Instructions Manual: Nitrogen Pumping Unit

2016
Instructions Manual
Nitrogen Pumping Unit
GOES GmbH
German Oilfield Equipment &
Services
Münchener Str. 32
29392 Wesendorf | Germany

Table of contents
Scope of delivery
1 Table of contents
1 TABLE OF CONTENTS .................................................... 2
2 FUNDAMENTAL INFORMATION ..................................... 9
2.1 Scope of delivery ............................................................ 9
2.2 Documentation ............................................................. 11
2.2.1 Content and Set-up...................................................... 11
2.2.2 Conventions of Labelling ............................................. 11
2.2.3 Documentation from other Manufacturers ................... 12
2.2.4 Inspection and Maintenance Intervals ......................... 13
2.3 User Groups ................................................................. 15
2.4 Responsibilities............................................................. 16
2.4.1 Responsibility of the Manufacturer .............................. 16
2.4.2 Norms and Guidelines ................................................. 16
2.4.3 Responsibility of the Operator ..................................... 16
2.5 Interfaces ...................................................................... 18
2.6 Legal Information .......................................................... 19
2.7 Warranty ....................................................................... 20
2.8 Service Address ........................................................... 20
3 SAFETY ........................................................................... 21
3.1 Following the Operating Instructions ............................ 21
3.2 Conventions of the Safety Notes .................................. 22
3.2.1 Structure of the Warning Notes ................................... 22
3.2.2 Danger Levels.............................................................. 23
3.2.3 Safety Symbols / Pictograms ....................................... 24
3.2.4 Mandatory Signs .......................................................... 27
3.3 Intended Use ................................................................ 29
3.4 Foreseeable Misuse ..................................................... 29
3.5 Range of Application .................................................... 30
3.6 Personnel Requirements .............................................. 30
3.7 Residual Risks .............................................................. 32
3.7.1 Electrical system .......................................................... 32
3.7.2 Pressurised Components ............................................ 33
3.7.3 Operating and auxiliary materials ................................ 34
3.7.4 Working areas.............................................................. 35
3.7.5 Temperature ................................................................ 35
Nitrogen Pumping Unit Instructions Manual

Version 01, [12.07.2016] Original translation, English
Page 2 of 182
Table of contents
Scope of delivery
3.7.6 Nitrogen ........................................................................ 36

3.8 Conduct in an Emergency ............................................. 37
3.8.1 First aid ......................................................................... 37
3.8.2 Emergency plan ........................................................... 38
3.8.3 Electrical accidents ....................................................... 38
3.8.4 Fire ............................................................................... 38
3.8.5 Cryogenic burns ........................................................... 39
3.8.6 Environmental hazard .................................................. 39
4 TECHNICAL DATA .......................................................... 41
5 STRUCTURE AND FUNCTION ....................................... 43
5.1 Side Definition ............................................................... 43
5.2 Functional description ................................................... 44
5.3 Off-road-truck ................................................................ 45
5.4 Nitrogen tank skid ......................................................... 47
5.5 N2 pump skid ................................................................ 49
5.6 N2 pump, drive .............................................................. 51
5.6.1 Drive Motor ................................................................... 52
5.6.2 Pump distributor gearbox ............................................. 53
5.6.3 Pump S90 ..................................................................... 54
5.6.4 Pump S45 ..................................................................... 55
5.7 N2 pump, water circuit .................................................. 56
5.7.1 Heat exchanger charge air cooler ................................ 57
5.7.2 Heat exchanger Lubrication oil ..................................... 58
5.7.3 Heat exchanger Hydraulic return .................................. 59
5.7.4 Heat exchanger Heat load ............................................ 60
5.7.5 Heat exchanger Engine Jacket water ........................... 61
5.7.6 Heat exchanger Exhaust gas ....................................... 62
5.8 N2 pump, nitrogen circuit .............................................. 64
5.8.1 Booster pump ............................................................... 65
5.8.2 Triplex pump ................................................................. 66
5.8.3 Vaporizer ...................................................................... 68
5.8.4 Transfer interface ......................................................... 69
5.9 N2 pump, preheater ...................................................... 70
5.10 N2 pump, connections .................................................. 74
5.11 EMERGENCY STOP Devices ...................................... 75
5.11.1 Right EMERGENCY STOP button ............................... 77
5.11.2 Left EMERGENCY STOP button ................................. 78
5.11.3 EMERGENCY STOP panel .......................................... 78
Instructions Manual Nitrogen Pumping Unit

Original translation, English Version 01, [12.07.2016]
Page 3 of 182
Table of contents
Scope of delivery
5.12 Operator Workstation ................................................... 79

5.13 Cabin heating ............................................................... 80
5.14 Operating panel ............................................................ 82
5.14.1 Overview ...................................................................... 82
5.14.2 Triplex pump controls .................................................. 83
5.14.3 Heat load controls ........................................................ 87
5.14.4 Boost pump controls .................................................... 89
5.14.5 Motor and system controls ........................................... 90
5.14.6 Readjustments and cool down..................................... 92
5.14.7 Exhaust gas control ..................................................... 95
6 ASSEMBLY / COMMISSIONING .................................... 97
7 DELIVERY AND TRANSPORT ....................................... 99
7.1 Safety ........................................................................... 99
7.2 Delivery....................................................................... 100
7.3 Transport .................................................................... 100
7.3.1 Personnel................................................................... 100
7.3.2 Preparation ................................................................ 100
7.3.3 Nitrogen skid .............................................................. 101
7.3.4 Departure check ........................................................ 102
8 STORAGE ..................................................................... 103
9 INSTALLATION CONDITIONS ..................................... 105
9.1 Safety ......................................................................... 105
9.2 Installation site ............................................................ 105
9.3 Substrate .................................................................... 106
9.4 Attachment ................................................................. 106
9.5 Connections................................................................ 106
10 OPERATION .................................................................. 107
10.1 Safety ......................................................................... 107
10.2 Filling the nitrogen tank .............................................. 107
10.2.1 Valve overview........................................................... 108
10.2.2 Preparation ................................................................ 110
10.2.3 Initial filling ................................................................. 110
10.2.4 Filling ......................................................................... 111
10.3 Cool down................................................................... 112
10.3.1 General inspections ................................................... 112
10.3.2 Reducing the overpressure ........................................ 113

Page 4 of 182
Table of contents
Scope of delivery
10.3.3 Starting the drive motor .............................................. 114

10.3.4 Building up admission pressure ................................. 116
10.3.5 Boost pump ................................................................ 117
10.3.6 High-pressure pump ................................................... 122
10.3.7 Return flow ................................................................. 124
10.4 Pumping nitrogen ........................................................ 124
10.5 Take out of operation .................................................. 128
10.6 Operation after Emergency Stop ................................. 131
10.7 Operation after a Prolonged Downtime ....................... 132
10.8 Miscellaneous. ............................................................ 133
10.8.1 Operation with cabin heating ...................................... 133
10.8.2 Operation with preheating .......................................... 135
11 FAULTS AND TROUBLESHOOTING ........................... 137
11.1 Drive motor .................................................................. 137
11.2 Filters .......................................................................... 138
11.3 Battery ......................................................................... 139
11.4 Exhaust gas heat exchanger ....................................... 140
11.5 Plate heat exchanger .................................................. 143
12 INSPECTION AND MAINTENANCE.............................. 145
12.1 Safety .......................................................................... 147
12.2 Truck ........................................................................... 149
12.3 Nitrogen skid ............................................................... 149
12.3.1 Before each operation ................................................ 150
12.3.2 Inspection after 2.5 years ........................................... 152
12.3.3 Inspection after 5 years .............................................. 152
12.4 Pump unit .................................................................... 152
12.4.1 Drive motor ................................................................. 152
12.5 Heating circuit ............................................................. 156
12.5.1 Exhaust gas heat exchanger ...................................... 156
12.5.2 Plate heat exchanger ................................................. 158
13 DECOMMISSIONING ..................................................... 161
13.1 Safety .......................................................................... 161
13.2 Disassembly ................................................................ 163
13.3 Disposal ...................................................................... 164
14 ADDITIONAL DOCUMENTS ......................................... 165

Page 5 of 182
Table of contents
Scope of delivery
14.1 Manufacturer’s Certificate ........................................... 165

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

Page 6 of 182
Table of contents
Scope of delivery
15.5.4 Hydraulic motor .......................................................... 176

15.5.5 Vaporizer .................................................................... 176
15.5.6 Plug valve ................................................................... 176
15.6 Cabin heating .............................................................. 177
15.7 Electric components .................................................... 177
15.8 Control system components ........................................ 177
16 ANNEX ........................................................................... 179
16.1 List of Figures .............................................................. 179
16.2 Table Headings ........................................................... 181

Page 7 of 182
Fundamental Information
Scope of delivery
2 Fundamental Information
2.1 Scope of delivery
The delivered product consists of the following functional main
components:
1. Off-road-Truck
2. Nitrogen tank in skid construction
3. Nitrogen pump in skid construction
4. Operator cabin
Through the interaction of the components results in a complex
function unit. The N2-Skid is referred in accordance with
technical, normative and legal standards as machine
The Nitrogen Pumping Unit machine is completely assembled,
set-up, calibrated and tested as it is transferred to the customer.
All main components are placed on the off-road-truck.
The customer therefore receives a complete product that is
ready to be used upon delivery.
Table 1: Scope of delivery
The delivery scope includes:
Truck
Manufacturer MERCEDES BENZ

Type ACTROS 4141 8x8/4
Series number See Passport
Nitrogen tank
Manufacturer GAZGIR TOC

Type CZN-H/S-8.2K
Nitrogen pump
Manufacturer GOES GmbH

Page 9 of 182
Scope of delivery
Type NU500
Operator cabin
Type
 Pullout Ladders, 2 pcs. (front and
cabin access)
 Handrails Assembly for Cabin
Ladder
Accessories
 Stainless steel hoses DN40, 2 x
L=3,05 m and 1 x L= 4,57 m
 45deg elbow, 2 pcs.
 Fire extinguisher
The main documentation for the
machine Nitrogen Pumping Unit,
version 01, in original translation in
English and Russian.
Documentation
This instruction manual for the
machine N2 Skid, version 01, in
original translation in English and
Russian.
Existing supplier documentation is
Supplier
listed in Chapter 15 and is supplied
documentation
as accompanying documents.

Page 10 of 182
Documentation
2.2 Documentation
The operating instructions are designed as a print version and
shall be transferred to the customer as such.
These operating instructions help you,
 Familiarize yourself with the machine Nitrogen Pumping

Unit
 Operate the machine safely and properly
 And avoid unintended usage.
You are in a position to operate the machine safely if you use
these operating instructions as a quick reference, a source of
information and a guidance for actions.
You must have understood the safety and warning notes
contained here in context and observe them at all times. These
operating instructions must always be kept in the vicinity of the
machine as they are a key component of the product.
2.2.1 Content and Set-up

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

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

Page 11 of 182
Documentation
The tables are numbered consecutively and are marked with a

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

Instructions and technical documents of the components
supplied can be found in Chapter 15 and in the annex.

Page 12 of 182
Documentation
The conventions and language versions of documents

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

These Instructions Manual uses inspection and maintenance
intervals.
Table 2: Inspection and Maintenance Intervals
Time interval Operating hour interval

W00 As required B10 After 10 OprHrs
W10 Before each run B20 After 25 OprHrs
W20 Daily B30 After 50 OprHrs
W30 Weekly B40 After 100 OprHrs
W40 Every 2 weeks B50 After 250 OprHrs
W50 Monthly B60 After 500 OprHrs
W60 Quarterly B70 After 750 OprHrs
W70 Every 6 months B80 After 1000 prHrs
W80 Annually B90 After 1500 OprHrs
W90 Every 2 years B100 After 2000 OprHrs
W100 every 3 years B110 After 2500 OprHrs
B190 After 7500 OprHrs

Page 13 of 182
Documentation
Time interval Operating hour interval


Page 14 of 182
User Groups
2.3 User Groups

The Instructions Manual are intended for those who
 assemble the machine or parts of the machine

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

Page 15 of 182
Responsibilities
2.4 Responsibilities
2.4.1 Responsibility of the Manufacturer

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

 the quality control, testing and inspection of components
and the product as a whole
 the documentation and the required certification of the
product.
2.4.2 Norms and Guidelines

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

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

Page 16 of 182
Responsibilities
The operator must also ensure, that
 the individuals authorized by them, that are tasked with

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

Page 17 of 182
Interfaces
2.5 Interfaces
The Nitrogen Pumping Unit machine has the following
interfaces:
Table 3: Interfaces
Input  Interface for filling the nitrogen tank

 Interface between nitrogen tank and
nitrogen pump
Output  Interface for dispensing the temperate
nitrogen with an increase in pressure
Internal  Data link / diagnostics
 Operating panel cable connection /
cabin for lighting and heating
The machine is otherwise autonomous.

