Plug Valves - Weir In Action
Contents
1. Release Date 6 30 2014 SPM OIL amp GAS Revision B SPM 3 and 4 Plug Valves SPM three inch and four inch plug valves are available in pressure ratings to 15 000 psi NSCWP Features include a flanged body for easier maintenance integral inlets and outlets hand crank locked open and shut gear drive standard and multiple lubricating inlets Standard service and sour gas service models are available Characteristics e Low operating torque due to balanced stem makes valve easier to operate e Flanged body for easier maintenance e Integral inlets and outlets are standard Quality components throughout unit including forged steel body e Hand crank and locked open and shut gear drive is standard e Hydraulic and pneumatic actuators with either a 12 volt power system or hand operated hydraulic pump are optional e New manual actuated design now available e Cylindrical balanced plug utilizes sealing segments to permit easier operation under pressure and assure positive seal e Flanged body construction for safer operation and easier maintenance e No adjustments or special tools needed for maintenance or operation e Visible quarter turn stop indicates when the valve is open or fully closed EIL L 7 L TN Document P N 2P36784 9 Release Date 6 30 2014 SPM OIL amp GAS Revision B End Connection Options The SPM Plug Valve family is available with2. Document P N 2P36784 SPMP Release Date 6 30 2014 Revision B Using the grease gun pump the lever in order to push the grease into the valve Val Tex 972 SPM Part Number P32553 stick grease is recommended Caution Do NOT mix greases between different manufacturers Alternatively use a heavy duty pneumatic grease gun 5 P28682 4 Keep pumping the grease gun until you can see the grease expanding around the plug Inject a minimum of 6 000 psi to insure proper filling of valve gauge reading on pneumatic grease qun 5 Visually inspect inside the valve to ensure the grease is extracting around the sides of the plug NOTE Use extreme caution when inspecting the interior portion of the valve for grease is under high pressure 21 Document P N 2P36784 ess Release Date 6 30 2014 SPM OIL amp GAS Revision 6 Close the valve and reopen it NOTE Air will be heard popping during opening and closing and allow more complete filling of grease in the valve assembly Repeat the above grease process two more times to insure complete valve filling while maintaining the 6000 psi pressure 22 Document P N 2P36784 a Release Date 6 30 2014 SPM OIL amp GAS Revision B BOM Table ENIENNEETTNNLIIO e X 8 2 Pi2850 Sea 27 O 9 2 3P12840 BakupRing o OZ o o 23 Exploded View Document P N 2P36784 59 Releas
3. Excellent SPM Oil amp Gas Well Service Pumps amp Flow Control Products Solutions Plug Valves Operation Instruction and Service Manual OIL amp GAS Document P N 2P36784 Release Date 6 30 2014 Revision Copyright 2014 S P M Flow Control Inc All rights reserved S P M Flow Control Inc is the owner of the copyright and all confidential information in this document which must not be copied in whole or in part in any form or by any means and the information in it must not be used for any purpose other than the specific purpose for which it has been provided without the prior written consent of the copyright owner SPM SAFETY IRON SAFETY HAMMER SUR DROP DESTINY STAMPEDE VERIBAND DURALAST and GLADIATOR are trademarks and or registered trademarks of S P M Flow Control Inc WEIR is a trademark and or registered trademark of Weir Engineering Services Limited Certain features of some of the products disclosed in this document may be protected worldwide by patents pending and registered in the name of S P M Flow Control Inc Document P N 2P36784 Release Date 6 30 2014 We SPM OIL amp GAS Revision B THE FOLLOWING ICONS DENOTE IMPORTANT INFORMATION WITHIN THIS MANUAL GENERAL INFORMATION INSTALLATION AND OPERATION MAINTENANCE AND REPAIR SALES AND SUPPORT e CAUTION WARNING DANGER Document P N 2P36784 ERN e
