Rejuvenation Instructions #402 Air Systems iupr & SPR Trademarks: http://www.novinium.com/trademarks/ Patents: http://www.novinium.com/patents/ This NRI covers the following: Novinium, Inc. engineering@novinium.com 22820 Russell Rd Kent, WA 98032 Revised: January 12, 2018 (253) 395-0200 How to refill Compact CO 2 kits. How to transport, secure and connect the regulator to large CO 2 cylinders. Understand the types of Flow Test Equipment that will be used to test cables for flow prior to injection WARNING: It is dangerous working around energized high-voltage systems, pressurized systems, and chemicals. Always work in accordance to the Novinium Field Operations Safety Handbook (FOSH) or other local governing safety standards.
Table of Contents CO 2 Tanks... 3 1. Compact CO 2 kit iupr.... 3 2. Refilling the compact CO 2 kit.... 3 3. Large CO 2 cylinders.... 7 4. Transporting large compressed gas and CO 2 tanks... 8 5. Securing compressed gas and CO 2 tanks during injection.... 9 6. Connecting a CO 2 regulator.... 10 Flow Test Equipment... 11 1. Air flow meters.... 11 2. Cable test adapters (CTAs)... 11 Air Driven Equipment... 13 1. Enerpac Pumps... 13 Revised: January 12, 2018 Page 2 of 13
CO 2 Tanks 1. Compact CO 2 kit iupr. The compact CO 2 kit is used in conjunction with the UP1.5L tank during iupr injection. The kit supplies up to 12 oz. of CO 2 to be left with the feed tank during the injection. This amount of CO 2 should be sufficient for the majority of injections required. The CO 2 comes with a regulator to set the output pressure. Novinium-made dual stage regulators also have a gauge showing the remaining pressure in the tank. If the CO 2 tank ever runs out, it can be refilled using the CO 2 refill kit. Figure 1: Compact CO 2 kit (left) and refill kit (right). 2. Refilling the compact CO 2 kit. a. Insert the CO 2 washer into the Ninja Tool. Figure 3: Insert the CO 2 washer. b. Attach the Ninja Tool to the source tank. Make sure that the washer does not fall out. Figure 4: Attach the Ninja Tool to the tank. c. Turn the bottle clockwise to attach the Ninja Tool to the CO 2 bottle. Revised: January 12, 2018 Page 3 of 13
Figure 5: Tighten the Ninja Tool onto the CO 2 bottle. d. Turn the Ninja Tool s bleed valve clockwise to close it. Figure 6: Close the bleed valve. e. Turn the knob on the CO 2 bottle counter-clockwise to close the Ninja Tool. Figure 7: Close the Ninja Tool. f. Tilt the source tank on its side. Prevent the tank from rolling. This transfers liquid CO 2 into the bottle. Figure 8: Lay the source tank on its side. g. Turn the knob on the bottle clockwise to open the Ninja Tool. Revised: January 12, 2018 Page 4 of 13
Figure 9: Open the Ninja Tool. h. Open the source tank by turning its knob counter-clockwise to start filling. Figure 10: Open the source tank to transfer liquid CO 2. i. j. Place the CO 2 bottle below the source tank. Let the bottle fill for three minutes, letting the pressure equalize. Figure 11: CO 2 bottle needs to be lower than the source tank. k. l. Turn the source tank s knob clockwise to close. Turn the Ninja Tool s knob counter-clockwise to close. Revised: January 12, 2018 Page 5 of 13
Figure 12: Close all valves. m. Turn the bleed valve counter-clockwise to vent trapped gas in the line. Figure 13: Open the bleed valve. n. Turn the CO 2 bottle counter-clockwise to detach from the Ninja Tool. Figure 14: Unscrew the CO 2 bottle. Revised: January 12, 2018 Page 6 of 13
o. When finished, remove the Ninja Tool from the source tank. Be sure to remove and keep the CO 2 washer. 3. Large CO 2 cylinders. Figure 15: Remove Ninja Tool from source tank and store CO 2 washer. CO 2 gas has many purposes within the iupr and SPR processes: Flow and pressure tests of the cable and components. The driving force behind injection. Drives the swaging and lug-splitting equipment. Purges air from an opened pail for resealing. Figure 16: CO 2 cylinders. Revised: January 12, 2018 Page 7 of 13
4. Transporting large compressed gas and CO 2 tanks. Refer to the Compressed Gas Cylinder Safety section in Chapter 5 of the FOSH. Carefully handle and store compressed gas and CO 2 cylinders to avoid damage. When storing or transporting containers that are under pressure, always secure them using nylon, metal straps, or chains in an upright position. Remove the regulators and put safety caps in place, if it has provisions for a cap. Figure 17: 20 pound cylinders secured for transportation with metal bands and nylon straps Figure 18: Cylinder with protective safety cap installed. Revised: January 12, 2018 Page 8 of 13
