6 - Nitrogen Pumping

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<ul><li><p>Italfluid Egypt ConfidentialNitrogen Pumping</p><p>INTRODUCTION TONITROGENPUMPING</p></li><li><p>Italfluid Egypt ConfidentialNitrogen Pumping</p><p>Overview</p><p> Nitrogen characteristics</p><p> Nitrogen pumping unit - Operating instructions and main components</p><p>- Operations (Tanks filling, Assembly and Tests, Cool-down, Pumping)</p><p> Main applications in oilfield:- Pressurizations, Replacement/Purging, Gas lift</p></li><li><p>Italfluid Egypt ConfidentialNitrogen Pumping</p><p>Nitrogen characteristicsNitrogen:Nitrogen: odourless, colourless, and inert gas, present in nature at elementary </p><p>state; indeed it constitutes 78% of the earth atmosphere in wich molecule N2 can be found.</p><p>Chemical symbol NAtomic number 7Atomic weight 14,007Fusion temperature -210 CBoilling temperature -196 CGas density 1,251 Kg/m3</p><p>Liquid density 808,2 Kg/m3</p><p>Critical temperature 126,1K (-147,1C)Critical pressure 34,6 bar</p></li><li><p>Italfluid Egypt ConfidentialNitrogen Pumping</p><p> Industrially, nitrogen is prepared through fractioned distillation of liquid air</p><p>Nitrogen characteristics</p><p> On the market, nitrogen can be found in: Gaseous state, stored inside gas-cylinders with pressure of 150-200 bar Liquid state, stored in boiling state, inside special thermal insulated tanks at </p><p>-196C with pressure of 3 bar</p></li><li><p>Italfluid Egypt ConfidentialNitrogen Pumping</p><p>Nitrogen pumping unit</p><p>Nitrogen PumpNitrogen Pump</p><p>Nitrogen TankNitrogen Tank</p><p>Pipes and componentsPipes and components</p><p>Operating instructions and main component</p></li><li><p>Italfluid Egypt ConfidentialNitrogen Pumping</p><p>Nitrogen pumping unitOperating instructions and main component</p><p>Cryogenic unit which pumps liquid nitrogen at very low temperature (-196C) and pressures up to 10000 psi, and coverts it into a gas (max 70C) by means of vaporizer</p><p>Nitrogen pumpNitrogen pump</p><p>Operating instructions:</p><p>Main components:</p><p> Engine / Transmission</p><p> Return and suction manifold section - Liquid nitrogen suction line system - Tanks return line system</p><p> Triplex pump section - Cold ends - Warm end</p><p> Intake manifold section (high pressure line system) - Liquid nitrogen high pressure line system - Vaporizer - Gaseous nitrogen high pressure line system</p><p> Coolant circuit (water brake)</p><p>Nitrogen pumpNitrogen pump</p></li><li><p>Italfluid Egypt ConfidentialNitrogen Pumping</p><p>Nitrogen pumpNitrogen pump</p><p>Nitrogen pumping unitOperating instructions and main component</p></li><li><p>Italfluid Egypt ConfidentialNitrogen Pumping</p><p>Nitrogen pumping unitOperating instructions and main component</p><p>Engine / TransmissionEngine / Transmission It supplies the necessary power for the movement of the triplex pump, and to carry out additional functions</p><p> It is directly connected to the waterbrake and different hydraulic pumps</p><p> Hydraulic pumps supply power to the hydraulic engines of the circuits of the triplex pump, centrifugal pump, coolant and lubrication</p><p> It is equipped with air start-up</p><p> The compressor, activated by diesel engine, keeps the pressure of the air circuit around 8 bar</p><p>Main components</p><p>Nitrogen pumpNitrogen pump</p></li><li><p>Italfluid Egypt ConfidentialNitrogen Pumping</p><p>Nitrogen pumping unitOperating instructions and main component</p><p>Return and suction manifold sectionReturn and suction manifold section(Low pressure line system)(Low pressure line system)</p><p> A line is present at the outlet side of the centrifugal pump (centrifugal pump's recirculation) which by-passes the triplex pump for the recirculation of the liquid nitrogen inside the tank during the cool-down phase</p><p> It is connected to the intake line of the nitrogen tank through cryogenic flexible pipes</p><p> Liquid nitrogen suction line system:</p><p> It supplies liquid nitrogen to the triplex pump with a pressure of 40-100 psi</p><p> A centrifugal pump (boost pump) is installed on the line, in order to bring