Page 18 of 182
Legal Information
2.6 Legal Information

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

layout
 errors and omissions in the documents
 content and accuracy
 information on compatibility, performance, reliability
 compliance with the copyright laws, legality, decency, or
any other aspect
 references to third party products and services in this
documentation. These in no way imply a specific
recommendation to the third party products and services
by the manufacturer.
In so far as the use of brand names, trademarks, trade names

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

Page 19 of 182
Warranty
2.7 Warranty
The manufacturer assumes warranty within the scope of the
statutory provisions for the machine and its equipment.
Deviations or additions optionally form an integral part of the
contract.
Any liability and all warranty claims are voided when external
parts are installed and used (accessories or replacement parts
that have not been approved by the manufacturer)
The manufacturer is not liable for incorrect operation, non-
observance of the operating instructions, improper use, misuse
and the resulting damage and any violation of the
responsibilities of the operator (see Chapter 2.4.3).
The user/operator alone bears the risk in this case.
2.8 Service Address

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

Page 20 of 182
Safety
Following the Operating Instructions
3 Safety
The following safety notes are of fundamental significance for
the handling of the machine.
In order to avoid irregularities, malfunctions or accidents, all
individuals working directly on the machine must demonstrate a
solid understanding of the employment protection provisions
and develop a high and committed safety awareness.
This presupposes in-depth knowledge of the complex
influences on the machine. All employees concerned must
therefore be specifically instructed on safety issues at regular
intervals. The specialist personnel must be authorized and
appointed by the operator or superior for these tasks.
The warning notices attached to the machine must be observed
and followed.
Make sure that all employees have a thorough knowledge of
first aid, fire detection and fire-fighting procedures.
Observe the permissible operating limits during operation.
3.1 Following the Operating Instructions

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

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

Page 21 of 182
Safety
Conventions of the Safety Notes
The operating instructions, safety and warning information in

the manuals of the manufacturer, whose products are installed
in the machine, are likewise valid.
Operating and maintenance instructions of the installed

components can be found in the Annex and in the Supplier
Documentation chapter.
3.2 Conventions of the Safety Notes
3.2.1 Structure of the Warning Notes

The warning notes denote safety-relevant information and
indicate hazards that may occur during the individual
procedures or with the machine itself. They are in line with the
ANSI 535.6 and the SAFE method:
 Preceding warning symbol (pictogram)

 Severity of the hazard (signal word)
 Type and source of the hazard
 Consequence if the hazard is disregarded
 Escape (measures to avert the hazard)

Page 22 of 182
Safety
3.2.2 Danger Levels

The warning notes are classified in the following danger levels
in line with the ANSI 535.6:
DANGER
Indicates an extraordinarily hazard / dangerous situation
If this note is ignored, then fatal or serious permanent injuries
will result.
WARNING
Indicates a particularly hazard / dangerous situation
If this note is ignored, serious, permanent or fatal injuries could
result.
CAUTION
Indicates a hazard or dangerous situation
If this note is ignored, minor or moderate injuries may occur.
ATTENTION
Indicates a non-personal hazard
If this note is ignored, material damages or environmental
damages may occur.

Page 23 of 182
Safety
3.2.3 Safety Symbols / Pictograms

The safety notes in these operating instructions correspond to
the norm DIN EN ISO 7010 and are integrated into the warning
notes in accordance with DIN ISO 3864 in order for the hazard
to be visualized. The following symbols are used within the
warning notes of these operating instructions:
General warning of a danger, a danger point or a dangerous

situation
Warning of a danger, a danger point or a dangerous situation

due to explosive substances or media.

due to non-ionizing radiation.

due to a magnetic field.

due to obstacles in the path. (Tripping and/or falling).

due to slipping or falling (fall).

due to low temperature and cold.

with smooth or slippery ground (risk of slipping).

due to electrical voltage (electrical shock / short circuiting /
electrical current through the body).

Page 24 of 182
Safety

due to industrial trucks.

due to suspended loads.

due to poisonous substances.

due to hot surfaces (burning / reflex reaction).

due to automatic start-up / restart.

due to wedging / crushing of the body.

due to obstacles in the head area.

due to flammable substances.

due to pointed or sharp objects.

due to corrosive substances.

due to crushing (hands).

due to offsetting and co-rotating shafts, rollers or wheels
(danger of infeed).

Page 25 of 182
Safety

due to batteries.

due to oxidizing substances.

through which environmental damage may occur.

due to pressurized or bursting components.

due to pressurized or bursting pipes.

due to leaks from pipes.

due to contact with sensitizing substances.

that leads to crushing of the feet.

that leads to loss of consciousness.

Page 26 of 182
Safety
3.2.4 Mandatory Signs
Notice
Additional documents or documents from other manufacturers
are referred to here.
Notice
Wear reflective clothing or high visibility vest.
Notice
Wear safety helmet / hard hat.
Notice
Wear safety shoes.
Notice
Wear safety gloves.
Notice
Wear protective clothing.
Notice
Wear ear protection.
Notice
Wear protective goggles.
Notice
Wear dust mask.
Notice
Wear breathing mask.
Notice
Wear welding mask, goggles, protection.

Page 27 of 182
Safety
Notice
Perform grounding.
Notice
Use this/these attachment point(s)
Notice
Observe this note

Page 28 of 182
Safety
Foreseeable Misuse
3.3 Intended Use

The Nitrogen Pumping Unit is a low temperature unit.
The intended use includes
 pumping of extremely cold and liquid nitrogen

 Increasing the nitrogen pressure
 Converting physical form into a gas
 Increasing the temperature of the gas
 Facilitating the onward processing procedure
All other usages are not classed as “proper intended usage”.
3.4 Foreseeable Misuse

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

Page 29 of 182
Safety
Range of Application
It is prohibited to use the Nitrogen Pumping Unit as a

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

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

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

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

Page 30 of 182
Safety
Personnel Requirements
Activity Training / Instruction

Assembly work  Training as an industrial mechanic
or comparable position
 Instruction in the hazards posed
during assembly
Electrical work  Training in an electrotechnical
profession
 Instruction in the electrical system
of the machine as a whole and the
hazards posed
Operation  Professional qualification with
machine operation (operating
parameters, processing steps,
identifying malfunctions)
during operation of the machine
Cleaning  Instruction in the hazards posed
during cleaning work
Maintenance Work  Training as an industrial
mechatronics engineer or
electrotechnical profession
during maintenance work
Fault removal  Training as an industrial
during work on fault removal
Disassembly  Training as an industrial
during disassembly of the system

Page 31 of 182
Safety
Residual Risks
3.7 Residual Risks
3.7.1 Electrical system

There is a residual risk with the hazard:
 Short circuiting with electrical current through the body

 Arcing
Work on the electrical system may only be carried out by

authorized and sufficiently qualified personnel (see chapter
3.6).
Before you begin work
1. Switch off the system and components.

2. Perform the steps prescribed in VDE 0105:
3. Isolate
4. Secure against re-start
5. Ensure that there is no voltage
6. Ground and short circuit
7. Wear personal protective equipment (PPE) in
accordance with DIN EN 340.
Work when the system is live or when the components are

under voltage may only be carried out in exceptional cases.
The following must also be observed if necessary:
8. Secure the system against unintentional or automatic

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

Page 32 of 182
Safety
Residual Risks
The work must not lead to any safety restrictions or

reduced intervals
3.7.2 Pressurised Components

There is a residual risk due to pressurized components
(hydraulic / pneumatic / liquid) and their active media with the
hazard:
Sensitization
 due to skin contact or inhalation of aerosol.
Poisoning
 due to swallowing or intake of aerosol
Injury
 due to penetration of the pressurized media
Injury
 due to foreign bodies (bursting pipe)
Injury
 due to lashing pipes and hoses
Work may only be carried out by authorized and sufficiently

qualified personnel (see Chapter 3.6).
1. Decommission the system

2. Secure the system against unintentional commissioning
3. Lock manual valves against unintentional control
4. Depressurize hydraulic and/or pneumatic system
5. Release accumulator

Page 33 of 182
Safety
Residual Risks
Work when the system is pressurized may only be

performed in exceptional cases. The following must be
observed if necessary:
1. Secure the system against unintentional or automatic

restart.
2. Lock valves against unintentional control.
3.7.3 Operating and auxiliary materials

There is a residual risk due to fuels, lubricants, hydraulic oils
and chemical auxiliary materials with the hazard:
Sensitization
 due to skin contact or inhalation of aerosol.
Poisoning
 due to swallowing or intake of aerosol
Corrosion
 due to contact with alkaline or acidic substances.
Environmental Hazard
 due to careless handling with the substances mentioned
Work may only be carried out by authorized and sufficiently

qualified personnel (see chapter 3.6).
1. Decommission the system.

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

Page 34 of 182
Safety
Residual Risks
3.7.4 Working areas

There is a residual risk due to components and assemblies
which protrude into working areas with the hazard:
Injuries due to
 Bruising and limb injuries
 Bruising and head injuries
Injuries due to
 Tripping
Injuries due to
 Falling
Work areas may only be accessed by authorized personnel

(see Chapter 3.6).

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

Page 35 of 182
Safety
Residual Risks

4. Let the machine cool down.
3.7.6 Nitrogen
There is a residual risk from liquid nitrogen (LIN).
Loss of consciousness / suffocation

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

Page 36 of 182
Safety
Conduct in an Emergency
Increased risk of fire

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

3. Wear special personal protective equipment.
4. Only work on the system outdoors or in areas with good
ventilation and extraction in terms of a specialized
suction device.
5. Always work on the side exposed to the wind.
6. Carry portable oxygen-deficiency warning equipment.
3.8 Conduct in an Emergency
3.8.1 First aid

At least two persons must be trained first aiders in each
industrial premises / production facility.
Carry out the following steps if an accident occurs:
1. Switch off the machine (EMERGENCY STOP) and

secure against restart / reconnection.
2. Rescue the injured from the danger zone and provide
first aid.
3. Inform the emergency services.
4. Make sure that any other individuals are prevented from
entering the danger area.
Inform the superiors or the management, who will in turn
undertake further measures on their part.

Page 37 of 182
Safety
3.8.2 Emergency plan

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

The machine must be immediately switched off using the
EMERGENCY STOP button in the event of an electrical
accident.
 You must always initially exclude other people being

affected by the hazard when rescuing those affected.
 Auxiliaries and safety devices, which are used for
rescue purposes, must always consist of nonconductive
material.
 Always consult a doctor even if there is only a slight
electrical shock.
3.8.4 Fire
Before any work takes place, a plan must be drawn up, which
governs personnel behaviour in the event of a fire. All
individuals must be briefed on the location and operation of fire
extinguishers.
There may be considerable risks in part, when attempts are
made at extinguishing fires, if the prescribed minimum distance
from the source of the fire is not respected or unsuitable
extinguishing agents used.
Carry out the following actions in the event of a fire:
 Remove any individuals from the danger zone.

