIC LOAD VALVE TO HYDRAULIC LOAD PRESSURE GAUGE IN PANEL
P/H 15 Microbore ST ST 1 20 PRESSURE OUT OF HYDRAULIC BOOST PUMP CONTROL VALVE TO BOOST PUMP PRESSURE GAUGE IN PANEL
P/H 16 Microbore ST ST 1 25.5 MAIN AIR PRESSURE FROM PANEL BULKHEAD TO AIR PRESSURE GAUGE IN CONTROL PANEL
P/H 17 Microbore ST ST 1 29 MAIN ENGINE OIL PRESSURE FROM PANEL BULKHEAD TO ENGINE OIL PRESSURE IN GAUGE IN PANEL
P/H 18 Microbore ST ST 1 33.5 TRIPLEX LUBE OIL PRESSURE FROM PANEL BULKHEAD TO TRIPLEX LUBE OIL PRESSURE GAUGE IN PANEL
P/H 19 Microbore ST ST 1 30 SYSTEM HYDRAULIC PRESSURE FROM PANEL BULKHEAD TO SYSTEM HYDRAULIC PRESSURE GAUGE IN PANEL
P/H 20 Microbore ST ST 1 31 CHARGE PRESSURE FROM PANEL BULKHEAD TO CHARGE PRESSURE GAUGE IN PANEL
J15177001 HOSE REGISTER
LENGTH
1 ½" 3K ST ST 1 36 INLET MAN TO COMP IN PORT
2 ⅜" 3K ST ST 1 56 SEC FUEL FILTER OUT PORT TO AMOT FUEL VALVE PORT B
3 ⅜" 3K ST 90 1 37½ LIFT PUMP TO SEC FUEL FILTER IN PORT
4 ⅜" 3K 90 90 1 36 AMOT VALVE (T) TO FUEL PUMP OUT PORT
5 ⅜" 3K ST 90 1 39 AMOT VALVE PORT (A) TO FUEL PUMP IN PORT
6 2" 32G1H ST 90 1 26 HEAT EXCHANGER TO T67 MANIFOLD
7 2" 32G1H 90 ST 1 75 HEAT EXCHANGER TO VAPORISER POT WATER OUT
8 2" 32G1H 90 45 1 60 WATER PUMP TO VAPORISER POT WATER IN
9 1¼" 20G1H 90 ST 1 31 V12 VALVE TO V10 LINK HOSE
10 1¼" 20G1H ST 90 1 41 BOTTOM HYDRAULIC TANK TO RETURN FILTER OUT PORT
11 1¼" 20G1H ST 90 1 66 RETURN FILTER OUT PORT TO HEAT EXCHANGER MANIFOLD
12 1¼" 20G1H ST ST 1 61 TOP OF T ON V10 VALVE TO MANIFOLD ON HEAT EXCHANGER
13 1¼" 20G1H 90 ST 1 70 BOTTOM OF P14 TO SUCTION FILTER MANIFOLD
14 1¼" 20G1H ST 90 1 67 RETURN FILTER IN PORT TO FLOW DIVIDER ON T67
15 1¼" 20G1H 90 ST 1 14½ RETURN FILTER IN PORT TO CHECK VALVE ON MANIFOLD T67
16 1¼" 20G1H 90 ST 1 18 STARTING MOTOR TO STARTING SOLENOID
17 1¼" 20G1H ST 90 1 63 TRIPLEX N.R.V. TO LUBE PUMP
18 1¼" 20G1H ST 45 1 73 AIR RECEIVER TO STARTER LUBRICATOR
19 1" 3K ST ST 1 44½ SUCTION FILTER MANIFOLD TO TANDEM GEAR PUMP
20 1" 3K ST ST 1 64 TOP OF HYDRAULIC TANK TO P14 CASEDRAIN/RETURN
21 1" 3K ST 90 1 29 MANICOOLER TO BOTTOM OF DUPLEX
22 1" 3K ST 90 1 30 MANICOOLER PIPEWORK TO MANICOOLER
23 1" 3K ST 90 1 82 AIR RECEIVER TO RIG AIR
24 ¾" 3K ST ST 1 52½ BOTTOM OF TRIPLEX TO FULFLO OUT PORT
LENGTH
25 ¾" 3K ST 90 1 90 LUBE PUMP TO LUBE FILTER 'IN' PORT
26 ¾" 3K ST 90 1 71 HIGH PRESSURE FILTER OUT PORT TO P14 K PORT (UPPER)