4. Bernard Rd Broussard LA 70518 Mailing PO Box 82099 Lafayette LA 70508 Ph 1 337 837 3161 Fax 1 337 839 1985 Pleasanton TX Service Center 772 HWY 281 South Pleasanton TX 78064 Ph 1 830 569 3571 Fax 1 830 569 3643 MID CONTINENT Bossier City LA Service Center 2403 Grimmett Dr Shreveport LA 71107 Ph 1 318 677 2422 Fax 1 318 677 5385 Elk City OK Service Center 2111 S Main Elk City OK 73648 Ph 1 580 225 2385 Fax 1 580 225 3402 Fort Worth TX Service Center 7711 Wyatt Dr Ft Worth TX 76108 Ph 1 817 935 7900 Fax 1 817 246 3970 Kilgore TX Service Center 1102 State Hwy 31W Kilgore TX 75662 Ph 1 903 984 8153 Fax 1 903 984 8626 Searcy AR Service Center Searcy AR 72143 Ph 1 501 305 3296 Fax 1 501 305 3419 PERMIAN Odessa TX Service Center 2424 E 1 20 Odessa TX 79766 Ph 1 432 580 3887 Fax 1 432 333 1351 NORTH EAST Blairsville PA Service Center 1519 Route 22 Hwy East Blairsville PA 15717 Ph 1 724 459 4770 Fax 1 724 459 4771 Buckhannon WV Service Center 52 Norwins Drive Buckhannon WV 26201 Ph 1 304 472 9701 Fax 1 304 472 91 30 Horseheads NY Service Center 36 Level Acres Dr Horseheads NY 14845 Ph 1 607 739 1215 Fax 1 607 739 1314 Williamsport PA Service Center 76 Odell Road Muncy PA 17756 Ph 1 570 546 1005 Fax 1 570 546 2033 ROCKIES Fort Lupton CO Service Center 1
5. amp GAS Revision B Product Description SPM Plug Valves are designed to regulate the transport of fluid through a flow line By rotating the plug 90 the flow can either be terminated or allowed to flow through the Plug Valve Bore They require minimum Space are simple to operate exhibit a fast response and add relatively little internal disturbance to the flow Therefore pressure drop across the valve is low The valves are intended for both onshore and offshore use Onshore the plug valves are used in connection with mobile pumping service units used to kill wells cement wells acidize and fracture wells They are also used in hydraulic lines to control wellhead protector tools The lists of applications are lengthy Offshore the valves are used on stimulation vessels in a number of applications They are used in essentially permanent installations in pump rooms to Isolate the discharges of the triplex pumps used in fracturing wells They have also been used in choke and kill manifold systems Operation is accomplished by a 90 rotation of the plug This can be performed manually or with pneumatic or hydraulic actuators All SPM Plug Valves are in compliance with the following regulations e Pressure Equipment Directive 97 23 EC e U K DEN SI 289 e Det Norske Veritas Rules of Classification of Mobile Offshore Units e API 6A 16C Approved e NACE MRO175 09 H2S Exposure WARNING OBSERVE ALL INSTRUCTIONS CAUTIONS
6. the application of this product subjects it to handling fluids which are by their very nature corrosive and abrasive These fluids operate at high velocities and usually at high pressures Some fluids may also require being conveyed at elevated temperatures Combinations of any and all of these conditions will speed up the deterioration of internal surfaces including seals and seal surfaces Without the benefit of scheduled maintenance to routinely service and inspect the condition of components premature failure of parts can occur This can lead to unnecessary material replacement along with the danger of injury to personnel Proper knowledge and application of the plug valve is necessary for safe operation It is recommended that a routine maintenance program include at the very least 1 Inspection of wall thickness loss 2 Routine replacement of o rings and seals 3 Scheduled greasing of the Plug Valve after every fracturing job with recommended lubricants e Val Tex 1502 Temp Range 20F to 400F SPM P N P36791 e Val Tex 972 Temp Range 20F to 600F SPM P N P32553 Do not mix Assembly Greases This will increase the amount of friction between internal components of the valve Contact Weir Oil amp Gas Engineering for other approved grease Frequent greasing will prevent the voids from occurring and will ensure easy operation of the valve Please reference Recommended Greasing Procedure on Page 20 Once the plug valve b
7. CAUSE SERIOUS INJURY OR DEATH ALWAYS REMEMBER 1 DISASSEMBLY UNDER PRESSURE CAN CAUSE SERIOUS INJURY OR DEATH 2 Clean all components thoroughly prior to reassembly using protective clothing and safety glasses wear appropriate PPE 3 Check sealing areas of segments plug and body for pitting or erosion Failure in sealing can result if these areas are not smooth 4 Reassemble with quality valve assembly grease 5 Use seal segments in pairs from the same manufacturer 6 Use only SPM body caps and actuator caps with SPM valves Pressure test in accordance with instructions given in every repair kit prior to putting the valve into service 8 Flush and grease valve thoroughly after each use Required Tools 400 Grit Sandpaper Soft Face Mallet Grease Gun SPM P13335 Val Tex 1502 Temp Range 20F to 400F SPM P N P36791 For Re greasing Val Tex 972 Temp Range 20F to 600F SPM P N P32553 For assembly Appropriate PPE for your company Safety Glasses Steel Toe Boots Gloves Protective Clothing Special tool for specific SPM valve size Body Cap Wrench 1 valve SPM 2P12258 2 valve SPM 2P12259 3 valve 3 4 inch allen wrench QUUM ee D I 17 Document P N 2P36784 Release Date 6 30 2014 SPM OIL amp GAS Revision B Maintenance Requirements SPM s Plug Valves are made from high quality materials selected to provide the best service to the customer However