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

Page 38 of 182
Safety
3.8.5 Cryogenic burns

Cryogenic burns can also occur even with brief contact with
extremely cold substances such as cryogenic liquid nitrogen.
The resulting injuries are comparable with severe burning.
Carry out the following actions in the event of cryogenic burns:
 Remove any individuals from the danger zone. Do not

endanger anybody else and observe your own safety.
 Immediately seek medical help.
 Bring those concerned to a warm area (> 22 °C).
 Carefully remove clothing from the affected area.
 Rinse affected skin area with plenty of lukewarm water.
Avoid direct heat through hot water or using heating
equipment.
 Protect frozen areas using dry, sterile compresses.
Smoking and alcoholic drinks reduce the blood supply and
should therefore be avoided
3.8.6 Environmental hazard

The improper use of the machine or insufficient or improper
maintenance can lead to environmental hazards.
Carry out the following actions in the event of an environmental
hazard:
 Notify the fire department and competent authorities.

 Specify information on the hazardous substances in
question.
Inform the executive management or the project management,
who in turn will continue to take measures on their part.

Page 39 of 182
Technical Data
4 Technical Data
Nitrogen Pumping Unit Truck mounted
Table 5: Technical data of the product
Product Nitrogen Pumping Unit

Type NU500
Series number Please see Passport
Length 12 000 mm
Width 2 550 mm
Height 4 000 mm
Weight (dry) 31 600 kg
Total weight 39 000 kg
Truck
Type 4141 AK 8x8/4
Chassis number Please see Passport
Number of axes 4
Permissible total weight 44 000 kg

Cryotank
Manufacturer GAZGIR
Type CZN-H/S-8.4K
N2 pump:
Type NU500

Page 41 of 182
Structure and Function
Side Definition
5 Structure and Function

5.1 Side Definition
Front
Right side
Left side
Cabin
Figure 1: Side Definition Rear

Page 43 of 182
Functional description
5.2 Functional description

All components of the product are placed on an off-road-truck. Off-road-truck
Thus, the machine is deployed for mobile applications and the
work-location can be changed. The truck has been approved for
use on public roads.
A double-walled cryotank can be found to the rear of the truck Nitrogen tank
load area. The cryotank is filled with liquid nitrogen and
provides the nitrogen to the pumping unit. The cryotank is
installed to a skid, certified in accordance with ADR and may be
transported using public roads with the appropriate labelling
and qualification of the driver.
A pump unit can be found to the front of the truck. A diesel Pump unit
aggregate is used to power the hydraulic motors and pump
flow. The heat generated by the motor and hydraulic
components is used for the nitrogen evaporation process.
The liquid nitrogen is supplied to a triplex pump and brought to
the desired discharge pressure by the lifting piston. The liquid
nitrogen that is now under high pressure then flows through the
nitrogen / water heat exchanger, is vaporized, heated to a
temperature of 20 °C and made available for further processing
procedures – e.g. to the coiled tubing unit – via a transfer
interface.
The transfer of heat energy between the water circuit / nitrogen
circuit is undertaken via a vaporizer.
An operator cabin can be found between the nitrogen tank and Operator cabin
the pump unit. The machine can be controlled and monitored
using the control platform.

Page 44 of 182
Off-road-truck
5.3 Off-road-truck
Figure 2: Off-road-truck
Table 6: Technical data Off-road-truck

Type ACTROS 4141 8x8/4
Chassis No. Please refer passport
Dimensions:
Length 11 950 mm
Width 2 450 mm
Height 3 400 mm
Empty weight 13 850 kg

Permissible total weight 44 000 kg
Number of driven axes 4
Engine
Displacement 12 l
Number of cylinders 6
Engine power 300 kW

Page 45 of 182
Off-road-truck
The off-road-truck forms the basis for the containment of the Functional description
machine components.
The locking on the load area is undertaken using Twistlocks.
Figure 3: Twistlock

Page 46 of 182
Nitrogen tank skid
5.4 Nitrogen tank skid
Figure 4: Nitrogen skid
Table 7: Technological data of the nitrogen skid
Manufacturer GAZGIR TOC

Type CZN-H/S-8.2K
Series number Please refer passport
Dimensions:
Length 3 645 mm
Width 2 438 mm
Height 2 591 mm
Weight
Unladen weight 4 963 kg
Permissible 11 620 kg
total weight
Payload 6 657 kg
Tank
Holding capacity 8 400 l

Page 47 of 182
Nitrogen tank skid
Medium Cryogenic liquid nitrogen (LIN)

Operational pressure max. 3.1 bar
Temperature range -196 °C to +50 °C
Approval  DNV 2.7.1
 ADR / RID / IMDG
 EN 12079
The nitrogen tank stockpiles cryogenic liquid nitrogen (LIN) and Functional description
provides this for the processing procedure.
The nitrogen tank is installed in a skid for safe transport and
operation. The skid is placed on the truck and secured with
container locks.
Figure 5: Container corner with twistlock

Page 48 of 182
N2 pump skid
5.5 N2 pump skid
Figure 6: N2 pump, frame
Table 8: Technical data of the N2 pump, frame

Dimensions:
Length 4 572 mm
Width 2 438 mm
Height 2 350 mm
Weight inclusive
10 000 kg
Components
Temperature range -40 °C to +50 °C
Functional The N2 pump machine is installed in a skid for safe transport

description and operation. The skid is placed on the truck and secured with
container locks.

Page 49 of 182
N2 pump skid
Figure 7: Container corner with N2 skid twistlock

Page 50 of 182
N2 pump, drive
5.6 N2 pump, drive

Functional description The driving energy for the N2 pump is generated by a diesel
aggregate. Mechanical energy is transferred to three hydraulic
pumps via a pump distributor gear. The hydraulic drive energy
for the individual components of the machine is provided via the
hydraulic pumps.
Figure 8: N2 pump, drive
1 Engine radiator
1 Drive engine
2 Pump drives gearbox
3 Pump S45
4 Pump S90

Page 51 of 182
N2 pump, drive
5.6.1 Drive Motor
Figure 9: Drive motor
Table 9: Technical data of the drive motor
Manufacturer VOLVO PENTA

Type TAD 1650VE-B
Serial number Please refer passport
Fuel Diesel
Performance 405 kW
Cylinder number 6
Cubic capacity 16 l.
Weight (wet) 1 395 kg
Motor oil quantity motor
53 l
side, initial filling
Motor coolant motor side 100 l

Page 52 of 182
N2 pump, drive
5.6.2 Pump distributor gearbox
Figure 10: Pump distributor gearbox
Table 10: Technical data of the pump distributor gearbox
GOES item No,
Manufacturer STIEBEL
Type 4396
Performance 700 kW
Rotational speed 2000 rev/min
Ratio 0.9184
Weight (dry) 283 kg
Gear unit oil quantity 9.5 l.

Page 53 of 182
N2 pump, drive
5.6.3 Pump S90
Figure 11: Hydraulic pump S90
Table 11: Technical data of the hydraulic pump S90
GOES item No, 108156
Manufacturer DANFOSS
Type Series 90 Size 250 cm3
Operating conditions
min. 500 rev/min

Rotational speed
max. 2 500 rev/min
System pressure max. 480 bar
Volumetric flow 575 l/min
Media temperature -40 °C to 104 °C
This pump is installed twice. The first pump ensures the

hydraulic volume flow rate for driving the triplex pump. The
second pump ensures the hydraulic volume flow rate for driving
the heat load unit.

Page 54 of 182
N2 pump, drive
5.6.4 Pump S45
Figure 12: Hydraulic pump S45
Table 12: Technical data of the hydraulic pump S45
Manufacturer DANFOSS
Type Series 45 Size 100 cm3
min. 500 rev/min

Rotational speed max. 2 880 rev/min
rated 2 450 rev/min
rated 310 bar
This regulated pump ensures the volume flow rate and drives
the circulation water pump, the booster pump, the lubricant
pump of the triplex pump and the cylinder discharge device.

Page 55 of 182
N2 pump, water circuit
5.7 N2 pump, water circuit

The nitrogen pump unit functions based on a passive principle, Functional description
this means that the liquid nitrogen is not vaporized by the
supply of external heat energy (fired principle), but by heat
energy which is generated by the pump unit itself (non-fired
principle). The media of all heat-emitting components are
administered by heat exchangers in this instance and circulated
in a water circuit.
The circulation is brought about using a hydraulically driven
pump.
Figure 13: Water circuit circulation pump
1 Circulation pump
2 Hydraulic drive motor
3 Adapter and coupling
Table 13: Technical data of the circulation pump
Manufacturer EDUR
Type NU604 D160L

Page 56 of 182
Environmental -20 °C to 40 °C
temperature:
Media temperature max. 90 °C
Permissible operating 25 bar

pressure
Flow 18 to 42 m3/h
Rotational speed 2 900 rev/min
5.7.1 Heat exchanger charge air cooler
Figure 14: Heat exchanger charge air cooler
Table 14: Technical data of the heat exchanger charge air cooler
GOES item No 108290

Manufacturer BOWMAN
Type PK190
Performance
Charge Air Flow 40,3 kg/min
Water Flow 200 l/min
Heat rejection 100 kW

Page 57 of 182
The drive motor has a charge air cooler. The heat energy that is Functional description
generated here is administered via a heat exchanger. The heat
energy accumulated is supplied for the nitrogen vaporization
process.
5.7.2 Heat exchanger Lubrication oil
Figure 15: Lubrication oil heat exchanger
Table 15: Technical data of the lubrication oil heat exchanger

Manufacturer FUNKE
Type TPL 02 K 24 11
Heat duty 3 kW
temperature:
pressure

Page 58 of 182
Functional description A variety of mechanical components are lubricated during

operation. The lubrication oil stores heat energy in this instance,
a portion of the heat energy is released to the water circuit with
this heat exchanger.
5.7.3 Heat exchanger Hydraulic return
Figure 16: Hydraulic oil heat exchanger
Table 16: Technical data of the hydraulic oil heat exchanger

Manufacturer FUNKE
Type TPL 02 K 16 11
Heat duty 40 kW
temperature:
pressure

Page 59 of 182
A number of the mechanical components are driven Functional description

hydraulically. The hydraulic oil stores heat energy in this
instance, a portion of the heat energy is released to the water
circuit with this heat exchanger.
5.7.4 Heat exchanger Heat load
Figure 17: Heat load heat exchanger
Table 17: Technical data, heat load heat exchanger

Manufacturer FUNKE
Type TPL 02 K 80 22
Heat duty 300 kW
temperature:
pressure

Page 60 of 182
Functional description Heat energy is generated here by means of a closed hydraulic

circuit. The hydraulic oil stores heat energy in this instance, a
portion of the heat energy is released to the water circuit with
this heat exchanger.
5.7.5 Heat exchanger Engine Jacket water
Figure 18: Cooling water heat exchanger

Manufacturer FUNKE
Type TPL 02 K 30 11
Heat duty 211 kW
temperature:
pressure
Functional The drive motor is kept at the optimum operating temperature

description during operation using a coolant. The coolant stores heat

Page 61 of 182
energy in this instance, a portion of the heat energy is released

to the water circuit with this heat exchanger.
5.7.6 Heat exchanger Exhaust gas
Figure 19: Exhaust gas heat exchanger
Table 18: Technical data of the exhaust gas heat exchanger
Series number
Manufacturer ENKOTHERM
Type ASN-15-3-EG251
Performance 200 kW
Surface heat transfer 9.7 m2
Through the piping
Medium Flue gas

Mass flow 2460 kg/h
Inlet temperature 480 °C
Outlet temperature 200 °C
Maximum operating
550 °C
temperature

Page 62 of 182
Maximum operating
0.1 bar
overpressure
Around the piping

Medium Water / glycol (50% / 50%)
Quantity 36300 kg/h
34.2 Bm3/h at Tmean
Volumetric flow
25 Bm3/h minimum
Inlet temperature 54.8 °C
Outlet temperature 60 °C
Max. operating
110 °C
temperature
Max. operating
6 bar
overpressure
Functional description The drive motor is a combustion motor according to the self-
ignition principle (diesel) which produces very hot exhaust
gases during operation. In the exhaust gas heat exchanger, a
portion of the heat energy is detracted from the exhaust air of
the combustion motor and supplied to the water circuit. The
exhaust gas flows through the piping here, the coolant
circulates around the piping and is heated by the exhaust gas.