27 ¾" 3K ST 90 1 63½ HIGH PRESSURE FILTER IN PORT TO P14 J PORT (LOWER)
28 1¼" 20GIH ST ST 1 50 SUCTION FILTER MANIFOLD TO SINGLE VANE PUMP
29 ¾" 3K 90 ST 1 145 HEAT EXCHANGER PIPEWORK TO HEADER TANK
30 ¾" 3K ST 90 1 39 BOOST PUMP RV RETURN TO T ON SINGLE VANE PUMP
31 ¾" 3K ST 45 1 105 WATER PUMP MOTOR IN PORT TO T67 WATER PUMP (RV) PORT B
32 ¾" 3K ST 90 1 80 WATER PUMP MOTOR OUT PORT TO RETURN MANIFOLD PORT A
33 ¾" 3K ST 90 1 65 WATER PUMP RV RETURN TO RETURN MANIFOLD
34 ¾" 3K ST 90 1 75 TOP OF DUPLEX TO ENGINE WATER JACKET
35 ¾" 3K ST 90 1 29½ LUBE OIL FILTER OUT TO TRIPLEX LUBE MANIFOLD
36 ¾" 3K ST ST 1 24 TRIPLEX LUBE MANIFOLD TO TRIPLEX SWIVEL
37 ¾" 3K ST ST 1 54 TOP OF TRIPLEX MOTOR TO TOP OF HYDRAULIC TANK
38 NOT USED
39 ½" 3K ST 45 1 86 AIR DRYER IN PORT TO COMPRESSOR CHECK VALVE
40 ½" 3K ST ST 1 178 AIR DRYER OUT PORT TO AIR RECEIVER
41 ½" 3K ST ST 1 265 AIR RECEIVER TO AIR REG IN PORT
42 ½" 3K ST 90 1 22 HEAT LOAD RV LINK HOSE
43 ½" 3K ST 90 1 78½ PANEL B/H TO HEAT LOAD RV
44 ½" 3K ST ST 1 93½ TOP OF HYDRAULIC TANK TO PANEL B/H (RETURN)
45 ½" 3K 90 ST 1 32 PANEL B/H TO AIR REG OUT PORT
46 ½" 3K 45 90 1 45 BOOST PUMP RV TO BOOST PUMP IN PORT
47 ½" 3K 45 ST 1 50½ BOOST PUMP OUT PORT TO T ON SINGLE VANE PUMP
48 ½" 3K ST ST 1 136 FUEL FILTER IN PORT TO FUEL TANK OUT PORT
LENGTH
49 ½" 3K 90 ST 1 136 AMOT FUEL VALVE TO FUEL TANK IN PORT
50 ⅜" 3K ST 90 1 67 TRIPLEX MOTOR TOP PORT TO HYD TANK
51 NOT USED
52 ⅜" 3K ST ST 1 136 WATER PUMP MOTOR TO TOP OF HYDRAULIC TANK
53 ⅜" 3K ST ST 1 29 4D01 LINK HOSE 45 TO TOP OF TEE
54 ⅜" 3K ST 90 1 76 TOP OF HYDRAULIC TANK TO 4D01 VALVE
55 ⅜" 3K ST ST 1 94 TOP OF HYDRAULIC TANK TO PANEL B/H (SUN RETURN)
56 ⅜" 3K ST ST 1 115 TOP OF HYDRAULIC TANK TO BOOST PUMP CASE DRAIN
57 ¼" 3K ST 90 1 246 PANEL B/H (DIS CLOSE) TO DISCHARGE VALVE CLOSE SHUTTLE HYDRAULIC
58 ¼" 3K ST 90 1 239 PANEL B/H (DIS OPEN) TO DISCHARGE VALVE OPEN SHUTTLE HYDRAULIC
59 ¼" 3K ST 90 1 225 AIR REGULATOR TEE TO DISCHARGE VALVE OPEN SHUTTLE TEE
60 ¼" 3K ST 90 1 16 DISCHARGE VALVE OPEN SHUTTLE TEE TO DISCHARGE VALVE CLOSE SHUTTLE
61 ¼" 3K ST ST 1 239 DISCHARGE VALVE PORT B TO PANEL B/H (DIS OPEN) INDICATOR
62 ¼" 3K ST ST 1 238 DISCHARGE VALVE PORT A TO PANEL B/H (DIS CLOSE) INDICATOR
63 ¼" 3K ST 90 1 52 WATER PUMP RV TO DISCHARGE 4D01 PORT P
64 ¼" 3K ST ST 1 120 PANEL B/H (DIS PILOT) TO DISCHARGE 4D01 PILOT