the liquid nitrogen from the pressure outgoing from the tank (generally 10-20 psi) to that entering the triplex pump (40-100 psi)</p><p> Nitrogen pumps are usually equipped with a by-pass line of the boost pump</p><p>Main components</p><p>Nitrogen pumpNitrogen pump</p></li><li><p>Italfluid Egypt ConfidentialNitrogen Pumping</p><p>Nitrogen pumping unitOperating instructions and main component</p><p>Return and suction manifold sectionReturn and suction manifold section(Low pressure line system)(Low pressure line system)</p><p> It is connected to the nitrogen tanks return line through cryogenic flexible pipes</p><p> Tanks return line system:</p><p> It allows the return of non-pumped liquid nitrogen inside the tank</p><p> A quick cool-down line is installed on the line to fill the pump</p><p> A line is installed on the outlet of triplex pump for the recirculation of liquid nitrogen during cool-down phase</p><p>Main components</p><p>Nitrogen pumpNitrogen pump</p></li><li><p>Italfluid Egypt ConfidentialNitrogen Pumping</p><p>Nitrogen pumping unitOperating instructions and main component</p><p>Triplex pump sectionTriplex pump section</p><p>Those are pistons that suck liquid nitrogen with low pressure and discharge liquid </p><p>nitrogen with high pressure. The cold ends are connected and guided by the warm end</p><p> Cold ends:</p><p> It is a 3-piston pump, whose task is to increase the pressure of liquid nitrogen until a maximum operating pressure of 10000 psi</p><p> It is enabled through the hydraulic transmission: the diesel engine enables a pump with variable displacement which convoys the oil under pressure to the engine with fixed displacement</p><p> The speed of the triplex pump (and therefore the nitrogen output) is regulated by changing the displacement of the pump with variable displacement</p><p>It is made up by the following parts:</p><p> Warm ends:</p><p>It is the section that guides the cold end</p><p>Main components</p><p>Nitrogen pumpNitrogen pump</p></li><li><p>Italfluid Egypt ConfidentialNitrogen Pumping</p><p>Nitrogen pumping unitOperating instructions and main component</p><p>Intake manifold sectionIntake manifold section(High pressure line system)(High pressure line system)</p><p>It is constituted by lines outgoing from the triplex pumps cold ends (intake lines)</p><p>Liquid nitrogen high pressure line systemIt is the line section that connects the cold ends to the vaporizer; the nitrogen that flows inside is pressurized but still at liquid state</p><p>Main components</p><p>It is made up by the following parts:</p><p>Gaseous nitrogen high pressure line system</p><p> Vaporizer</p><p>It is that line section outgoing from the vaporizer; the nitrogen that flows is pressurized and at gaseous state, ready to be pumped; a plug valve (hydraulically actuated) is installed at the end of this line</p><p>It is a particular heat exchanger, constituted by a cylindrical chamber filled up by a pipe bundle inside of which liquid nitrogen flows. The coolant fills the chamber and flows around the coiled tubes at a pressure of 80-150 psi. When the liquid nitrogen (-196C) circulates through the coil, it changes into gaseous state.</p><p>Nitrogen pumpNitrogen pump</p></li><li><p>Italfluid Egypt ConfidentialNitrogen Pumping</p><p>Nitrogen pumping unitOperating instructions and main component</p><p>Intake manifold sectionIntake manifold section(High pressure line system)(High pressure line system)</p><p>Main components</p><p> The temperature of gaseous nitrogen is controlled by the coolant's output and temperature. The gas temperature is kept between 60 and 70F (15-20C). The temperature of the coolants circuit is controlled manually to keep the vaporizers temperature constant between 100 and 120F (38-49C).