Page 63 of 182
N2 pump, nitrogen circuit
5.8 N2 pump, nitrogen circuit
Figure 20: Nitrogen circuit
1 Liquid nitrogen primary inflow connection

2 Liquid nitrogen return feed connection
3 Booster pump
4 Triplex pump
5 Vaporizer
6 Gaseous nitrogen transfer interface
Liquid nitrogen secondary inflow connection to work
7
without boost pump
The nitrogen circuit is divided into the low pressure section Functional
(shown in gray) and high pressure (shown in red). description
Low pressure
Liquid nitrogen is fed from the nitrogen tank via the inflow
(20/1). The booster pump (20/3) pushes the liquid nitrogen to
the triplex pump with approx. 7.5 bar (20/4). Excess liquid

Page 64 of 182
nitrogen is returned to the nitrogen tank via the return flow

(20/2).
High pressure
The liquid nitrogen is applied with intense pressure in the
pressure cylinders of the triplex pump (20/4) and pushed to the
vaporizer (20/5) via the high pressure line. The liquid nitrogen is
vaporized in the vaporizer by means of heat energy from the
water circuit and heated to a temperature of 20°C. This results
in a strong volume intensification (1 litre LIN = 697 litres
gaseous N2) and pressure increase. The pressure by the triplex
pump must be kept as high as such, that more and more liquid
nitrogen is passed into the vaporizer. The now gaseous and
tempered nitrogen is released via the transfer interface (20/6).
5.8.1 Booster pump
Figure 21: Booster pump
Table 19: Technical data of the booster pump
Manufacturer ACD
Type AC18HD, 1.5 x 2.5 x 6
Serial number Please refer passport

Page 65 of 182
Rotational speed max. 4 366 rev/min

5.8.2 Triplex pump
Figure 22: Triplex assembly
1 Triplex pump
2 Gear unit
3 Hydraulic drive motor for triplex pump
4 Triplex pump lubrication tank
5 Hydraulic drive motor for lubrication
6 Triplex pump lubrication pump
7 Coupling
The components two to six are omitted from the description at

this point. The technical documents for these components can
be found Chapter 15.5.

Page 66 of 182
Figure 23: Triplex pump
Table 20: Technical data of the triplex pump
GOES item No 108617

Manufacturer ACD
Type 3-GUPD
Rotational speed max. 940 rev/min
Volumetric efficiency 85 %
Functional The triplex pump receives a continuous volumetric flow of LIN

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

Page 67 of 182
5.8.3 Vaporizer
Figure 24: Vaporizer
1 Liquid nitrogen inlet of the triplex pump

2 Gaseous nitrogen outlet for the transfer
3 Water circuit inlet
4 Water circuit outlet
Table 21: Technical data of the vaporizer
Manufacturer CRYOQUIP
Type VWP 145-10

Series number Please refer Passport
Water side 10 bar at 20 - 90 °C
Nitrogen side 689 bar at -196 °C

Page 68 of 182
5.8.4 Transfer interface
Figure 25: Transfer interface
Table 22: Technical data of the plug valve

Manufacturer SPM
Type 1A14443
Temperature -30 °C to 110 °C
System pressure max. 1 034 bar

Page 69 of 182
N2 pump, preheater
5.9 N2 pump, preheater

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

auxiliary heater here
Figure 26: Position of the auxiliary heater
The auxiliary heater is installed in a storage box (Figure 27/2).
2 | Fuel tank for preheater
1 | Housing with build preheater
Figure 27: Webasto storage box
The fuel tank (Figure 27/1) is situated directly above it and

holds 55 litres of special “Arctic” diesel fuel.

Page 70 of 182
N2 pump, preheater
Figure 28: Auxiliary heater
1 Fluid heater
2 Circulation pump auxiliary heating system
Table 23: Technical data of Spheros

Manufacturer SPEHROS
Type 350
Table 24: Technical data of the AH circulation pump

Manufacturer SPEHROS
Type U 4814
The fuel display is found on the front of the storage box

together with the switch to switch on the auxiliary heater.

Page 71 of 182
N2 pump, preheater
Figure 29: Auxiliary heater switch
1 Tank display
2 Switch ON/OFF
3 Control light
Auxiliary heater
Two manifolds for the circuits of the auxiliary heater are likewise manifold
located on the left side of the machine. These can be activated
or pushed via the ball valves.
Figure 30: Auxiliary heater manifold

Page 72 of 182
N2 pump, preheater
Figure 31: Auxiliary heater distributor supply
1 Hydraulic tank pre-heater circuit

2 Diesel tank pre-heater circuit
3 Lubrication oil tank pre-heater circuit
4 Motor cooling pre-heater circuit

Page 73 of 182
N2 pump, connections
5.10 N2 pump, connections
1
2
Figure 32: Connections
1 Liquid nitrogen inflow

2 Liquid nitrogen return flow
3 Liquid nitrogen external inflow
4 Gaseous nitrogen outlet
The connections 1, 2 and 4 must be connected by default.

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

Page 74 of 182
EMERGENCY STOP Devices
Figure 32/3 illustrates a special connection.

The inflow for feeding in the liquid nitrogen can be established
here without having to use the machines very own booster
pump. This might be necessary if the booster pump breaks
down or if a second N2 system is connected upstream.
5.11 EMERGENCY STOP Devices

The safety equipment must always be fully functional and in
good working order.
Trained personnel are responsible and are obliged to regularly
check the equipment for functionality and reliable operation.
The machine must not be operated if

 Part of the safety equipment is defective
 Part of the safety equipment has been modified
If a safety device is not in operation or is defective, then the

personnel are obliged to stop the machine.
Machines may only be put back into operation if all the safety
equipment is fully functional again.
Work on the safety equipment is only permitted when the
machine is switched off, thus avoiding any hazards.
Never bridge any safety equipment or make changes to the

components that could lead to bridging.
The safety equipment on the machine conforms to the

requirements of the EC Machinery Directive.

Page 75 of 182
The EMERGENCY STOP buttons must be triggered at least

once a year for testing purposes by the responsible personnel,
with the following checked for correct functioning:
 Mechanical functionality
 Electrical functionality
 Secure mounting
 Tampering and damages
 Loose cable connections
The machine has three EMERGENCY STOP devices in the

form of buttons. Actuation is always made from RED to
YELLOW.
Figure 33: EMERGENCY STOP button
If the EMERGENCY STOP button is actuated, then the

electrical components / displays are disconnected from their
power source and all moving parts brought to a standstill.

Page 76 of 182
It must be ensured that the reason for such a triggering is

resolved before the system is put back into operation. The
EMERGENCY STOP button is then drawn out.
Table 25: EMERGENCY STOP button

Quantity 3
Contacts N/C 1
Contacts N/O 1
Protection class IP 66
Unlocking device Pull release
Miscellaneous Tamper-proof in accordance with ISO
13850
5.11.1 Right EMERGENCY STOP button
Figure 34: Right EMERGENCY STOP button

Page 77 of 182
5.11.2 Left EMERGENCY STOP button
Figure 35: Left EMERGENCY STOP button
5.11.3 EMERGENCY STOP panel
Figure 36: EMERGENCY STOP panel

Page 78 of 182
Operator Workstation
5.12 Operator Workstation
Figure 37: Operator workstation
The machine has an operator workstation.

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

Page 79 of 182
Cabin heating
5.13 Cabin heating

The operator cabin is equipped with a cabin heating system.
Figure 38: Cabin heating
1 Toolbox with thermostat

2 Webasto air heater
Table 26: Technical data of the cabin heating system

Manufacturer WEBASTO
Type Air Top Evo 3900
Performance 3 900 W
Heating medium Air

Page 80 of 182
Cabin heating
Fuel Diesel
temperature:
Miscellaneous Fuel consumption 0.51 l/h
Functional description The cabin heating system consists of an independent hot-air

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

Page 81 of 182
Operating panel
5.14 Operating panel

The operating panel is found on the rear side of the N2 pump.
The machine can be controlled and monitored using the
operating panel. Access to the operating panel is possible both
with and without an operator cabin attached.
5.14.1 Overview
Figure 39: Panel overview
1 Triplex pump controls

2 Heat load controls
3 Booster pump controls
4 Motor and system controls
Figure 40: Panel down overview
5 Exhaust diverter
6 Cool down and Readjustments

Page 82 of 182
Operating panel
5.14.2 Triplex pump controls

The triplex pump pushes the liquid nitrogen into the vaporizer
with high pressure. The pump is controlled and monitored using
this detailed area of the panel.
Figure 41: Triplex pump panel field left
1 Pressure gauge – Triplex pump lubrication oil pressure

2 Pressure gauge – Triplex pump drive charge pressure
3 Digital display – Gaseous nitrogen discharge pressure
4 Digital display – Triplex pump lube oil temperature
5 Pressure gauge – Triplex pump drive pressure
Digital display – Gaseous nitrogen discharge
6
temperature
Figure 41/1 The gauge for lubrication oil shows the current pressure of the
lubrication oil. The display scale is read in bar and psi. The
pressure in operation should be not less than 5 bar.
Figure 41/2

Page 83 of 182
Operating panel
This gauge shows you the current supply pressure from the
hydraulic pump. The display scale is read in bar and psi. The
pressure in operation should be at 28 bar.
The digital display for the discharge pressure shows the values Figure 41/3
of a measuring sensor. The values are given in bar and
conform to the current discharge pressure of the gaseous,
vaporized nitrogen at the transfer interface. The permissible
overpressure in operation are 700 bar.
The digital display for the lubrication oil temperature of the Figure 41/4
triplex pump shows the values of a measuring sensor. The
values are given in degrees Celsius and conform to the current
lubrication oil temperature in the oil circuit. In operation should
be max. 80 °C.
This gauge shows you the current drive pressure from the Figure 41/5
hydraulic drive circuit. The display scale is read in bar and psi.
The pressure in operation should be max. 320 bar.
The digital display for the discharge temperature (Figure 41/6) Figure 41/6
shows the values of a measuring sensor. The values are given
in degrees Celsius and conform to the current discharge
temperature of the gaseous, vaporized nitrogen at the transfer
interface. The temperature should be between 20 °C and 32 °C.

Page 84 of 182
Operating panel
Figure 42: Triplex pump panel field middle
This gauge (Figure 42/1) shows you the current overpressure

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

Page 85 of 182
Operating panel
Figure 43: Triplex pump panel field right
The pump speed of the triplex pump is controlled via a hydraulic

valve. Using the rotary switch (43/1) for the manual adjustable
valve. The maximum rotation speed is 910 rpm.
This digital display (43/2) for the Triplex pump speed shows the
values of a measuring sensor. The values correspond to the
pump speed in rev/min.
All major production and job data are recorded in a Memograph
(43/3). The display indicates the current values of the pump rate
and discharge pressure.
AMS
Channel Measurement Sensor
Nummer
Discharge Pressure-sensor 0-1034bar
1 100399
pressure 4-20mA, BD1502
2 Pump rate Speed-sensor, EDD 4.303 100472

Page 86 of 182
Operating panel
5.14.3 Heat load controls

The heat load circuit is used to keep the temperatures constant.
The hydraulic circuit is controlled and monitored via this
detailed section of the panel.
Figure 44: Heat load panel field
1 Pressure gauge – coolant pressure

Pressure gauge – hydraulic charge pressure of the
2
hydraulic pump
Pressure gauge – hydraulic pressure in the heat load
3
circuit
Rotary switch – selector switch between automatic and
4
manual control
Rotary switch - Hydraulic load pump control with manual
5
adjustable valve
6 Pressure gauge – aux Pump pressure
7 Digital display – Coolant temperature
The pressure gauge (Figure 44/1) shows the current pressure

of the coolant fluid. The scale can be read in bar and psi.

Page 87 of 182
Operating panel
The pressure gauge (Figure 44/2) shows the current charge

pressure of the hydraulic pump. The scale can be read in bar
and psi.
The pressure gauge (Figure 44/3) shows the current pressure

in the working area of the heat load circuit. The scale can be
read in bar and psi.
You can select the control mode with the rotary switch (Figure
44/4. Select the AUTO control mode, the hydraulic circuit is
automatically controlled so that the temperature within the water
circuit is kept constant. This is set as such, that the discharge
temperature of the gaseous nitrogen at the transfer interface is
20°C.
Select the MANUAL control mode, the temperature can then be
controlled independently of the Automatic mode. This is carried
out using the rotary switches: Load pump (Figure 44/5).
The pump speed of the heat load pump is controlled in the

manual adjustable valve using the rotary switch (Figure 44/5).
This digital display (Figure 44/7) shows the values of a

measuring sensor. The values correspond to the temperature in
the water circuit in ° C.