65 ¼" 3K ST 90 1 127 PANEL B/H (DIS PRESS) TO DISCHARGE 4D01 PORT B
66 ¼" 3K ST 90 1 131 IDEAL VALVE TEE TO SPEED 4D01 PILOT
67 ¼" 3K ST 90 1 109 PANEL B/H (SUN OUT) TO SPEED 4D01 PORT P
68 ¼" 3K ST ST 1 18 SPEED 4D01 PORT B TO P14 PORT P2
69 ¼" 3K ST ST 1 92½ P14 PORT P1 TO TOP OF HYDRAULIC TANK
70 ¼" 3K ST ST 1 92 PANEL B/H (CHARGE) TO P14 PORT KG
71 ¼" 3K ST ST 1 89 PANEL B/H (SUN IN) TO P14 PORT G
72 ¼" 3K ST 90 1 107 PANEL B/H (BOOST) TO BOOST PUMP RV
LENGTH
73 ¼" 3K ST ST 1 155 PANEL B/H (LUBE) TO LUBE FILTER
74 ¼" 3K ST ST 1 33 PANEL B/H (REG AIR) TO IDEAL VALVE 90
75 ¼" 3K ST 90 1 30 PANEL B/H (N2 O/PRESS) TO IDEAL VALVE TEE
76 ¼" 6K ST ST 1 91 PANEL B/H (SYSTEM) TO P14 PORT BG
77 ¼" 3K ST 90 1 207 ENGINE BLOCK TO OIL AMOT TOP OF TEE
78 ¼" 3K ST ST 1 172 ENGINE WATER TEMP AMOT TO PANEL B/H (HIGH WATER)
79 ¼" 3K ST ST 1 147 EXHAUST TEMP AMOT TO PANEL B/H (HIGH EXHAUST)
80 ¼" 3K 90 45 1 78 ENGINE AIR FLAP TO OVERSPEED
81 ¼" 3K 90 ST 1 140 FUEL AMOT 5.2 VALVE PORT 1 TO PANEL B/H (STOP)
82 ¼" 3K 90 ST 1 136 ENGINE STARTER LH PORT TO PANEL B/H (START)
83 ¼" 3K ST ST 1 274 AIR RECEIVER TO PANEL B/H (AIR PRESSURE)
84 ¼" 3K ST ST 1 87 FUEL AMOT TO ENGINE AIR FLAP
85 ¼" 3K 90 ST 1 70 ENGINE STARTER MOTOR RH PORT TO START SOLENOID
86 ¼" 3K 90 ST 1 36 ENGINE OVERSPEED TO PANEL B/H (EM STOP)
87 ¼" 3K 90 ST 1 34 ENGINE STOP RAM TO FUEL AMOT 5.2 VALVE PORT 2
88 ¼" 3K ST 90 1 152 AIR RECEIVER TO COMPRESSOR GOVENOR R/H PORT
89 ¼" 3K ST 90 1 125 AIR DRYER TO COMPRESSOR GOVENOR L/H PORT
90 ¼" 3K ST ST 1 103 TOP OF DUPLEX TO TOP OF RADIATOR
91 ¼" 3K ST 90 1 18 LUBE MANIFOLD TO COLD END LUBE
92 ¼" 3K ST 90 1 27½ LUBE MANIFOLD TO COLD END LUBE
93 ¼" 3K ST 90 1 36 TRIPLEX LUBE MANIFOLD TO COLD END LUBE
94 ¼" 3K ST ST 1 134 HEADER TANK TO VAPORISER POT
95 1½ R13R 90 90 1 50 TRIPLEX MOTOR TO P14
96 1½ 20G1 ST ST 1 58½ TRIPLEX MOTOR TO P14
LENGTH
97 ¼" 3K ST ST 1 44 OIL AMOT TEE TO PANEL B/H OIL PRESSURE
98 ¼" 3K 90 ST 1 52 OIL AMOT TO PANEL B/H LOW OIL
99 1 ¼ FC300 ST ST 1 78 ENGINE OIL IN PORT TO OIL FILTER HOUSING OUT
100 1 ¼ FC300 ST ST 1 78 ENGINE OIL OUT PORT TO OIL FILTER HOUSING IN
101 ¼" 3K ST ST 1 31 PANEL B/H N2 O/PRS TO OPP ON MOUNTING FRAME
102 ½" 3K ST NPT 90 1 78 GEARBOX DRAIN
103 ¾" 3K ST NPT 90 1 78 ENGINE DRAIN
104 ¾" 3K ST ST 1 19 ENGINE WATER JACKET TO TURBO LOWER PORT
ASSET No. 12220042
SECTION 10.0 – UNIT SAFETY

