Leutert DLE-station User manual

PVT Instrumentation
The Leutert Booster Station is used to compress nitrogen into the
sample chambers of the one phase™ samplers and cylinders to a
pressure rate above the well pressure.
Booster Station
Operating Instructions
Picture Courtesy of the Petroleum Engineering Department
at the Colorado School of Mines, Golden, CO USA

2 Friedrich Leutert GmbH & Co. KG
Booster Station - Operating Instructions
Contents
1 Basic Information...............................................................................4
1.1 Information about the Instructions............................................4
1.2 Other Applicable Documents....................................................4
1.3 Warranty and Liability ...............................................................4
1.4 Explanation of Symbols 1..........................................................5
1.5 Explanation of Symbols 2..........................................................6
2 Basic Safety Information.....................................................................7
2.1 Standards and Directives...........................................................7
2.2 Intended Use ............................................................................7
2.3 Foreseeable Misuse...................................................................7
2.4 Personal Protective Equipment..................................................7
2.5 Hazards that may emanate from the System .............................8
2.6 Basic Safety Measures.............................................................10
2.7 Requirements on Specialist Personnel...................................... 11
3 Technical Data ................................................................................. 12
3.1 Features..................................................................................12
3.2 Specifications Booster Station .................................................12
3.3 Specifications Gas Booster ......................................................13
3.4 Fluid Diagram .........................................................................14
3.5 Dimension Drawing ................................................................15
3.6 Performance Graph ................................................................16
4 Commissioning the System .............................................................. 17
4.1 Safety Guidelines....................................................................17
4.2 Requirements on the Installation Location...............................18
4.3 Minimum clearance ................................................................18
4.4 Supply lines ............................................................................18
4.5 Operating materials ................................................................19
4.5.1 Drive Fluid ..................................................................19
4.5.2 Gas Quality ................................................................19
4.6 Valve adjustment ....................................................................19
4.7 Initial start-up and re-start / operation........................................19
5 Technical Description .......................................................................20
5.1 Essential Components.............................................................20
5.2 Connections ...........................................................................20
5.3 Operator Panel .......................................................................21
5.4 Functional Description ............................................................21
5.4.1 Drive Pressure Supply..................................................21
5.4.2 Fluid Supply / Gas Supply............................................22
5.4.3 Pressure Generation ...................................................22
5.4.4 Discharging ................................................................22

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Booster Station - Operating Instructions
6 Service and Maintenance .................................................................23
6.1 Safety Information, Maintenance and Repair...........................23
6.2 Maintenance Intervals.............................................................23
7 Faults...............................................................................................24
7.1 Safety Guidelines....................................................................24
7.2 What to do in the Event of a Fault ..........................................24
7.3 What to do once the Fault has been removed.........................25
7.4 Faults, Causes and Remedies ..................................................25
7.4.1 Pressure Holding Test .................................................25
8 Spare Parts ......................................................................................26
8.1 Ordering Spare Parts...............................................................26
8.2 Returns / Complaints...............................................................26
9 Transport, Packaging and Storage ....................................................27
9.1 Transportation ........................................................................27
9.2 Packing Materials....................................................................29
9.3 Storage...................................................................................29
10 Dismantling and Disposal .................................................................30
10.1 Dismantling ............................................................................30
10.2 Waste Disposal .......................................................................30
11 Declaration of Conformity................................................................31
12 Parts List..........................................................................................32