8. Release Date 6 30 2014 SPM OIL amp GAS Revision B WARNING IMPORTANT SAFETY INFORMATION ENCLOSED READ THIS OPERATING AND MAINTENANCE INSTRUCTIONS MANUAL BEFORE OPERATING PRODUCT WARNING THIS INFORMATION MUST BE AVAILABLE TO ALL PERSONNEL THAT WILL OPERATE AND MAINTAIN EQUIPMENT FAILURE TO READ UNDERSTAND AND FOLLOW THE OPERATING AND MAINTENANCE INSTRUCTIONS MANUAL COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH Most SPM products generate control or direct pressurized fluids therefore it is critical that those who work with these products be thoroughly trained in their proper application and safe handling It is also critical that these products be used and maintained properly SPM flow products contain elastomeric seals and are not intended to provide proper functionality when exposed to fire WARNING MISUSE SIDE LOADING IMPROPER MAINTENANCE OR DISASSEMBLY UNDER PRESSURE CAN CAUSE SERIOUS INJURY OR DEATH The following information is given in good faith and should aid in the safe use of your SPM products This information is not meant to replace existing Company s safety policies or practices It is important to read and understand the General Safety Data for all SPM Products and the SPM Product Safety Guide for Union and Union End Products Both of these are available from Weir Oil amp Gas Safety Guide for Plug Valves Personal Responsibilities A 1 When using these assemblies appropriate P
9. available from Weir Oil amp Gas and should be used for this purpose If used for bleeding ample anchoring of the valve manifold must be done Specially designed torture valves are available from Weir Oil amp Gas for bleed off applications WARNING GASES OR FLUIDS CONTAINING GASES WILL CAUSE VALVES TO WHIP AND CAN CAUSE SERIOUS INJURY OR DEATH B 8 When opening an SPM plug valve under pressure the initial torque to start the stem turning is always greater than the moving torque You must position your body to be able to compensate for this change B 9 Do not position any part of your body in the path of exit flow of the valve B 10 Do not position the exit of any plug valve used for bleeding where rocks or debris may be picked up by the exit stream B 11 If any valve becomes plugged or does not operate properly contact a supervisor immediately DO NOT look into the end of the valve to check for debris blockage or for any other reason B 12 If valve is slow to open or close remove it from service Do not hammer on the valve s actuator cap Document P N 2P36784 9 Release Date 6 30 2014 SPM OIL amp GAS Revision B B 13 It is recommended that a rate in excess of 42 feet per second be avoided Rates above this will cause a more rapid wear and erosion B 14 Flush clean and grease after each job with water and the proper SPM valve grease Use only an SPM pressure rated gun for greasing Cycle valve to insure
10. grease is evenly distributed Special Precautions C 1 Welding brazing or heating on SPM plug valves is prohibited C 2 Valve operation sometimes requires personnel to be around pressured lines Experienced personnel only should be dispatched for this purpose Exposure time should be a minimum Always use remote controlled valves whenever possible Never look into or position yourself in the path of the exit flow of the valve C 3 Never alternate a valve s service Acid service should never be followed by cold temperature service When acid etching or erosion is present replace the valve C 4 Weir Oil amp Gas offers specially designed valves for torture service cold temperature service H2S service and aromatic service Only valves designed and approved for these special services should be used in these applications C 5 Each integral union connection is clearly marked with a pressure code i e 1502 15 000 psi This pressure must not be exceeded This code should also be used with mating unions Improper mating can result in failures All integral union connections must match according to size pressure rating etc These connections must also match the service of the designated string they are installed in Inspection Repair Testing D 1 Valves should be greased after each use Use only the following SPM gun and grease Recommended Lube Grease Valtex 972 SPM P32553 Gun Assembly SPM P13335 Do not mix Ass