Page 88 of 182
Operating panel
5.14.4 Boost pump controls
Figure 45: Boost pump panel field
Pressure gauge – pressure of the liquid nitrogen through

1
the boost pump
2 Potentiometer – adjusts the speed of the boost pump
The liquid nitrogen is continuously fed to the triplex pump using

the boost pump. The pressure gauge (Figure 45/1) shows the
current delivery pressure of the boost pump.
The pressure can be manually regulated. This is done by using

the Potentiometer BOOST PUMP SPEED CONTROL
(Figure 45/2).

Page 89 of 182
Operating panel
5.14.5 Motor and system controls
Figure 46: Motor and system control panel field
1 EMERGENCY STOP button

2 IDLE SPEED switch for the drive motor
3 System key / ignition key
4 Display – motor functions
5 Operating hours counter
6 Digital display – hydraulic oil temperature
7 Fuel Display
8 ON / OFF switch – working lights of the machine
9 ON / OFF switch – panel lights
10 Alarm LED – batteries charging
11 Alarm LED – return flow filter contaminated
12 Alarm LED – suction filter contaminated
13 Alarm LED – oil change

Page 90 of 182
Operating panel
The EMERGENCY STOP switch (Figure 46/1) disconnects all

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

Page 91 of 182
Operating panel
Figure 47: Panel detail Volvo Penta
The green START button starts the drive motor.

The red STOP button stops the drive motor.
With the plus and minus button the speed of the drive motor is
controlled.
On the right site of the digital control panel you can switch with
the up and down arrow the displayed function.
There is also the possibility of setup settings.
5.14.6 Readjustments and cool down
Figure 48: Readjustments and cool down

Page 92 of 182
Operating panel
1 RAPID COOL DOWN Valve

2 METERING Valve
3 HIGH PRESSURE BLEED
4 RECIRCULATION Valve
5 TEMPERING Valve
6 HIGH PRESSURE RECIRCULATION Valve
The RAPID COOL DOWN Valve

open or close the pipe to the outlet
point. This will be used by the cool
down process.
The METERING Valve controls flow

through vent ports on the cold ends.
This will be used by the cool down
process.
If the pressure of the gaseous

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

Page 93 of 182
Operating panel
The return flow of the nitrogen to the

nitrogen tank can be manually
controlled using the recirculation
valve
If the temperature of the gaseous

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

is used during cool down prodedure.

Page 94 of 182
Operating panel
5.14.7 Exhaust gas control
Figure 49: Exhaust gas control
The bypass flapper valve to the exhaust gas heat exchanger

can be opened or closed via a control lever
Process description

Page 95 of 182
Assembly / Commissioning
Operating panel
6 Assembly / Commissioning
Assembly Assembly of the machine Nitrogen Pumping Unit is carried out
by the manufacturer’s employees. Assembly by the operator is
not required.
Commissioning “Commissioning” here refers to the initial commissioning of the

machine in accordance with the current normative and legal
definition. Commissioning of the machine is carried out by the
manufacturer’s employees.
As part of commissioning, the Nitrogen Pumping Unit machine
has been
 set up
 calibrated
 tested
The test results can be found in the Full Application Test (FAT).

Page 97 of 182
Delivery and Transport
Safety
7 Delivery and Transport

7.1 Safety
DANGER
Fatal injuries due to falling machines / machine parts /
loads
 Never place yourself under raised loads.

 Do not enter danger zones or swivelling ranges and
immediately leave these as quickly as possible.
 Communicate with crane drivers or accompanying
persons.
 Wear personal protective equipment.
WARNING
Vehicles in motion
 Never move within vehicle or transport routes without

addressing the drivers of vehicles or cranes or draw clear
attention to yourself.
 Wear a high visibility vest so that you are easily
recognisable.
WARNING
Squeezing / crushing of body and limbs
 Never position your moving body or parts thereof between
machines / vehicles if these are moving towards each
other.
 Keep a sufficient safety distance.

Page 99 of 182
Delivery
7.2 Delivery
Delivery is not made by the manufacturer. The manufacturer’s
employees prepare the machine for transport and make it
available on the factory premises. Delivery and transport to the
installation site is the responsibility of the operator.
7.3 Transport
7.3.1 Personnel
Transport work on or with the machine may only be carried out
by authorized and sufficiently qualified personnel (see chapter
3.6).
7.3.2 Preparation
In principle, the Nitrogen Pumping Unit machine may only be
transported in a "dry" state, so without operating materials,
auxiliary materials or process materials.
Transport with operational, processing and auxiliary materials

may be a violation of national or international provisions of road
and freight transport.
 Check the filling levels of the tanks and vessels. If the

storage tanks have to be emptied before transport, then
this must be done in accordance with the national valid
working, operational safety and environmental
protection guidelines.
 All moving parts must be fixed.
 Accessory parts must be stored safely for transport.
 Secure cabin doors against unintentional opening.
If moving away from the principle of “Transport in a dry state”,
then it is the responsibility of the operator to implement all
necessary measures and identification signs on the machine,
which are necessary for safe transport in compliance with the
national legislation.

Page 100 of 182
Transport
7.3.3 Nitrogen skid

Transport the liquid nitrogen in the tank, thus the excess tank
pressure is kept lower than the permissible operating pressure.
Transport valve A relief valve is installed for the transport in this instance (V-20,
Road Relief Valve global). This is controlled by a Regulator
Valve (R-1) which is factory set at 160 mbar.
Figure 50: Transport Valve
1 Valve V-20
2 Valve R-1
Valve settings for transport:
1. Close all valves

2. Open valve V-20

Page 101 of 182
Transport
7.3.4 Departure check
WARNING
Unretracted supports
If the supports are still extended during the movement, then
they might come into contact with the floor and lead to the
trailer toppling.
 Retract and secure supports.
WARNING
Unsecured crank
Crank can swing out during transport and injure people.
 Lock crank into place and secure.
Carry out an examination of the following points before starting Inspection

each journey. Resolve any arising defects immediately.
 Are the on-board documents in place?

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

Page 102 of 182
Storage
Transport
8 Storage
If the machine is not intended for immediate operation or if the
machine is out of operation for a long time, then it must be
stored in a dry, well-ventilated site with a low relative humidity.
Large temperature deviations at the site of storage must be
avoided.
Nitrogen skid
A residual amount of nitrogen should be left in the nitrogen tank
if it is decommissioned for an extended amount of time. This is
necessary to prevent any moisture from penetrating.
The Nitrogen Pumping Unit machine may only be stored in a
"dry" state, so without operating materials, auxiliary materials or
process materials.
Storage with operational, processing and auxiliary materials

may be a violation of national or international provisions.
Depressurize all pressurized components, check lines and

hoses of the pneumatic and hydraulic systems.
Clean motors, pumps, lines, hoses and containers.
Also read and follow the instructions from the supplier with
reference to the topic of storage. These documents can be
found in the Supplier Documentation chapter and in the annex.

Page 103 of 182
Installation Conditions
Installation site
9 Installation Conditions
9.1 Safety
WARNING
other.
WARNING
Vehicles in motion

recognisable.
CAUTION
Wedging of the feet between the supports and floor
 Keep a sufficient safety distance to the supports.
 Wear safety shoes
9.2 Installation site

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

Page 105 of 182
Installation Conditions
Substrate
9.3 Substrate
A level and secure working platform must be in place to ensure
safe operation of the machine.
The maximum capacity of the installation area must be
observed.
If there is no fixed working platform in place, then the floor
space must be as compressed as such, that the stability should
be at least sufficient under normal operating conditions.
A deviation of more than three degrees to the horizontal is not
permitted.
9.4 Attachment
The machine can be set up freely, fastening or anchoring to the
substrate is not required.
The machine must be set up horizontally. Use a spirit level in
this case (not included as part of delivery).
 Secure the machine so it can’t roll away.
9.5 Connections
Connect the connections of the machine described in Chapter
2.5 and Chapter 5.10 with the interfaces / lines. This must only
be carried out by personnel trained especially for it.

Page 106 of 182
Operation
Filling the nitrogen tank
10 Operation
10.1 Safety
10.2 Filling the nitrogen tank
DANGER
Loss of consciousness and suffocation due to nitrogen
Evaporating nitrogen displaces oxygen in the breathing air and
leads to loss of consciousness and death due to suffocation
without prior physical warning signs.
 Prevent nitrogen from escaping
 Only carry out filling outside or in well-ventilated areas
with special extraction equipment
 Use warning apparatus / oxygen monitor
WARNING
Cryogenic burns due to extremely cold media
Contact with extremely cold media leads to cyrogenic burning of
the skin, eyes, with a risk of blinding, and the respiratory tract.
 Avoid any contact
 Do not touch piping, lines or containers
 Wear specialist personal protective equipment when
handling extremely cold media
Also read and follow the operating instructions / maintenance

instructions of the manufacturer of such components. The
documents are listed in Chapter 15.2
Supplier Documentation.

Page 107 of 182
Operation
10.2.1 Valve overview
Figure 51: Valve overview nitrogen tank
This overview shows the circuit diagram of the valves on the

nitrogen tank.
The next picture show you the valve list.
You also find both plates in front on the nitrogen tank.

Page 108 of 182
Operation
Figure 52: Valve list nitrogen tank

Page 109 of 182
Operation
10.2.2 Preparation
1. The nitrogen tank can only be filled by personnel who Check before filling
have been especially trained and instructed to carry out
this task.
2. Make sure that the working area is kept free of
obstacles, that the delivery vehicle has a secure access
route. The emergency routes must be kept clear.
3. Make sure that the type and data plates are present on
the tank, well legible and match the certificates of the
inspection organization / designated body.
4. Make sure that the time period for the latest tank
inspection period has not been exceeded.
5. Inspect the nitrogen skid, the nitrogen tank and the
safety-relevant components before you start the filling
process. The nitrogen tank may only be filled if all
criteria listed have been complied with (see chapter
12.3).
10.2.3 Initial filling

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

Page 110 of 182
Operation
10.2.4 Filling
The nitrogen tank can be filled form above or from below with
separate fill lines. A filling from abow is to prefer.
Maximum filling quantity should not be more than 200 l per
minute
Monitor the pressure in the tank during the filling process.
The primary safety valves are set to the maximum working
pressure. The external filling pressure must therefore be set
lower to prevent any unnecessary venting through the relief
valve.
The nitrogen tank has fill connections in the rear and the front.
For more information see the valve schema plate on the tank.

Page 111 of 182
Operation
Cool down
10.3 Cool down

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

1. Inspect
 All water levels on the machine.

 All oil levels on the machine.
 Visual inspections for damages to the nitrogen
tank and nitrogen pump
 Visual inspection for leakages on components,
lines and conduits.
2. Check the hose connections between the nitrogen tank

and nitrogen pump for damages. Check proper
connection (see also Chapter 5.10 N2 pump,
connections). All valves must be closed.
Flow out
Return flow
Figure 53: Tank connections

Page 112 of 182
Operation
Cool down
Inflow
Return flow
Figure 54: N2 pump connections
10.3.2 Reducing the overpressure

Reduce any excess pressure within the nitrogen tank.
1. Open valve V-3 (vent) for this.
Figure 55: Pressure reduction valve
2. Observe the pressure gauge on the nitrogen tank.

Page 113 of 182
Operation
Cool down
Figure 56: Pressure gauge
3. Close the valve again if the excess pressure within the

nitrogen tank has reached a value of less than 0.2 bar.
10.3.3 Starting the drive motor

The N2 pump machine has a main switch for the electrical
power supply. This battery master switch can be found on the
left side of the N2 pump in front of the preheater-toolbox.
Figure 57:Battery master switch

Page 114 of 182
Operation
Cool down
1. Turn the battery master switch on the system to I.