4 Friedrich Leutert GmbH & Co. KG
Booster Station - Operating Instructions
1 Basic Information
1.1 Information about the Instructions
These instructions describe how to use the system safely and appropriately.
The safety information and instructions, as stated, must be complied
with. In addition, local occupational safety provisions and general safety
regulations apply to the area in which the system is used.
1.2 Other Applicable Documents
Components from other manufacturers are installed in the system.
These purchased assemblies have been subjected to a risk analysis by
the manufacturers. The manufacturers of the components have declared
that the designs are consistent with applicable European and national
regulations.
1.3 Warranty and Liability
In principle, the “General Terms and Conditions of Sale and Delivery”
submitted to the operating company by the manufacturer shall apply. Any
warranty and liability claims in the event of personal injury or material
damage are precluded if they are due to one or more of the following
causes:
•Improper use of the system.
•Incorrect commissioning, operation and maintenance of the system.
•Modifications of the system without the manufacturer’s prior
agreement.
•Operating the system with defective safety equipment or improperly
installed safety and protective equipment.
•Failure to comply with the information in these instructions in
respect of assembly, commissioning, operation and maintenance.
•Inadequate monitoring of system parts that are subject to wear and
tear.
•Improper repair work on the system or system parts.

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Booster Station - Operating Instructions
1.4 Explanation of Symbols 1
Important safety information is marked by means of symbols in these
instructions. This information must be observed in order to avoid personal
injuries and material damage.
WARNING! Injury hazard or life-threatening hazard!
This symbol identifies information which, if not observed, may
result in an impairment of health, injuries, permanent physical
harm or even death and/or material damage.
WARNING! Electric shock hazard!
This symbol draws attention to hazardous situations caused by
electric currents. If the safety information is not observed, there is
a risk of serious injuries or death. Any work to be performed may
be carried out only by an instructed qualified electrician.
WARNING! Hazardous substances!
This symbol indicates environmental pollution or health risks
associated with the use of hazardous substances.
WARNING! Explosion hazard!
This symbol indicates a risk in the event of use in explosive
atmospheres.
WARNING! Toxic substances!
This symbol indicates a health hazard due to toxic substances or
accumulations of gases / vapours that may lead to unconsciousness
or adverse health effects.
WARNING! Flying particle hazard!
This symbol indicates a hazard due to flying particles.
NOTE about wearing personal protective equipment!
This symbol indicates a situation in which wearing appropriate
protective equipment is necessary.
NOTE about reading the documentation and data sheets!
This symbol indicates that the enclosed documents must be read.
Reference to additional information!
This symbol refers to useful additional information.

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Booster Station - Operating Instructions
1.5 Explanation of Symbols 2
Important safety information is marked by means of symbols in these
instructions. This information must be observed in order to avoid personal
injuries and material damage.
Warning: Suspended load!
This symbol identifies a risk which, if not observed, may result in
an impairment of health, injuries, permanent physical harm or even
death and/or material damage.
Prohibition sign: No anchor points!
This symbol identifies a prohibited action which, if not observed,
may result in an impairment of health, injuries, permanent physical
harm or even death and/or material damage.
Observe advice about anchor points!
This symbol identifies information which, if not observed, may
result in an impairment of health, injuries, permanent physical
harm or even death and/or material damage.
Note: Use a stacker!
This symbol identifies information which, if not observed, may
result in an impairment of health, injuries, permanent physical
harm or even death and/or material damage.

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Booster Station - Operating Instructions
2 Basic Safety Information
2.1 Standards and Directives
The system has been built in accordance with the current state of the art
and generally accepted safety rules. In designing the system, basic safety
requirements, as well as standards and directives, have been applied
in accordance with the declaration of conformity. All safety information
is based on currently applicable regulations issued by the European
Union. Apart from the safety information provided in these instructions,
the generally accepted rules of accident prevention and environmental
protection have been observed and complied with.
2.2 Intended Use
The Booster Station is used for boosting pressure in gas systems up to max.
1,300 bar and is intended for the following fluid: Nitrogen (N2)
It is solely designed for assembly with other machines to create a complete
machine. Operational safety is guaranteed only if the system is used
appropriately.
Appropriate use also includes compliance with the operating conditions, as
well as the information contained in these instructions.
2.3 Foreseeable Misuse
The system is designed for operating fluids according to the intended use.
Compliance with these instructions must be taken into account. Using
other fluids without first consulting the manufacturer is prohibited and
may cause personal injury and material damage.
Drive pressure > 10 bar, max. 20°C (PL)
Falling below or exceeding the operating temperatures -20 °C to 60°C
2.4 Personal Protective Equipment
In line with the risk assessment, the following protective clothing must be
worn:
•Gloves and protective goggles when carrying out maintenance
activities
•Protective goggles during initial start-up and re-start operations due
to possible leaks
•Wear a helmet when lifting loads