OP99
10.0 UNIT SAFETY
10.1 Loler/Puwer
A. LOLER
The skid and framework of the unit was proof loaded as part of the manufacturing
process with welds MPI tested pre and post test.
Lifting slings are provided certified to DNV 2.7-1.
B. PUWER
Evaluation questionnaire included.

OP999
Operation & Maintenance Volume 1
EQUIPMENT SAFETY CHECKLIST
Open Skid 180K Liquid Nitrogen Unit – Serial No. J15177001
The checklist is designed so that the ideal outcome is "Yes" to each question.
Information, Instruction and Safe Use

1. Are there written instructions covering:
a) Any unusual hazards or complicated features? YES
b) Where appropriate, emergency shutdown? YES
2. a) Has instruction in readily comprehensive form (written or verbal) on all hazards been passed on to all those who use the equipment? YES
b) Have any written instructions provided by the manufacturer been passed on to users? YES
3. a) Have all users of the equipment been given adequate training in correct use, risks and precautions? YES
b) Is a training record kept which verifies this? YES
4. Is the equipment being used in accordance with the manufacturer’s instructions? YES
5. If it has been adapted, is the adaptation suitable and safe? YES
6. Is the equipment used in an appropriate environment? (consider e.g. ventilation, damp, flammable conditions). YES
7. If the equipment may be moved, is the weight known? YES
8. a) Are the start and stop controls clearly marked? YES
b) Are other operating controls, and the contents of any containers, clearly marked? YES
9. Are there clear warning notices or markings (e.g. to wear personal protection, restrictions on use, list of authorised users) where appropriate? YES
Maintenance
10. What are the appropriate intervals for checking:
a) Electrical safety? (Refer to Manual of Safety, Section 2)________________________________ YES
b) Any safety devices? Annual Inspection & calibration
11. If inadequate maintenance could cause the equipment, guards, or other protection to fail in a dangerous way, are there a system of planned preventive YES
maintenance, including where appropriate the periodic replacement or refurbishing of items before they reach the end of their usual life?
12. Have clear maintenance instructions been given to those responsible for maintaining the equipment? YES
13. Is the equipment and system of maintenance designed to minimise the risks which may arise during maintenance? YES
Specific Hazards
14. Is protection adequate in relation to:
a) Items falling from the equipment? YES
b) Items being ejected? YES

OP999
c) Overturning? YES
d) Collapse? YES
e) Overheating or fire? YES
f) Disintegration? YES
g) Explosion? YES
15. Is the equipment made stable where appropriate by bolting, clamping or tying? YES
16. Is there sufficient general and (where necessary) local lighting? YES
17. Is there protection against contact with hot or very cold temperature, so far as is appropriate? YES
18. In the case of pressurised equipment, is there a written scheme of examination?
19. If gas, fume or dust is released when the equipment is used, is there:
a) A local exhaust ventilation, tested annually? YES
or b) A COSHH assessment YES
Dangerous Parts of Machinery
20. Are all dangerous parts of machinery guarded? YES
21. Are all guards sound and in good working order? YES
22. Do they permit an adequate view of the operation where this is necessary? YES
23. Is it difficult to bypass or disable them? YES
24. Can the machinery only be started when a specific labelled start device is used: (NB. the normal cycle of automated machinery is exempt from this YES
requirement?)
25. Is it impossible to start the machine just by resetting a safety device? YES
26. Is there a readily accessible stop device which stops the machinery in a safe way? YES
27. Where appropriate (i.e. where in a foreseeable emergency it could help) is there a prominent easily accessible emergency stop device? YES
28. Can controls be operated safely and easily? YES
29. Is there a system of work which ensures that nobody is in a dangerous position when machinery is about to be started? YES
30. Does the start device need to be activated to restart the machine if:
a) The power fails? YES
b) A control or safety device fails or trips out? YES
31. If the power is isolated does the machinery come to rest safely without the possibility of access to dangerous parts? YES
32. Can the equipment be securely isolated from power to prevent inadvertent reconnection
a) By removing a plug from a socket which is easily visible to the person at risk? YES
b) By locking it off? YES

OP999
Summary
Action to be taken in order of priority and timescale.
Date for review (maximum interval 5 years): ..........................................................................

OP999
10.2 Design Safety
The equipment operates with adjacent components at opposite ends of the temperature
spectrum. The cryogenic system having a lower limit of -196°C, the temperature of liquid
nitrogen, whilst the maximum will be 200°C, the temperature at which the high exhaust
temperature shutdown will operate. Coupled with the temperature extremes pressures of
up to 9000 psi may be seen.
The unit also contains the following quantities of inflammable liquids:
Diesel - 100 US Gallons

Hydraulic Oil - 130 US Gallons
Triplex Lubricating Oil - 12 US Gallons
As described in the previous sections the unit is fitted with a range of measures designed
to minimise risk to both the operator and the environment
The circuits are tested, witnessed and certified prior to shipment.