 The power supply for the machine is now activated.
2. Enter the operator cabin.

3. Insert the ignition key into the ignition lock and turn the
ignition key in the ignition lock to position I.
 The control panel is now unlocked.
4. Press the green START button on the engine control

panel and keep it pressed down until the drive motor
starts.
If the drive motor still doesn’t start after 10 seconds, then the
process must be stopped to prevent damages to the starter
system. Repeat the process after a break of 20 seconds.
5. Set the speed of the motor
using the buttons.
All hydraulic drives and components are not in operation for

the first 10 seconds after motor start. This serves to ensure a
un-load motor start. After this 10 seconds all components
ready for use.

Page 115 of 182
Operation
Cool down
10.3.4 Building up admission pressure

The liquid nitrogen in the nitrogen tank must be applied with an
overpressure of 1.5 - 2.0 bar for the further processing. The
nitrogen tank has its own vaporizer for this operational function
that is activated.
1. Check that all valves are closed.

2. Open valve V-4 (pressure build) on the nitrogen skid.
Figure 58: Valve N2-Tank vaporizer
3. Observe the pressure gauge on the nitrogen tank.

Page 116 of 182
Operation
Cool down
Figure 59: N2-Tank pressure gauge
4. Set the admission valve by incremental opening /

closing valve V-4 (pressure build) so that the admission
pressure is kept constant.
This process may have to be repeated during the
subsequent preparatory work and the operation.
10.3.5 Boost pump

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

Page 117 of 182
Operation
Cool down
Figure 60: Cool down boost pump
Figure reference table 60
PRIMARY INLET VALVE
SECONDARY INLET VALVE
BOOST PUMP ISOLATION VALVE
RAPID COOL DOWN VALVE
RECIRCULATION VALVE
METERING VALVE
Discharge outlet

Page 118 of 182
Operation
Cool down
Table 27: Cool down boost pump
1. Check that the METERING

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

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

PUMP ISOLATION is open.
This valve can be found on
the right side in front of the
operator cabin and must be
actuated externally.
4. Open the valve V-6 for the

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

Page 119 of 182
Operation
Cool down
5. Open the PRIMARY INLET

VALVE. This valve can be
found on the right side in
front of the operator cabin. It
can be actuated from the
operator cabin about a push
rod.
You find the grip of the push

rod on the right site of the
operator cabin under the
window.
6. Open the RECIRCULATION

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

Page 120 of 182
Operation
Cool down
7. Open the RAPID COOL

DOWN VALVE. This valve is
found on the operator panel
and can be actuated from the
operator cabin.
As soon as the RAPID COOL DOWN VALVE is opened, liquid

nitrogen flows into the low pressure circuit of the N2 pump from
the nitrogen tank. The liquid nitrogen very quickly absorbs heat
energy and vaporizes. In this instance, the pipe lines and
components / boost pump are intensely cooled – recognizable
by the frost formation.
The gaseous nitrogen is discharged into the environment via
the pipeline. The outlet point is found on the left side in front of
the operator cabin.
This procedure must be carried out until the nitrogen at the

outlet point passes from gas into liquid.
The boost pump can only pump liquid media.

Page 121 of 182
Operation
Cool down
In the meantime, test whether the boost pump already has

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

The circuit switches to the high-pressure pump as soon as the
low-pressure circuit and the boost pump are prepared. The high
pressure pump has a "warm" Power End and a "cold" Fluid End
working area. The Fluid End area must be cooled down before
operation of the pump. The following figure shows the area
coloured in blue.
Figure 61: Cool down triplex
METERING VALVE
Cool end of the high pressure pump

Page 122 of 182
Operation
Cool down
1. Open the METERING VALVE.

This valve is found on the
operator panel and can be
actuated from the operator
cabin.
2. Pay attention to the Fluid End

of the high pressure pump. The
cylinder should exhibit a build
up of frost after a short while.
3. Switch on the high pressure

pump at minimum speed (max.
20 rev/min) using the TRIPLEX
SPEED ADJUST rotary switch
as soon as the first formation
of frost is present.
This procedure must be carried out until the nitrogen at the

outlet point passes from gas into liquid.
Although described in two sub-points in this manual, the "Boost

pump" and "High pressure pump" steps can also be completed
in parallel.

Page 123 of 182
Operation
Pumping nitrogen
10.3.7 Return flow

The return flow to the nitrogen tank is established once the low-
pressure circuit has cooled down (liquid nitrogen is blown out of
the outlet point).
Only liquid nitrogen is conveyed back into the tank via the
return flow line.
1. Open the bypass valve V-12

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

return flow at the nitrogen tank
incrementally. The reflux
volume flow into the tank must
be adjusted to the operating
conditions here.
Cooling down and preparation of the N2 pump is thus

completed. The N2 pump is now ready for operation.
10.4 Pumping nitrogen

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

Page 124 of 182
Operation
Pumping nitrogen
1. Set the motor speed to the

desired rotational speed using
the using the

buttons
Boost Pump 2. Read off feed pressure of the

5 – 7.5 bar
boost pump using the LN2
BOOST PRESSURE gauge.
3. Set the speed of the boost
pump with the BOOST PUMP
SPEED CONTROL rotary
switch.
The feed pressure of the boost

pump should amount to
approx. 5 – 7.5 bar.
High pressure pump 4. Triggering the high pressure
max. 910 rev/min
pump. The speed of the triplex
max. 689 bar
pump is set via the TRIPLEX
SPEED ADJUST rotary switch
and can be read off from the
TRIPLEX SPEED digital
display over the rotary switch.
The maximum permissible

rotational speed is 910 rev/min.
5. The pressure in the high-

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

Page 125 of 182
Operation
Pumping nitrogen
6. The temperature of the warm

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

Page 126 of 182
Operation
Pumping nitrogen
7. The temperature of the

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

VALVE switch to OPEN to
open the transfer valve at the
discharge interface.
9. All relevant job data where

displayed and record in a
memograph.

Page 127 of 182
Operation
Take out of operation
10.5 Take out of operation

1. Switch the DISCHARGE
VALVE switch to CLOSE to
close the transfer valve at the
discharge interface.
2. Turn the TRIPLEX SPEED

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

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

Page 128 of 182
Operation
4. Using the buttons on

the Volvo display to turn the
motor to idling speed.
A second option is to use the

idle speed switch in the motor-
panel-section.
5. Close the flow valve V-6 at the

nitrogen tank
6. Close the PRIMARY INLET

VALVE on the N2 Pump.

Page 129 of 182
Operation
7. Open the HIGH PRESSURE

BLEED valve. Thus, the
remaining pressure in the pipe
system is released.
8. The other three bleed vales

must be open externally. You
find them on the right site in
front of the cabin.
The bleed valve are try cocks,
one each in the
 primary inline
 secondary inline
 outline
9. Close the return flow valve V-1

at the nitrogen tank
10. Press the STOP button on the

Volvo display. The motor is
switched off.

Page 130 of 182
Operation
Operation after Emergency Stop
11. Turn the ignition key in the

IGNITION ignition lock to “0”
and remove.
10.6 Operation after Emergency Stop

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

Page 131 of 182
Operation
Operation after a Prolonged Downtime
Bowden
To reopen pull the sling down.
10.7 Operation after a Prolonged Downtime

Verify the following points when re-commissioning the machine
after a prolonged downtime:
 All liquids must be inspected (cooler, motor, gear unit,

hydraulics).
 All hoses must be checked for leaks.
 The the motor oil must be changed.
 The battery must be recharged or replaced if necessary

Page 132 of 182
Operation
Miscellaneous.
10.8 Miscellaneous.
10.8.1 Operation with cabin heating
Figure 62: Operation with cabin heating
1 Thermostat and ON/OFF switch

2 Webasto Air Top

Page 133 of 182
Operation
Miscellaneous.
The operator cabin can be warmed up with the auxiliary heater

if the temperatures are low.
Preparation
Check the level in the diesel tank. The cabin heating uses the
same fuel tank as the Preheater.
Switching on the heating
1. Switch on the heating with the rotary switch.

2. The blower runs at low speed.
3. The fuel transportation system is automatically activated
after approx. 60 seconds and the air-fuel mixture in the
combustion chamber ignited.
4. The heating system now runs in normal mode.
5. Set the desired heating power with the rotary switch.
The maximum heating capacity (POWER) is available after
approx. three minutes.
Switching off the heating
1. Turn the rotational switch to position 0

The fuel transportation system is automatically switched off
The blower runs to dissipate the residual heat from the device

Page 134 of 182
Operation
Miscellaneous.
10.8.2 Operation with preheating

Preheating may be necessary using the auxiliary heater for
temperatures of < 5 °C.
Auxiliary heater
1. Check the filling level of the fuel storage tank and fill up
with fuel (diesel) if necessary. The fuel storage tank can
be found directly above the storage box of the auxiliary
heater.
2. Turn the rotary switch to the right. The heater is now
ignited.
3. The yellow indicator light lights up.
4. The auxiliary heater is now ready for use.
Switching the circuit

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

 Motor cooling circuit
 Diesel tank circuit
 Lubrication oil tank circuit
You will also find the distributor (one for forerun, one for return)
and ball valves of the respective circuits to open / close here.

Page 135 of 182
Faults and Troubleshooting
Drive motor
11 Faults and Troubleshooting

11.1 Drive motor
Fault Motor does not start
Cause  Air intake shutoff valve closed
Rectification  Check that the rig saver is open.
 Inspection and Maintenance Chapter
 Supplier Documentation
Alarm LED for oil pressure lights up on

Fault
the control panel
 Too little motor oil present in the

lubrication circuit
 Lubrication oil pump does not build up
Cause
enough pressure
 Pressure sensor defect
 Water in the lubrication oil
 Check the motor oil filling level.
Rectification  If the filling level is normal, then inform
the service personnel.

Page 137 of 182
Filters
11.2 Filters
Alarm LED for suction filters lights up on
Fault
the control panel
 The filter elements of the suction filters

Cause
are contaminated.
 Check the machine’s suction filters
Rectification  Change the filter inserts of the suction
filters.
Alarm LED for return flow filter lights up

Fault
on the control panel
 The filter elements of the return flow

Cause
filters are contaminated.
 Check the machine’s return flow
filters.
Rectification
 Change the filter inserts of the return
flow filters.

Page 138 of 182
Battery
11.3 Battery
Status LED of the battery lights up on the
Fault
control panel
 The charge level of the battery is not

functioning properly.
Cause
 The charging current is too low
 The battery acid level is abnormal.
 Check the battery acid level.
Rectification  Check the charging current to the
battery

Page 139 of 182
Exhaust gas heat exchanger
11.4 Exhaust gas heat exchanger
ATTENTION
Damage due to overheating
Immediate switch-off leads to overheating damages to the
exhaust gas heat exchanger.
 Carry out circulation with the minimum flow rate for at least
15 minutes.
Table 28: Exhaust gas heat exchanger troubleshooting
Fault Decreasing performance
 Waterside contamination
Cause
 Exhaust gas side contamination
 Check waterside and clean if
necessary
Rectification
 Check exhaust air side and clean if
necessary
Fault Increasing loss of pressure on the water

side
Cause  Increased flow rate

Rectification  Check circulation and pumps

Page 140 of 182
Fault Increasing loss of pressure on the water

side
Cause  Waterside contamination

Rectification  Check waterside and clean if necessary
Fault Increasing loss of pressure on the exhaust

gas side
Cause  Increased flow rate
Rectification  Check circulation
 Check opening of a bypass
 Check modifications to the installation
Fault Increasing loss of pressure on the exhaust

gas side
Cause  Exhaust gas side contamination
 Pipes blocked
Rectification  Check exhaust air side and clean if
necessary

Page 141 of 182
Fault Water discharge at the condensate

Cause  Tube weldings on the shell side leaky
Rectification  Decommission the system
 Inform the manufacturer
Fault Flange and tube connections leaky
Cause  Seal defect

Rectification  Replace seal
Fault Flange and tube connections leaky
Cause  Screw connections loose

Rectification  Tighten screw connections

Page 142 of 182
Plate heat exchanger
11.5 Plate heat exchanger

Table 29: Faults plate heat exchanger
Fault Declining plate heat exchanger capacity
 Calcium deposits or similar encrustations

Cause
in the heat exchanger.
 Cleaning of the plate heat exchanger
through rinsing
Rectification
 Cleaning of the plate heat exchanger
through rinsing with chemicals
The operating mode has a significant influence on the level of

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

Page 143 of 182
Inspection and Maintenance
12 Inspection and Maintenance

Maintenance is a part of the servicing process. Servicing is
regulated by the standards DIN 31051 and DIN EN 13306.
Delimitation This chapter solely focuses on inspection and maintenance.