5. Securing compressed gas and CO 2 tanks during injection. An unsecured CO 2 cylinder is a potential hazard, as it can tip over and rupture if bumped into or pulled. Observe all local requirements when securing compressed gas cylinders. Some possible ideas to accomplish this: Secure the cylinders in the vehicle and run an air hose to the injection equipment. Figure 20: Secured in bay with hose on regulator. Figure 19: Secured tank with coil for easy storage and management of hose length. Figure 21: Clamps secure the tank for injection. Construct a wheeled cart that holds the injection tanks and CO 2 cylinder. Figure 22: Tank secured to back of injection cart. Lash the CO 2 cylinder to a solid fixture, like the transformer box or utility pole, with nylon straps. Revised: January 12, 2018 Page 9 of 13
6. Connecting a CO 2 regulator. a. Insert the CO 2 washer into the regulator s fitting. Figure 23: Insert CO 2 washer into regulator s fitting. b. Thread the regulator s fitting, along with the CO 2 washer, onto the threading of the CO 2 cylinder. c. Tighten the regulator to the CO 2 tank with a wrench. Figure 24: Thread the fitting onto the cylinder. Be careful not to over-tighten the fitting. Figure 25: Tighten the fitting with a wrench. Revised: January 12, 2018 Page 10 of 13
Flow Test Equipment 1. Air flow meters. The air flow meter is used during flow and pressure tests, typically with the cable test adapter (CTA). The meter s needle valve enables setting of specific flow rates. This is useful for flow tests. Setting the push flow meter at a maximum of 50 cc/min allows easy calculation of the cable s pneumatic resistance by reading the outlet flow. Do not use fluids with the flow meter. Fluids can degrade the meter s seals. The glass tube is rated for pressures up to 200psi, which exceeds typical operation ranges. Air flow meter should be kept upright when taking readings. Figure 26: Air flow meter. 2. Cable test adapters (CTAs). Cable test adapters (CTAs) are commonly used with the air flow meters to determine if a cable is unblocked. They are also used to test whether splices in the cable can withstand the pressures of injection. There are many different sizes of CTAs to accommodate the various sizes of cables encountered. Use the tightest fitting CTA when doing a flow and pressure test of cable, components, and accessories. When using the CTA for flow and pressure testing, secure the CTA to the cable or item being tested to prevent the CTA from popping off and potentially injuring someone. a. Attach an air flow meter to the CTA by using zip ties. There are two CTA assemblies: The push assembly and the catch assembly. Figure 27: Generic CTA assembly. Revised: January 12, 2018 Page 11 of 13
b. Build the CTA push assembly by connecting: The flow meter s outlet to the CTA. The flow meter s inlet to the inline gauge/co 2 tank. Figure 28: The push CTA assembly. c. Build the CTA catch assembly by connecting: The flow meter s inlet to the CTA. The flow meter s outlet is open to the air. d. Connect an inline gauge and a ¼ by 1/8 tubing ball valve together. Figure 29: The catch CTA assembly. Figure 30: Inline gauge to verify pressure output from CO 2 tank. Using an inline gauge helps verify the output pressure from the connected CO 2 tank. e. Connect the inline gauge to the push CTA assembly s inlet. f. The CTA assemblies are now ready for use. Revised: January 12, 2018 Page 12 of 13
Air Driven Equipment 1. Enerpac Pumps. The Enerpac Pump is one piece in the swaging operation for SPR craftwork. It is a pneumatic to hydraulic pump driven by CO 2 and is able to run the swage press for installing IAs and swaging connectors to create a good electrical connection. Output of the pump is up to 10,000 psi. The pump has an inlet working pressure range of 60 to 120 psi. Over pressurizing the pump will cause damage to the internal diaphragm. The inlet pressure should be set to 100 psi. Figure 31: The Enerpac pump. Revised: January 12, 2018 Page 13 of 13