Open 180K Liquid Nitrogen Unit J15177001
OP999
10.3 Critical Component Catastrophic Failure Analysis
ITEM COMPONENT
Caterpillar 3406C Loss of hydraulic power. All hydraulically driven

1
Engine fails components will stop operating.
Engine still under hydraulic load. Engine temperature

2 Triplex Pump fails will increase until high coolant shutdown valve is
activated shutting down the engine.
In most cases prime will be lost and pumping will cease.
3 Centrifugal Pump fails If full tank of nitrogen is being used it is possible to
maintain prime and keep pumping.
Reduced pumping throughput if cold end failure does
4 Cold End fails not affect the triplex pump. If the cold end failure
causes the triplex to fail see (2).
Failure of the triplex lubrication pump will cause failure

5 Triplex Lubrication fails
of the triplex pump. See (2).
Engine will overheat and the high coolant shutdown will

6 Radiator fails
operate.
Water temperature will increase and so will water

7 Heat Exchanger fails pressure. Header tank cap will blow. In some
circumstances a hose may blow.

OP999
10.4 ESR Check List
A check list for essential health and safety requirements relating to the design and
construction of machinery has been constructed to establish compliance with Schedule 3
of Statutory Instruments No. 3073 1992 and its 1994 Amendment SI 2063.
This check list has been applied to the NOV Hydra Rig UK Nitrogen Pumping System Serial
Number J15177001 manufactured for Halliburton.
Definitions
For the purposes of the Machinery Directive and this document:
1 "Danger zone" means any area within and/or around machinery in which an
exposed person is subject to a risk to his health or safety;
2 "Exposed person" means any person wholly or partially in a danger zone;
3 "Operator" means the person or persons given the task of installing, operating,
adjusting, maintaining, cleaning, repairing or transporting machinery.

OP999
SECTION: 1.1 - GENERAL REMARKS AND PRINCIPLES
Principles of Safety Integration (ESR ref: 1.1.2)

Could the machine present a hazard during:
1. Normal Use? YES
2. Foreseeable misuse? YES
Can any possible hazards be eliminated by:
3. Re-Design? NO
4. Safeguarding? YES
See sections 3.1 and 3.2 for detailed explanation.
5. Has the machine been designed to minimise the discomfort, fatigue, and psychological stress faced by the operator taking ergonomic principles in to account? YES
Does the operator need extra information on:
6. Operating conditions including any spatial constraints? NO – Details included in manual
7. Safety clothing/equipment? YES – Hard hat and eye protection
Details included in manual
8. Is the machine supplied with all of the essential special (including safety) equipment required for safe operation? YES
Materials and Products (ESR ref: 1.1.3)
9. Does the machine incorporate or use any hazardous metals/plastics/lubricants? YES – Liquid Nitrogen
10. Can any materials (i.e. lubricating agents) required for normal use, maintenance etc. be placed in the machine safely? YES
11. Do the construction materials comply with the relevant EC Directives? YES
Lighting (ESR ref: 1.1.4)
12. Is extra lighting required for safe machine operation, adjustment etc? NO
13. Does the provision of extra lighting give rise to light hazards (i.e. shadows, stroboscopic effects etc.)? N/A
Handling (ESR ref: 1.1.5)
Could there be possible hazards when the machine and/or any associated parts are:
14. Handled? YES – Weight of system
15. Packaged? NO
16. Transported? NO
17. If handling etc. of the machine could be hazardous has provision been made for lifting gear etc? YES

OP999
SECTION: 1.2 - CONTROLS
Safety and Reliability (ESR ref: 1.2.1)

18. Can the controls withstand the rigours of normal use/foreseeable misuse? YES
19. Could logical errors lead to possibly dangerous situations? NO
Control Devices (ESR ref: 1.2.2)
Are machine controls:
20. Clearly visible and identifiable? YES
21. Safely and unambiguously positioned? YES
22. Directionally consistent with their effect? YES
23. Located outside of any danger zones? YES
24. Designed to avoid unintentional operation? YES
25. Positioned so that the operator is able to use controls while wearing special (i.e. protective) clothing? YES
26. Able to withstand a lifetime of normal use/foreseeable misuse? YES
27. If the controls involve keyboard use, does the operator have to confirm any action selected? N/A
28. Are all indicators, dials etc. required for safe operation fitted and viewable? YES
29. Are visual or acoustic warning devices required? WARNING LIGHTS
Starting (ESR ref: 1.2.3)
30. Can the machine be started unintentionally? NO
31. Are precautions necessary before starting? YES – The operator's manual defines start up
sequence following shut down; these include
shut down following emergency stop.
Stopping (ESR ref: 1.2.4)

32. Does the machine stop safely? YES
33. Have a Stop control which inhibits the Start control? YES
34. Have Stop controls at each workstation? YES
35. Have an Emergency Stop? YES
36. Does the Emergency Stop function on all components of the system? YES
37. Are precautions necessary before restarting? YES - As defined in the operators manual.
Emergency stop buttons must be deactivated
and the fuel shut off valve reset prior to start
up