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Booster Station - Operating Instructions
2.5 Hazards that may emanate from the System
The following section lists residual risks that may emanate from the system
even if it is used as intended.
Symbol Event Cause Note
Starting No restart protection
available
In the event of returning drive
energy (drive pressure), the
pressure generator starts to pump
and build up pressure depending
on the system configuration.
Energy supply fault
Normal stopping Primary pressure present,
or in the case of more
than one pressure
generator, the “second
stage” continues even
though the “first stage”
has been switched off.
Depending on system
configuration, the line pressure of
a mains-side fluid supply may be
present at the outlet even after
a pressure generator has been
switched off. Likewise, pressure
generators can operate in parallel,
resulting in pressure continuing
to be built up after one pressure
generator has been switched off.
Completeness of
machinery
Partly completed machinery, no interface for emergency-stop
circuit exists.
Noise No noise protection measures present; must be analyzed
during incorporation into the system as a whole (if necessary,
wear hearing protectors).
Vibrations Vibrations may occur; this must be analyzed during
incorporation into the system as a whole.
Emission of
hazardous
materials and
substances
Some hazardous
substances are present;
this must be analyzed
during incorporation into
the system as a whole.
Hazardous substances can also
be pumped depending on the unit
configuration.
Isolation of energy
sources
Primary pressure still
present
Pressure may be present at
the unit’s inlet, depending on
configuration.
Explosion Implementation
according to ATEX
Only systems with corresponding
labelling and with an enclosed
declaration of conformity in
compliance with the ATEX
Directive have been implemented
appropriately.

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Booster Station - Operating Instructions
Symbol Note
Pneumatic and hydraulic energy can cause serious injuries.
If individual components are damaged, highly pressurized fluids may escape and
result in physical injury and/or material damage:
• Depressurize the system before beginning any work.
• Do not remove, modify or deactivate safety equipment.
• Do not modify pressure settings beyond the max. values indicated.
Flying particle hazard!
The system can be used to generate very high pressures. Therefore only use
attachment parts (adapters, hoses etc.) that have been approved for these pressure
ranges.
Asphyxiation hazard!
Nitrogen as a drive fluid displaces oxygen! When using nitrogen, ensure that there
is sufficient ventilation.

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Booster Station - Operating Instructions
2.6 Basic Safety Measures
The following basic safety measures must be complied with:
•The system may be used only as intended.
•All safety information contained in these instructions and in all other
documentation must be observed and complied with.
•The system may be assembled, operated and serviced only by
trained and instructed specialist personnel. The specialist personnel
must have read and understood the instructions. This includes,
in particular, knowledge about how to avert risks of injury to the
operator and third parties.
•No unauthorized persons may have access to the system.
•All safety information contained in these operating instructions and
in all other documentation must be observed and complied with.
•Outages and adverse environmental impact due to incorrect
handling must be precluded.
•Basic specific protection measures for handling hazardous or
environmentally harmful fluids must be observed.
•The operating company must take steps to ensure compliance with
the occupational safety provisions in terms of oil and grease content
in released compressed air / drive fluid.
•All work on the system must be carried out carefully and with safety
in mind.
•The relevant regulations on occupational safety and environmental
protection must be observed during transportation, assembly and
dismantling, operation, maintenance and service work.
•Spare parts must always be obtained from LEUTERT. LEUTERT
accepts no liability for damage resulting from the use of spare parts
supplied by other manufacturers.