</p><p> The output of the outgoing gas is measured in scfm (standard cubic feet per minute) or in Nm3/min (normal cubic metres per minute)</p><p> A line is present at the cold ends outlet which allows the liquid nitrogen, by opening a proper valve (tempering valvetempering valve), to by-pass the vaporizer and convoy liquid nitrogen inside the line (to use only in case of extreme need to rapidly cool the out flowing nitrogen) </p><p> Another line, always mounted at the outlet of the cool ends, allows to re-circulate the liquid nitrogen inside the tanks by opening a specific valve (prime valveprime valve) during the cool-down operation</p><p>Nitrogen pumpNitrogen pump</p></li><li><p>Italfluid Egypt ConfidentialNitrogen Pumping</p><p>Nitrogen pumpNitrogen pump</p><p>Nitrogen pumping unitOperating instructions and main component</p></li><li><p>Italfluid Egypt ConfidentialNitrogen Pumping</p><p>Nitrogen pumping unitOperating instructions and main component</p><p>Coolant circuitCoolant circuit</p><p>Main components</p><p>It is a water-glycol recirculation system that supplies (through thermal exchange with the vaporizer) the heat needed to cause the evaporation of the liquid nitrogen. The circulation of fluid inside the circuit takes place through a water pump enabled by a hydraulic engine.</p><p>The coolant (water-glycol) draws heat from the following sources:</p><p>WaterbrakeHydraulic circuit</p><p>Lubrication circuits of </p><p>triplex pump, etc.</p><p>Engines cooling circuitIt is a hydraulic brake assembled on an axis of the engines power take-off.By sending liquid to the waterbrake, the engine goes under load, and in this way, the engines power is converted in heat.</p><p>The coolant, flows through the coolant/hydraulic oil heat exchanger, from which it draws heat. In a cold environment, a reverse thermal exchange is possible: the coolant, heated up by the waterbrake, transfers heat to the hydraulic oil; this allows a quicker heating up of the unit.</p><p>The exchange between the two circuits takes place through a heat exchanger.Some thermostatic valves regulate the engines operating temperature so as to keep it constant within a range of 60-70C.</p><p>Nitrogen pumpNitrogen pump</p></li><li><p>Italfluid Egypt ConfidentialNitrogen Pumping</p><p>1) Registratore a carta2) Temperatura olio triplex3) Pressione olio triplex4) Portata azoto5) Pressione idraulica pompa cilindrata variabile6) Comando velocit pompa triplex7) Pressione sovralim. Pompa cilindrata variabile8) Giri pompa triplex9) Arresto di emergenza motore10) Arresto motore11) Giri motore12) Accensione motore13) Pressione olio motore14) Acceleratore motore15) Pressione aria16) Temperatura acqua motore17) Temperatura coolant18) Pressione motore centrifuga19) Controllo velocit centrifuga20) Pump saver21) Pressione mandata centrifuga22) Temperatura azoto in uscita23) Pressione azoto in uscita24) Pulsante di attivazione valvola pneumatica25) Selettore posizione valvola pneumatica26) Temperatura freno idraulico</p><p>1</p><p>2</p><p>3</p><p>4</p><p>5 6 7 8 9 10 11 12 13 14 15</p><p>16</p><p>21</p><p>192017</p><p>18</p><p>22</p><p>2324</p><p>26</p><p>25</p><p>Nitrogen pumping unitOperating instructions and main component</p><p>Control panelControl panel</p><p>Nitrogen pumpNitrogen pump</p></li><li><p>Italfluid Egypt ConfidentialNitrogen Pumping</p><p>Nitrogen pumpNitrogen pump</p><p>Nitrogen pumping unitOperating instructions and main component</p></li><li><p>Italfluid Egypt ConfidentialNitrogen Pumping</p><p>Nitrogen pumping unitOperating instructions and main component</p><p>Nitrogen pumping linesNitrogen pumping lines1 - DYNAMOMETERS PRESSURE VALVE:It regulates the pressure of the liquid flowing to the water-brake</p><p>2 - VAPORIZERS BY-PASS VALVE (TEMPERING VALVE):It opens the vaporizers by-pass valve (N.B.: this manoeuvre can considerably and dangerously cool down the outgoing nitrogens temperature).</p><p>3 - HIGH PRESSURE NITROGEN RECIRCULATION VALVE (PRIME VALVE): It opens the recirculation line, from the cold ends' outlets to the tank's return line</p><p>5 - NITROGEN TANK RETURN VALVE</p><p>8 - QUICK COOL-DOWN VALVE</p><p>10 - BOOST PUMP BY-PASS VALVE</p><p>6 - TRIPLEX BY-PASS VALVE</p><p>7 - CENTRIFUGAL VALVE</p><p>9 - NITROGEN INTAKE VALVE</p><p>13 - PLUG VALVE HYDRAULIC ACTUATED</p><p>11 - BOOST PUMP</p><p>12 - VAPORIZER</p><p>4 - NITROGEN RECIRCULATION VALVE</p><p>13131111 1212</p><p>77</p><p>88</p><p>99</p><p>1010</p><p>6655</p><p>3344</p><p>22</p><p>11</p><p>Nitrogen pumpNitrogen pump</p></li><li><p>Italfluid Egypt ConfidentialNitrogen Pumping</p><p>Nitrogen pumpNitrogen pump</p><p>Nitrogen pumping unitOperating instructions and main component</p></li><li><p>Italfluid Egypt ConfidentialNitrogen Pumping</p><p>Nitrogen pumping unitOperating instructions and main component</p><p>Nitrogen tankNitrogen tank</p><p>Nitrogen tankNitrogen tank</p><p> They are equipped with instruments (cryogenic valves, gauges) and with a very sturdy frame which has a protection role during transports and loading/unloading operations.