OP999
Mode Selection (ESR ref: 1.2.5) - not applicable

38. Can the machine operate in more than one mode? YES
39. Is the Mode Selection control lockable? YES – By operation of valve
40. Is the Automatic Mode disabled when any safeguarding devices are disabled? N/A
Failure of Power Supply (ESR ref: 1.2.6)
If the power supply fails or fluctuates, will the machine automatically:
41. Stop in a safe condition? YES
42. Restart if the power is reconnected? NO
43. Allow unimpeded stopping? YES
44. Keep protective devices effective? YES
45. Prevent parts/products from being ejected or causing other hazards? YES
Failure of Control Circuit (ESR ref: 1.2.7)
If the Control Circuits were to fail or were to develop fault(s), would the machine automatically:
46. Stop safely? YES
47. Be prevented from restarting? YES
48. Allow unimpeded stopping? YES
49. Allow protective devices to remain effective? YES
50. Prevent parts/product from being ejected or causing other hazards? YES
Software (ESR ref: 1.2.8) - not applicable
51. Is interactive software (between the operator and machine control system) user friendly? N/A

OP999
SECTION: 1.3 - MECHANICAL HAZARDS
Stability (ESR ref: 1.3.1)

52. Can the machine overturn, fall or move unexpectedly? NO
Risk of Machine Break Up during Operation (ESR ref: 1.3.2)
53. Will the machine withstand operational stresses (especially with reference to fatigue, ageing, corrosion etc)? YES
54. Do the operating instructions detail the frequency and type of safety inspections required? YES – A maintenance schedule is included
in the operations manual but this is very
dependent on the process used
55. Is all pipework on the machine which contains fluid or gas able to withstand foreseeable external stresses? YES
56. Will the area remain safe in the event of any type of system failure? YES
Risk due to Falling or Ejected Objects (ESR ref: 1.3.3)
57. Could the machine give rise to falling or ejected objects? YES
58. Could these objects be a hazard? YES – High pressure ~ 10000 psi could cause
ejected object if joint fails. Protection
plates fitted.
Risk due to Surfaces, Edges or Angles (ESR ref: 1.3.4)
59. Does the machine have any rough surfaces, sharp edges or angles which may cause injury? NO
Risk Related to combined machinery (ESR ref: 1.3.5)
60. Can each element of a complex operation be completed without risk? YES
Risk Relating to Variations in the Rotational Speed of Tools (ESR ref: 1.3.6)
61. Does the machine use different rotational speeds to achieve different operating conditions? YES – Speed adjustment via diesel engine)
Prevention of Risks Related to Moving Parts (ESR ref: 1.3.7)
62. Have hazards been designed out where possible? YES
63. Have guards and/or protection devices been used to eliminate hazards? YES
64. Are there still apparent risks from moving parts? NO
Choice of Protection against Risks Related to Moving Parts (ESR ref: 1.3.8)
If deemed a requirement due to possible hazards, have the following guard types been fitted:
65. Fixed guards only where access is infrequent? YES
66. Movable guards where access is frequent? YES

OP999
SECTION: 1.4 - REQUIRED CHARACTERISTICS OF GUARDS AND PROTECTIVE DEVICES
General Requirements (ESR ref: 1.4.1)

67. Does the machine have guards? YES
Are guards:
68. Robust and difficult to defeat? YES
69. Located near any danger zones? YES
70. Causing additional hazards? NO
71. Causing an obstruction? NO
72. Impeding access for maintenance? YES – Maintenance performed when
machine not operating - guards must be
removed to perform maintenance.
Special Requirements for Guards (ESR ref: 1.4.2)
73. Are fixed guards securely held in place? YES
74. Removable only with tools? YES
75. Able to remain in place without fixings? NO
76. Are movable guards fixed to machine? YES
77. Interlocked with Fail Safe devices? NO
78. Adjustable only with tools? YES
Special Requirements for Protective Devices (ESR ref: 1.4.3)
Are Protective Devices:
79. Fail Safe? YES
80. Difficult to adjust unintentionally? YES

OP999
SECTION: 1.5 - PROTECTION AGAINST OTHER HAZARDS
Electrical Supply (ESR ref: 1.5.1)