Repair and overhaul is not referred to in this manual.
Inspection Inspection activities shall be performed by the site’s inspection

team. These actions are carried out to determine the actual
condition of a defined unit with a particular focus on proper,
technically flawless operation, so that any hazards when the
unit in question is used can be avoided during normal usage.
Maintenance All measures to delay the depletion of the wear reserves

present in the reference unit are understood to be maintenance
measures. These shall be employed on a machine during it’s
entire service life.
Maintenance must be undertaken by specialist personnel
trained according to the technical regulations or manufacturer
provisions at regular intervals.
Maintenance shall include for example:
 readjustment
 lubrication
 preserving
 the refilling or replacing of operating materials or
consumables (e.g. fuel, lubrication or water)
 the scheduled replacement of basic wear parts (e.g.
filters or seals).

Page 145 of 182
The following does not belong to maintenance:
 Exchange or replacement of defective parts (this

belongs to repair)
 Cleaning works (this must be carried out at the
discretion of the operator or owner)
The operator of the machine must document the maintenance Maintenance protocol
and compliance of the maintenance intervals in a suitable
manner:
 For purposes of safeguarding and quality assurance.

 For reasons of occupational safety and health, where
failure of technical systems due to inadequate
maintenance or non-compliance with maintenance
intervals can lead to irreversible physical damage to
human life and health.
 For reasons of environmental protection, where failure
of technical systems due to inadequate maintenance or
non-compliance with maintenance intervals can lead to
irreversible damage to the environment.
In addition, the installation operator must observe the
respective national laws, legislation and provisions valid for the
installation site (e.g. the BetrSichV (Ordinance on Industrial
Safety and Health) and ProdSG (Product Safety Law) in
Germany).
Inspection and Maintenance Intervals
The values indicated are indicative and are dependent on the Intervals
individual operating conditions.
The operator of the system must adjust the inspection and
maintenance intervals to the current operating conditions if
necessary.
The complete overview and significance of the interval
definitions can be found in Chapter 2.2.4.

Page 146 of 182
Safety
12.1 Safety
DANGER
 Prevent nitrogen from escaping
 Ensure a sufficient fresh air supply
 Carry a warning device
WARNING
Automatic start-up
 Make sure that the machine is switched off
 Make sure that the machine is not accidentally switched on
WARNING
Danger due to pressurized components
Components and media of the hydraulics, pneumatics, cooling
system and functional circuits are pressurized.
They can penetrate the skin, body and eyes.
 Switch all systems an circuits into a depressurised state
and discharge before you begin work.
WARNING
the skin, eyes with a risk of blinding and the respiratory tract.

Page 147 of 182
Safety
WARNING
Poisoning due to swallowing or intake of aerosol
Consumables, operating materials and process materials may
be toxic if swallowed or inhaled.
 Avoid direct or indirect contact
 Do not breathe in vapours
CAUTION
Head injuries in the working area
Machine components and assemblies can protrude into the
working area and thus come into contact with you.
 Work with caution and pay attention to components that
protrude into the working area
CAUTION
Risk of falling in the machine room
You may stumble over components, pipes and lines. Working
areas can be slippery.
 Please enter these areas with caution and ensure firm
support when you move around in them
 Clean working areas
 Keep working paths free
CAUTION
Sensitization
Breathing in aerosols and skin contact with consumables,
operating and process materials leads to sensitization.
 Avoid any direct or indirect contact
 Immediately change contaminated clothing
 Clean and rinse any affected skin parts

Page 148 of 182
Nitrogen skid
CAUTION
Burns due to hot surfaces
Touching hot surfaces leads to burns and adverse reactions.
 Switch off the machine and allow it to cool down.
12.2 Truck
All information about inspection and maintenance can be found
in the manual of the truck.
maintenance intervals to the present operating conditions if
necessary.
Read and follow the operating instructions / maintenance

documents can be found in the Chapter Supplier
Documentation.
12.3 Nitrogen skid

The values indicated are indicative and are dependent on the
maintenance intervals to the present operating conditions if
necessary.

instructions of the manufacturer of such supplied components.
The documents can be found in the Chapter 15.2 Supplier
Documentation.

Page 149 of 182
Nitrogen skid
12.3.1 Before each operation

Maintenance activities / inspection
Table 30: Nitrogen skid – before each operation Before each operation
Interval Activity
W020 Check Check external tank
W020 Check Check frost and ice formation
W020 Check Check overpressure valve
W020 Check Dents or other damages visible
W020 Check Check gauge function
W020 Check Operation of the valves
W020 Check Check safety valves
W020 Check Check overpressure valves
W020 Check Check relief valves
W020 Check Check connection hoses
Required for the maintenance
Small auxiliary No tools, auxiliary aids or third

materials persons are required.
Implementation of the maintenance / inspection

DANGER
 Carry a oxygen deficiency warning device

Page 150 of 182
Nitrogen skid
WARNING
the skin, eyes, with a risk of blinding, and the respiratory tract.
1. The external tank must not show any signs of moisture.

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

Page 151 of 182
Pump unit
12. Connection hoses or lines must be kept free from

contamination, oil, grease and water.
Repairs to cryogenic containers may only be carried out by

personnel who are trained and certified to do so. Any
unauthorized repairs will terminate the operating licence or
certification.
12.3.2 Inspection after 2.5 years

The tank must be subjected to a periodic inspection every 2.5
years. This includes a leakage test and a check of all service
equipment.
The inspection methods used can be determined by the
component authority or the testing organization commissioned.
12.3.3 Inspection after 5 years
The tank must be subjected to a periodic test and inspection

every 5 years. The internal and external tank must be pressure
tested separately in this instance, including a completely new
risk assessment and certification.
The operator is responsible for carrying out inspections (after

2.5 years, after 5 years). The certification for the nitrogen tank /
the nitrogen skid shall be voided if these inspections are not
carried out.
Operation of the nitrogen pump with a non-certified nitrogen
tank is prohibited.
12.4 Pump unit
12.4.1 Drive motor

necessary.

Page 152 of 182
Pump unit

Documentation.
Daily maintenance
Daily / before each Table 31: Drive motor maintenance – daily
operation
Interval Activity
W020 Check Check motor oil and coolant level
W020 Check General visual inspections
Check air filter contamination
W020 Check
display
W020 Check Check dust discharge valve
Check fuel filter / water separator
W020 Check
pan
W020 Check Check connection hoses
As required
As required Table 32: Drive motor maintenance – as required
Interval Activity
W000 Change Replace air filter inserts
W000 Vent Vent the fuel system
W000 Change Replace three-phase alternator and
fan belts
W000 Check Check fuses
W000 Check Check air compressors (if present)
W000 Check Check rear PTO (if present)
W000 Change Replace air pre-filter inserts, if the
contamination display shows a
negative pressure of 625 mm (25
in.) Water column indication
After the first 100 operating hours

Page 153 of 182
Pump unit
Table 33: Drive motor maintenance – after 100 OH After the first 100 OH
Interval Activity
B040 Change Change the oil and filters for the first
time after a maximum of 100
operating hours during the running-in
period of the motor
Every 500 operating hours

Table 34: Drive motor maintenance – every 500 OH Every 500 Oh
Interval Activity
B060 Check Service fire extinguisher
B060 Check Service the battery
B060 Change Change the motor oil
B060 Change Replace motor oil filter
B060 Check Check foam filter of the water
pumps-water drainage bore
B060 Change Replace fuel filter
B060 Clean Clean water separator
B060 Check Check motor speed
B060 Check Check the attachment parts of the
motor
B060 Clean Clean the ventilation hose and
ventilation valve of the crankcase
B060 Check Check air intake hose, connections
and system
B060 Check Check motor ground connection

Page 154 of 182
Pump unit
Interval Activity
B060 Check Check automatic belt tensioner and
belt wear
B060 Check Check the cooling system
B060 Adjust; Carry out a coolant analysis; add
check supplemental coolant additives
(SCAs) if necessary
B060 Check Pressure test of the cooling system

Every 2000 Oh Table 35: Drive motor maintenance – every 2000 OH
Interval Activity
B100 Check Check crankshaft vibration dampers
B100 Check Flush and refill cooling system
B100 Check Check the thermostats

Every 2500 Oh Table 36: Drive motor maintenance – every 2500 OH
Interval Activity
B110 Adjust; Adjust the motor valve clearance
check and pretension of the electronic
injector unit

Page 155 of 182
Heating circuit
12.5 Heating circuit
12.5.1 Exhaust gas heat exchanger

The operator of the machine must adjust the inspection and
necessary.

Documentation.

Page 156 of 182
Heating circuit
Daily maintenance
Table 37: Exhaust gas heat exchanger maintenance – daily Daily
Interval Activity
W020 Check Check all flange and pipe
connections and rectify leakages
Monthly maintenance
Table 38: Exhaust gas heat exchanger maintenance – monthly Monthly
Interval Activity
W050 Check Check all flange and pipe
connections and rectify leakages
W050 Check Check safety equipment (pressure
and temperature limiter, safety
valves, flow controller or water level
limiter) for functionality
W050 Check Check inner side of the hot tube
plate (water side) via endoscope
socket or discharge opening for
formation of deposits
W050 Clean Clean the water side if deposits
have formed (chemically)
W050 Check Check values of the circuit water
(see circuit water requirements)
W050 Check; clean Check the water side for sludge
formation and flush if necessary
W050 Check; clean Check heating surfaces on the
exhaust gas side for coatings or
deposits and clean if necessary
W050 Check Check steam traps for correct
function

Page 157 of 182
Heating circuit
Maintenance every 6 months

Every 6 months Table 39: Exhaust gas heat exchanger maintenance – every 6
months
Interval Activity
W070 Check Temperature displays functional test
via comparison measurement
W070 Check Value check on the water side;
values must comply with the
requirements for the properties and
condition of the circuit water
W070 Check Check formation of deposits and
sludge on the water side via
endoscope socket
12.5.2 Plate heat exchanger

The operator of the machine must adjust the inspection and
necessary.

Documentation.
As required
As required Table 40: Plate heat exchanger – as required
Interval Activity
W000 Clean Flush plate heat exchanger (with
chemicals should it be necessary) to
eliminate calcium deposits and
encrustations

Page 158 of 182
Heating circuit
Required for the maintenance
Phosphoric acid
Acid-based  Concentration max. 2%
cleaning agents  Temperature max. 20 °C
 Exposure time approx. 1 hour
or
Caustic soda
Lye-based  Concentration max. 4%
cleaning agents  Temperature 85 °C
 Exposure time 24 hours
Implementation of the maintenance

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

Page 159 of 182
Decommissioning
Safety
13 Decommissioning
Information about how to definitively decommission the
machine, to dismantle the machine and to dispose of the
machine can be found in this chapter.
13.1 Safety
DANGER
Fatal injuries due to falling machines / machine parts /
loads
 Never place yourself under raised loads.

 Do not enter danger zones or swivelling ranges and
immediately leave these as quickly as possible.
 Communicate with crane drivers or accompanying
persons.
DANGER
 Carry a warning device
WARNING
Vehicles in motion

recognisable.