11. ring 7 and back up ring 6 if installed 8 Clean all grease and foreign material from the valve and components parts 27 Document P N 2 36784 MSS e 6 30 2014 I SPM Release Date OIL amp GAS Revision B Assembly 1 For best results and most efficient use of time Weir Oil amp Gas recommends complete kit replacement If any old internal parts are to be reused degrease and inspect components for wear and corrosion 2 If using old side segments and seal segments thoroughly clean rust from sealing areas of seal segments that contact the plug and body Scrape and lightly sand rust with 400 grit sandpaper from valve body surfaces which touch the center portion of the seal segments 3 Using 400 grit sandpaper clean all other seal surfaces 4 Visually inspect all new parts and remove any foreign contaminates 5 Apply a thin film of assembly grease on OD of seal segments 11 seals 13 and ID of body 14 If excessive grease is used it can make the plug hard to start or dislodge the segment seal rings 6 Install seals 13 in seal segment grooves and install seal segments and side segments 12 in valve Seal segments should always be installed in pairs from the same manufacturer 28 Document P N 2P36784 e Release Date 6 30 2014 SPM OIL amp GAS Revision B 7 To test passages install grease fitting 1 into plug 10 tighten 50 60 ftlbs Pump grease into plug
12. until clean grease exits qrease passages 8 Coat plug 10 liberally with assembly grease and install top and bottom plug seals 8 and nylon back up rings 9 9 Install plug 19 into valve You should be able to install plug by hand If necessary a soft face mallet may be used to lightly tap plug in Coat large diameter of plug with grease cR e 8 29 Document P N 2P36784 less Release Date 6 30 2014 SPM OIL amp GAS Revision B 10 Install body cap seal 7 and back up ring 6 where required onto body cap 5 with valve assembly grease 11 Instally body cap in valve Use only SPM body caps in SPM valves On 3 valve socket head screws are to be torqued to 475 ft lbs dry 355 ft Ibs lubricated 12 Replace actuator cap and felt gasket when required Install grease fitting 1 using Teflon tape or pipe dope and tighten to 50 60 ft Ibs Tighten stop nut 2 until snug when required Use only SPMPactuator caps on SPM valves 30 Document P N 2P36784 IMS Release Date 6 30 2014 SPM OIL amp GAS Revision B 13 Install and bolt actuator assembly onto valve body when required Install adapter key 23 into adapter 24 and both into operator assembly 20 Install mountint adapter 26 onto operator assembly 20 Install upper washers and bolts 21 22 14 Install adapter 19 onto plug valve Lower gear operator assembly 20 onto plug valve Install lower
13. 3055 Weld County Road 8 Fort Lupton CO 80621 Ph 1 303 535 5450 Fax 1 303 535 5455 Grand Junction CO Service Center 842 21 1 2 Rd Building A Grand Junction CO 81505 Ph 1 970 243 4600 Fax 1 970 243 8027 Williston ND Service Center 5073 Owens Industrial Park Williston ND 58801 Ph 1 701 572 0776 Fax 1 701 572 0784 CANADA Edmonton AB Canada Service Center 4737 97th Street Edmonton Alberta T6E 5W2 Ph 1 780 438 1122 Fax 1 780 437 5218 Fort St John BC Canada Service Center 10508 89th Avenue Fort St John British Columbia V1 5P9 Ph 1 250 785 6627 Fax 1 250 785 4501 Grande Prairie AB Canada Service Center 8801 99th Street Clairmont Alberta TOH OWO Ph 1 780 567 3857 Fax 1 780 567 2808 Medicine Hat AB Canada Service Center 1202 Dirkson Drive N E Redcliff Alberta 2P0 Ph 1 403 504 8353 Fax 1 403 504 8370 Red Deer AB Canada Service Center Unit A 8060 Edgar Industrial Crescent Red Deer Alberta T4P 3R3 Ph 1 403 341 3410 Fax 1 403 341 3072 OIL amp GAS INTERNATIONAL MEXICO Villahermosa Mexico Service Center Bodega 3 Lote 8 Manzana 3 Sobre Calle San Lazaro Parque Logistico Industrial Tobasco Villahermosa Tabasco 86150 Ph 52 993 142 7083 Poza Rica Mexico Service Center San Miguel Mecatepec Tihuatlan Veracruz Bodega C Ph 782 111 73 55 BRAZIL Maca Brazil Service Center Rua Internac