</p><p> The tanks are used to store and transport nitrogen, which is conveniently kept in refrigerated liquid state (at -196C)</p><p> The generally used tanks have a capacity of about 8000 liters (about 2000 gal)</p><p> They are made up by an internal stainless steel shell, which contains the liquid. The shell is covered by an interspace which is filled with insulating material (perlite) in which vacuum is created. The external shell is carbon steel made</p></li><li><p>Italfluid Egypt ConfidentialNitrogen Pumping</p><p>Nitrogen tankNitrogen tank</p><p>Nitrogen pumping unitOperating instructions and main component</p></li><li><p>Italfluid Egypt ConfidentialNitrogen Pumping</p><p>Nitrogen pumping unitOperating instructions and main component</p><p>Nitrogen tankNitrogen tank(Components)(Components)</p><p>Nitrogen tankNitrogen tank</p><p>1 LEVEL INDICATOR:It indicates the level of the liquid nitrogen inside the tank2 PRESSURE GAUGE:It indicates the tanks internal pressure3 GASEOUS PHASE VALVE:It opens the inlet of the differential-meter connected to the gaseous phase</p><p>5 EQUALIZER VALVE:It connects the liquid phase valve and the gaseous phase valve</p><p>8 SAFETY VALVE 3 barSafety valves that open up when the pressure reaches 3-6 bar</p><p>10 RELIEF EXCLUSION VALVEIt stops the exhaust of pressure through a relief valve</p><p>6 VACUUM BREAK DISC:Disc located on the tanks exterior surface and kept in position by the vacuum inside the interspace of the same tank7 VACUUM PUMPS FITTING</p><p>9 TRANSPORT RELIEF VALVEValve that must be always kept operating during transport or parking while it must be closed during operations; it opens up when the internal pressure reaches 1.7 bar</p><p>13 CHECK VALVE</p><p>11 BLEED-OFF VALVEvalve used to manually exhaust the internal pressure12 OVER FLOW VALVEIt must always be kept open during fill up operations. it indicates the filling up level of about 80% of tank when the liquid overflows</p><p>4 LIQUID PHASE VALVE:It opens the inlet of the differential-meter connected to the liquid phase</p><p>1313</p><p>1111</p><p>1212</p><p>77 88 99</p><p>101066</p><p>55</p><p>33</p><p>44</p><p>22</p><p>11</p><p>88</p></li><li><p>Italfluid Egypt ConfidentialNitrogen Pumping</p><p>Nitrogen pumping unitOperating instructions and main component</p><p>Nitrogen tankNitrogen tank(Components)(Components)</p><p>Nitrogen tankNitrogen tank</p><p>1313</p><p>1111</p><p>1212</p><p>77 88 99</p><p>101066</p><p>55</p><p>33</p><p>44</p><p>22</p><p>11</p><p>8816 RETURN SHUT-OFF VALVE:Valve on the tanks return line that must be kept open during operations</p><p>1616</p><p>17 INTAKE SHUT-OFF VALVE:Valve on the pumps intake line that must be kept open during operations</p><p>1717</p><p>14 FILTER</p><p>1414</p><p>15 INTAKE VALVE</p><p>1515</p><p>18 SAFETY VALVE 10 bar:Valves located on the lines, which open up when the pressure reaches 10 bar.</p><p>1818</p><p>1818</p><p>19 REAR FILLING VALVE:Valve for the shut-off of the rear tanks filling </p><p>line</p><p>1919</p><p>20 DRAINING VALVE:Valve that allows to exhaust the lines pressure prior to remove the flexiblegrinding wheel.</p><p>202021 PRESSURIZATION VALVE:Valve that, once open, convoys liquid nitrogen to the vaporizer</p><p>212122 VAPORIZER</p><p>2222</p></li><li><p>Italfluid Egypt ConfidentialNitrogen Pumping</p><p>Nitrogen pumping unitOperating instructions and main component</p><p>Pipes and componentsPipes and components Pumping lines components (pup joints, valves, tee, elbows, cross-over, etc.) must be manufactured for 10000 psi w.p., and they must have weco fig. 1502...</p></li></ul>