Page 161 of 182
Decommissioning
Safety
WARNING
Poisoning due to swallowing or intake of aerosol
Consumables, operating materials and process materials may
be toxic if swallowed or inhaled.
 Avoid direct or indirect contact
 Do not breathe in vapours
WARNING
Danger due to pressurized components
Components and media of the hydraulics, pneumatics, cooling
system and function circuits are pressurized. They can
penetrate the skin, body and eyes.
 Switch all systems and circuits into a depressurised state
and discharge before you begin work.
WARNING
other.
CAUTION
Sensitization due to skin contact or intake of aerosol
 Avoid any direct or indirect contact
 Immediately change contaminated clothing
 Clean and rinse any affected skin parts

Page 162 of 182
Decommissioning
Disassembly
CAUTION
Spinal damage
Lifting and carrying heavy loads leads to spinal damage.
 Use technical aids and hoisting gear
ATTENTION
Environmental damage
Improper or reckless handling of environmentally hazardous
substances can result in serious environmental damages.
 Ensure careful handling of the hazardous substances with
environmental awareness.
 Read the information and observe the Material Safety Data
Sheets
13.2 Disassembly
Disassembly must only be performed by specialist personnel.
The national provisions for the disassembly of machines must
be observed (operational approvals, deposition equipment, etc.)
Before you begin with the disassembly
 Turn off electronic circuits

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

Page 163 of 182
Decommissioning
Disposal
down procedures such as cutting, separating and sawing can

lead to fires or explosions.
Secure components and assemblies before removing
connections.
Lift heavy machine parts using appropriate means and lifting
equipment.
Observe national safety and environmental requirements
13.3 Disposal
Dispose of hazardous or contaminated substances in the
designated collection points.
Separate recyclable material in accordance with the valid
provisions and recycling targets.

Page 164 of 182
Additional Documents
Manufacturer’s Certificate
14 Additional Documents
14.1 Manufacturer’s Certificate
14.1.1 Device pass

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

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

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

Page 165 of 182
Machine Structure
The Certificate of Origin of the manufacturer for the Nitrogen

Pumping Unit machine can be found as an electronic document
– in the form of a PDF file – on the CD supplied and can be
accessed via this link:
14.1.4 Certificate of Warranty

The Certificate of Warranty of the manufacturer for the Nitrogen
documentation under chapter 01 Unit / 1.4 Certificates.
The Certificate of Warranty of the manufacturer for the Nitrogen
14.1.5 Full Application Test

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

The Overall drawing of the manufacturer for the Nitrogen

Page 166 of 182
Hydraulics

documentation under chapter 01 Unit / 1.2 drawings.
The Overall drawing of the manufacturer for the Nitrogen
14.2.2 Construction BOM

The Construction BOM of the manufacturer for the Nitrogen
documentation under chapter 01 Unit / 1.2 Drawings.
The Construction BOM of the manufacturer for the Nitrogen
14.3 Hydraulics
14.3.1 Hydraulic plan

The Hydraulic plan of the manufacturer for the Nitrogen
documentation under chapter 04_Hydraulic System\4.1
Hydraulic System Diagram.
The Hydraulic plan of the manufacturer for the Nitrogen

Page 167 of 182
Electronics
14.3.2 Hydraulics BOM

The Hydraulics BOM of the manufacturer for the Nitrogen
Hydraulic System Parts List.
The Hydraulics BOM of the manufacturer for the Nitrogen
14.4 Electronics
14.4.1 Electronics plan

The Electronics plan of the manufacturer for the Nitrogen
documentation under chapter 05_Electric System\5.1 Electrical
System Diagram.
The Electronics plan of the manufacturer for the Nitrogen
14.4.2 Electronics BOM

The Electronics BOM of the manufacturer for the Nitrogen
System Parts List.
The Electronics BOM of the manufacturer for the Nitrogen

Page 168 of 182
Flow chart

14.5 Flow chart
14.5.1 Heat recovery circuit

The flow chart for the Heat recovery circuit of the Nitrogen
documentation under chapter 07_Heating circuit\7.1 Heat
Recocery Circuit Diagram.
The flow chart for the Heat recovery circuit of the Nitrogen
14.5.2 Heat recovery circuit BOM

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

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

Page 169 of 182
Flow chart
documentation under chapter 03_Flow System\3.1_Flow

System Diagram.
The flow chart for the Nitrogen circuit of the Nitrogen Pumping
Unit machine can be found as an electronic document – in the
form of a PDF file – on the CD supplied and can be accessed
via this link:
14.5.4 Nitrogen circuit BOM

The Nitrogen circuit BOM of the manufacturer for the Nitrogen
documentation under chapter 03_Flow System\3.2_Flow
System Parts List.
The Nitrogen circuit BOM of the manufacturer for the Nitrogen

Page 170 of 182
Supplier Documentation
N2 pump, drive
15 Supplier Documentation
15.1 Truck
The operating instructions / service manual of the supplier for
the Truck can be found in their original, English version and in
paper format in the main documentation under
chapter 2 Main Parts / 2.1 Chassis.
the Truck can be found as an electronic document – in the form
of a PDF file – on the CD supplied.
If the media is inserted into a CD ROM drive, then the
instructions can be opened using this link:
Open supplier documentation for the Truck
English, Russian
15.2 Nitrogen Tank Skid

the Nitrogen Tank Skid can be found in their original, English
version and in paper format in the main documentation under
chapter 02_Main Parts\2.2_2000 Gallon Tank.
the Nitrogen Tank Skid can be found as an electronic document
– in the form of a PDF file – on the CD supplied.
instructions can be opened using this link:
Open supplier documentation for the Nitrogen Tank Skid
15.3 N2 pump, drive
15.3.1 Drive motor

The operating instructions / service manual of the manufacturer
for the component Drive motor can be found in their original

Page 171 of 182
N2 pump, drive

chapter 02_Main Parts\2.3_Deck Engine.
These documents can also be found as an electronic document
documentation can be opened using this link:
Open supplier documentation for the Drive motor.
15.3.2 Pump distributor gearbox

for the component Pump distributor gearbox can be found in
their original version and in paper format in the main
Hydraulic System Parts Manual\4.3.4 Hydraulic Pump Drive.
Open supplier documentation for the Pump distributor gearbox.
15.3.3 Hydraulic pump S90

for the component Hydraulic pump S90 can be found in their
original version and in paper format in the main documentation
under chapter 04_Hydraulic System\4.3 Hydraulic System Parts
Manual\4.3.1 Hydraulic Pump.
Open supplier documentation for the Hydraulic pump S90.

Page 172 of 182
15.3.4 Hydraulic pump S45

for the component Hydraulic pump S45 can be found in their
under chapter 04_Hydraulic System\4.3 Hydraulic System Parts
Manual\4.3.1 Hydraulic Pump.
Open supplier documentation for the Hydraulic pump S45:
15.4 N2 pump, water circuit
15.4.1 Circulation pump

for the component Circulation pump can be found in their
under chapter 07_Heating circuit\7.3 Heat Recovery Circuit
Parts Manual\7.3.5 Segmental Pump.
Open supplier documentation for the Circulation pump.
15.4.2 Charge air cooler heat exchanger

for the component Charge air cooler heat exchanger can be
found in their original version and in paper format in the main
Recovery Circuit Parts Manual\7.3.2 Hydraulic Oil Cooler.

Page 173 of 182

Open supplier documentation for the Charge air cooler heat
exchanger.
15.4.3 Plate heat exchanger

for the component Plate heat exchanger can be found in their
under chapter 07_Heating circuit\7.3 Heat Recovery Circuit
Parts Manual\7.3.3 Brazend Plate Heat Exchangers.
Open supplier documentation for the Plate heat exchanger.
15.4.4 Exhaust gas heat exchanger

for the component Exhaust gas heat exchanger can be found in
Recovery Circuit Parts Manual\7.3.1 Exhaust Gas Heat
Exchanger.
Open supplier documentation for the Exhaust gas heat
exchanger.

Page 174 of 182
15.5 N2 pump, nitrogen circuit
15.5.1 Booster pump

for the component Booster pump can be found in their original
chapter 03_Flow System\3.3_Flow System Parts Manual.
Open supplier documentation for the Booster pump
15.5.2 Triplex pump

for the component Triplex pump can be found in their original
Open supplier documentation for the Triplex pump.
15.5.3 Gearbox
for the component Gearbox can be found in their original
chapter 02_Main Parts\2.4_Triplexpump.

Page 175 of 182
Open supplier documentation for the Gearbox.
15.5.4 Hydraulic motor

for the component Hydraulic motor can be found in their original
chapter 04_Hydraulic System\4.3 Hydraulic System Parts
Manual\4.3.3 Hydraulic Motor.
Open supplier documentation for the Hydraulic motor.
15.5.5 Vaporizer
for the component Vaporizer can be found in their original
Open supplier documentation for the Vaporizer.
15.5.6 Plug valve

for the component Plug valve can be found in their original
chapter 03_Flow System\3.3_Flow System Parts Manual\3.3.5
Valves.

Page 176 of 182
Control system components

Open supplier documentation for the Plug valve.
15.6 Cabin heating

for the component Cabin heating can be found in their original
chapter 02_Main Parts\2.1_Chassis.
Open supplier documentation for the Cabin heating.
15.7 Electric components

for the component Electric components can be found in their
under chapter 05_Electric System\5.3 Electrical System Parts
Manual.
Open supplier documentation for the Electric components.
15.8 Control system components

for the component Control system components can be found in

Page 177 of 182
Control system components

System Parts Manual.
Open supplier documentation for the Control system
components.

Page 178 of 182
Annex
List of Figures
16 Annex
16.1 List of Figures
Figure 1: Side Definition ........................................................... 43
Figure 2: Off-road-truck ............................................................ 45
Figure 3: Twistlock ................................................................... 46
Figure 4: Nitrogen skid ............................................................. 47
Figure 5: Container corner with twistlock ................................. 48
Figure 6: N2 pump, frame ........................................................ 49
Figure 7: Container corner with N2 skid twistlock .................... 50
Figure 8: N2 pump, drive ......................................................... 51
Figure 9: Drive motor ............................................................... 52
Figure 10: Pump distributor gearbox ........................................ 53
Figure 11: Hydraulic pump S90 ............................................... 54
Figure 12: Hydraulic pump S45 ............................................... 55
Figure 13: Water circuit circulation pump ................................. 56
Figure 14: Heat exchanger charge air cooler ........................... 57
Figure 15: Lubrication oil heat exchanger ................................ 58
Figure 16: Hydraulic oil heat exchanger .................................. 59
Figure 17: Heat load heat exchanger ....................................... 60
Figure 18: Cooling water heat exchanger ................................ 61
Figure 19: Exhaust gas heat exchanger .................................. 62
Figure 20: Nitrogen circuit ........................................................ 64
Figure 21: Booster pump ......................................................... 65
Figure 22: Triplex assembly ..................................................... 66
Figure 23: Triplex pump ........................................................... 67
Figure 24: Vaporizer ................................................................ 68
Figure 25: Transfer interface .................................................... 69
Figure 26: Position of the auxiliary heater ................................ 70
Figure 27: Webasto storage box .............................................. 70
Figure 28: Auxiliary heater ....................................................... 71
Figure 29: Auxiliary heater switch ............................................ 72
Figure 30: Auxiliary heater manifold ........................................ 72
Figure 31: Auxiliary heater distributor supply ........................... 73
Figure 32: Connections ............................................................ 74
Figure 33: EMERGENCY STOP button ................................... 76
Figure 34: Right EMERGENCY STOP button ......................... 77
Figure 35: Left EMERGENCY STOP button ............................ 78
Figure 36: EMERGENCY STOP panel .................................... 78
Figure 37: Operator workstation .............................................. 79

Page 179 of 182
Annex
List of Figures
Figure 38: Cabin heating ......................................................... 80

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

Page 180 of 182
Annex
Table Headings
16.2 Table Headings

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

Page 181 of 182
Annex
Table Headings
Table 39: Exhaust gas heat exchanger maintenance – every 6

months................................................................................... 158
Table 40: Plate heat exchanger – as required ...................... 158

Page 182 of 182

Instructions Manual: Nitrogen Pumping Unit

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Instructions Manual: Nitrogen Pumping Unit

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2016

Nitrogen Pumping Unit

29392 Wesendorf | Germany

Nitrogen Pumping Unit Instructions Manual

3.7.6 Nitrogen ........................................................................ 36