81. Have all electrical supply hazards been eliminated by design? N/A
82. Have the Codes of Practice relevant to supply voltage been followed, i.e.: N/A
Means of isolating machine from mains supply, e.g. unplug to isolate?
Protective conductor (earth) shall be readily distinguishable
Colour code for AC wiring shall be described in the manual/on the cable current carrying capacity of cables
Protective fuse appropriate to load
Static Electricity (ESR ref: 1.5.2)
83. Could the machine create a static electricity hazard? NO
Energy Supply other than Electricity (ESR ref: 1.5.3)
84. Does the machine use Hydraulic, Pneumatic or Thermal energy ? YES
85. Have any hazards associated with this type of supply been considered? YES
Errors of Fitting (ESR ref: 1.5.4)
Could a hazard be created by incorrect or faulty:
86. Components? YES
87. Electrical connections? N/A
88. Fluid connections? YES
89. Have any remaining specific hazards due to any of the above been detailed in machines operating instructions? YES
Extreme Temperatures (ESR ref: 1.5.5)
90. Have steps been taken to eliminate risk of injury caused by contact with or proximity to parts or materials at high or very low temperatures? YES
Fire (ESR ref: 1.5.6)
91. Have all the possible machine related sources of ignition been eliminated? YES
92. Are there any gases, liquids or other materials produced/used by the machine which constitute a fire hazard? YES
Machine has a total of 378 litres diesel fuel, 350 litres hydraulic oil and 45 litres lubricating oil.)
Explosion (ESR ref: 1.5.7)
93. Do any gases, liquids, vapours or dusts produced/used by the machine (inc. compressed air, hydraulic fluid etc.) constitute an explosion hazard? YES – Hydraulic fluid and compressed air.
94. Is the machine intended for use in an explosive environment? NON-ZONED
95. Could the machine cause an explosion if placed within an explosive atmosphere? NO

OP999
Noise (ESR ref: 1.5.8)

96. Where possible, has the machine been designed to minimise noise production? YES
97. Have noise level measurements been made and recorded? YES
98. Does the machine produce a noise level above 70db? YES
99. If appropriate are warnings present in operator manual & sales literature? NO
Vibration (ESR ref: 1.5.9)
100. Does the machine design minimise any vibration hazard? YES – Anti-vibration engine mounts used
throughout
Radiation (ESR ref: 1.5.10)
With respect to ionising radiation, does the machine:
101. Produce hazardous radiation? NO
102. Emit hazardous radiation? NO
103. Have safeguards been implemented to prevent emission of hazardous radiation? N/A
External Radiation (ESR ref: 1.5.11)
104. Can the machine be influenced by external ionising radiation? YES
Laser Equipment (ESR ref: 1.5.12)
105. Does the machine incorporate any type of Laser equipment? NO
106. Has it been adequately safeguarded? N/A
Emissions of Dust, Gases etc (ESR ref: 1.5.13) - not applicable
107. Does the machine produce hazardous dust, gases, vapours etc? YES – Nitrogen gas or liquid nitrogen at high
pressure.
108. Does the machine have the appropriate extraction equipment? N/A
109. Is the user advised of the need and uses of such equipment? YES
Risk of being trapped in a machine (ESR ref: 1.5.14)
110. Is it possible to be trapped in or by a machine? NO
Risk of Tripping, Slipping or Falling (ESR ref: 1.5.15)
Could the machine cause a slip, trip or fall:
111. By ejecting material? NO
112. Because of trailing wires, cables or other obstruction? YES – Nitrogen hoses connect the
equipment to an external liquid nitrogen
source.)

OP999
SECTION: 1.6 - MAINTENANCE
Machinery Maintenance (ESR ref: 1.6.1)

113. Can the machine be adjusted, maintained etc. from outside any danger zones or while the machine is immobilised? YES
114. Does the machine have diagnostic fault finding equipment or provision for such to be fitted? NO
115. Is special equipment required for servicing, maintenance, adjustment etc? YES
Access to Operating Position and Service Points (ESR ref: 1.6.2)
116. Can the machine be operated, cleaned and maintained safely without the need for access stairs, catwalks or ladders? NO – Access to roof required
117. Have they been provided? YES – Ladder fitted to skid
118. Is the customer advised of the need? N/A
Isolation of Energy Sources (ESR ref: 1.6.3) - not applicable
If the machine uses any energy supply other than that provided by a standard mains plug:
119. Can all energy sources be isolated by clearly identified devices? YES
120. Are these devices lockable? YES
121. Can any residual energy remaining after isolation be safely dissipated? YES
Operator Intervention (ESR ref: 1.6.4)
122. Is the machine designed to minimise the need for operator intervention? YES
123. If operator intervention cannot be avoided, can it be done easily and without risk? YES – Via external control panel
Cleaning of Internal Parts (ESR ref: 1.6.5) – not applicable as part f normal process
124. Can the machine be cleaned without entering any danger zones or while the machine is immobilised? YES
125. Can dangers be minimised further? NO

OP999
SECTION: 1.7 - INDICATORS
Information Devices (ESR ref: 1.7.0)

126. Are operation manuals provided? YES
127. Does the software provide on screen assistance? N/A
128. Are all instructions clear and unambiguous? YES
129. Is the equipment fitted with visual and audible warning light beacon and buzzers? YES
Warning Devices (ESR ref: 1.7.1)
Are the warning devices:
130. Unambiguous, easily understood? YES
131. Easily perceived? YES
132. Easily checked for operation during machine use? YES
133. Are the colours, symbols and safety signals used correct with respect to the requirements of the relevant Directives? YES
Warning of Residual Risk (ESR ref: 1.7.2) – not applicable
134. Does the operation of the machine involve coping with residual risks? N/A
135. Are residual risk warnings given? N/A
136. Are warnings in the language of the machines intended operator? YES
137. Are warning symbols used? YES
138. Are the colours, symbols and safety signals used correct with respect to the requirements of the relevant Directives? YES
Markings (ESR ref: 1.7.3)
Has the following information been marked legibly and indelibly on the machine:
139. Manufacturer name? YES
140. Manufacturer address? YES
141. Year of manufacture? YES
142. Serial number? YES
143. Model? YES
144. Type? YES
145. Maximum safe rotational speed? YES
146. CE mark? YES

OP999
Instructions (ESR ref: 1.7.4)

Do the instructions include the following information:
147. Details to facilitate maintenance, (i.e. Importers address, repairers)? YES
148. A repeat of the machine markings? YES
149. Details on the machines dimensions, weight etc? YES
150. Details on the use of any Personal Protective Equipment necessary for safe operation? YES
151. Foreseen uses of the machine? YES
152. Adequate warning of risk if the machine is used in ways not intended? YES
153. Description of the workstations to be occupied by the operator(s)? N/A
154. Diagrams/pictograms where clarification is required? YES
155. Repair/Service information? YES
156. Description, diagrams etc. relating to positioning of the machine to minimise noise and vibration hazards? N/A
Are there full instructions for safe:
157. Handling? N/A
158. Installation? N/A – Mobile and self-contained
159. Use? YES
160. Cleaning? YES
161. Adjustment? YES
162. Maintenance? YES
163. Dismantling? YES
Do the instructions indicate:
164. The training needs for the operator and maintenance staff? YES
165. The tools needed for safe maintenance? YES
166. The ways in which the machine should not be used? YES
167. All of this information in the language of the intended user? YES


Vol 1 - Operation Maintenance Manual

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Vol 1 - Operation Maintenance Manual

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OPEN 180K NITROGEN UNIT

SERIAL NUMBER J15177001

ASSET No. 12220042

VOLUME 1 – OPERATION AND MAINTENANCE

1.1. General Use

2.1. Liquid Nitrogen

2.2. Gaseous Nitrogen

2.3. Operating Safety

2.4. Safety Precaution

2.5. Rules and Regulations

2.7. General Safety

2.8. General Safety Instructions

Halliburton Asset No. 12220042 Page 1 of 4

2.8.7. Lubricant Hazards

2.10. Lift Safety

3.0 Definitions of Terms

3.1. Definition of Technical Terms

4.0 System Outline

4.1. Scope of Supply

Halliburton Asset No. 12220042 Page 2 of 4

4.7. SOS 3g Engine Protection System (where applicable)

5.0 Operating, Start-up & Stopping Procedures -

6.0 Maintenance and Troubleshooting

Halliburton Asset No. 12220042 Page 3 of 4

7.0 Drawings & Schematics

7.1. Schematic Coolant N2 CAT 3406 Open Frame 2NE090398

8.0 Parts Identification

8.1. Parts Identification & Function Hydraulic

9.0 Hose Registers

9.1. Panel Hose Register

10.0 Unit Safety

10.1. LOLER & PUWER

Halliburton Asset No. 12220042 Page 4 of 4

SERIAL NUMBER J15177001

ASSET No. 12220042

VOLUME 1 – OPERATION AND MAINTENANCE

SECTION 1.0 – INTRODUCTION

1.1 General Use

NOV Hydra Rig UK

Tel: 00 44 (0) 1493 666200

Halliburton Asset No. 12220042 Page 1 of 2

Halliburton Hydra Rig UK Description

Maximum working pressure: 690 Bar/10,000 psig

Halliburton Asset No. 12220042 Page 2 of 2

2. PRICES 4. PAYMENT TERMS

17. CONFIDENTIAL INFORMATION 20. GENERAL

SERIAL NUMBER J15177001

ASSET No. 12220042

VOLUME 1 – OPERATION AND MAINTENANCE

SECTION 2.0 – GENERAL SAFETY

2.1 Liquid Nitrogen

2.1.1 Exposure to Cool Temperatures

When spilled on a surface, it tends to cover it completely and therefore cools a

Halliburton Asset No. 12220042 Page 1 of 24

2.1.2 Personnel Equipment

2.1.3 Liquid to Gas Expansion

One volume of liquid nitrogen at one atmosphere vaporises to 695.5 volumes of

Halliburton Asset No. 12220042 Page 2 of 24

2.2 Gaseous Nitrogen

Nitrogen, although non-toxic, can constitute an asphyxiation hazard through the

Halliburton Asset No. 12220042 Page 3 of 24

2.3 Operating Safety

2. All pumping lines are restrained in case of joint or connection failure.

5. System and related piping should be pressure tested prior to commencement of