14. AND WARNINGS AS NOTED IN THIS MANUAL FAILURE TO DO SO CAN LEAD TO EQUIPMENT DAMAGE AND PERSONAL INJURY OR DEATH 10 Document P N 2 36784 9 Release Date 6 30 2014 SPM OIL amp GAS Revision B SPM 1 1 x 2 and 2 Plug Valves These plug valves are available for standard and H2S Service The H2S Plug Valves conform to NACE MR0175 09 for exposure to H2S It is important that the correct Plug Valve be used for the specific application Characteristics e Improved body cap seal arrangement eliminates cap leakage found in some competitive valves e No need to remove valve from line for maintenance e No special tools needed for operation or maintenance e Precision ground floating seal segments insure positive seal between fluid stream and cylindrical plug e Excellent sealing provided by precision ground metal to metal seal between seal segments and plug e Pressure enhanced sealing between segments and body provided by molded rubber static segment seal e Segment design ensures easy operation up to the full working pressure of the valve e Precision ground plug is plated standard for maximum corrosion protection e Quality components throughout unit including forged heat treated alloy steel body for greater dependability minimum weight and maximum strength e Plug bar cap has visible indication of open or closed position and detent spring to insure valve stays open or closed e Hydraulically actua
15. BSERVE ALL INSTRUCTIONS CAUTIONS AND WARNINGS AS NOTED IN THIS MANUAL FAILURE TO DO SO CAN LEAD TO EQUIPMENT DAMAGE AND PERSONAL INJURY OR DEATH 3 and 4 Plug Valves 3 and 4 Plug Valves are installed in line with the High Pressure Fracturing Lines or Manifold Trailers however other applications may apply Figures below show Plug Valves installed on a SPM Manifold Trailer and used as an isolation valve on a SPM Emergency Back Pressure Relief Valve 15 Document P N 2P36784 Release Date 6 30 2014 SPM OIL amp GAS Revision B Calibration Guide Refer to Vessel Testing Section on page 32 Pressure Temperature Ratings Part Temperature Description Service Pressure Number PSI Range F 1 X 2 SP150 WU STD 15000 30 110 TX 2 5P150WU LTAATON STD 15000 30 110 1 X 2 SP150 WU LT 1 X 2 5 150 WU TORTURE LT 1 X 2 SP150 WU TORTURE LT 1 11687 2 spisowu STD 1500 0 10 2 SP150WU LT VITON 2 5 1505 LT SAFETY IRON 3 SP1OOWU LT VITON 3 SP1SOWU LT VITON 3 SP150SI LT SAFETY IRON 4 SP150SI LT SAFETY IRON WARNING OBSERVE ALL INSTRUCTIONS CAUTIONS AND WARNINGS AS NOTED IN THIS MANUAL FAILURE TO DO SO CAN LEAD TO EQUIPMENT DAMAGE AND PERSONAL INJURY OR DEATH 16 Document P N 2P36784 9 Release Date 6 30 2014 SPM OIL amp GAS Revision B e SECTION Maintenance and Repair WARNING DISASSEMBLY UNDER PRESSURE CAN
16. PE is required safety glasses approved safety shoes and hard hat must be worn Hammering and lifting these assemblies must be done with caution Where unions are present read and understand the SPM Safety Guide for Unions and Union End Products A 2 Personnel should only hammer on makeup lugs and not strike union nut or valve body Fractures can occur from repeated misuse Excessive hammering can damage components A 3 Proper leg lifting should be used when lifting Back lifts Should be avoided A 4 Only the proper actuator bar should be used to turn SPM plug valves Valves require torque to operate Makeshift bars can become dislodged easily and cause an accident Use only an SPM actuator bar part number 3P19958 for 1 Plug Valves and 3P11542 for 2 amp 3 Plug Valves It is a personal responsibility to become knowledgeable and trained in the proper use and handling of this tool A 5 Do not hammer on or be around valve assemblies when pressure is present Hand actuation with the appropriate actuator bar should be done only by specially trained personnel under direct supervisory instruction and only when necessary due to application Document P N 2P36784 9 Release Date 6 30 2014 SPM OIL amp GAS Revision B On Location B 1 Proper transportation of plug valves is important Racks that will secure valves and prevent accidental unloading are critical Never transport any SPM product in a fashion that would allow i
17. SPM 1 1X2 AND 2 PLOG VALVES 11 SPM 2 LIGHT WEIGHT PLUG VALVE n 12 SPM 3 AND 4 PLUG VALVES 13 END CONNECTION OPTIONS 14 SECTION Il INSTALLATION AND OPERATION cceccccccceccsccccccccccsccsccccsccscesccccsccscesceccsccsccsceccecceccece 15 ONE 15 CAHBRATION E GUI IP EE OR T Em 16 PRESSURE TEMPERATURE RATINGS 2 u uuu uuu u u uu anasu cimi oe DOE ROO 16 SECTION IIE MAINTENANCE AND REPAIR sssssssssssssssssssssssssss 17 TOOLS uuu 17 MAINTENANCE setes ttre 18 RECOMMENDED RE GREASING PROCEDURE tese 20 POM 23 EXPLODED VIEW secccsecccsecccscccsscecsccccscccscenssccnsccescccuccccssccusccascccascceascccueseneccussecuecececcueceeeceasceuscceuesense
18. SPM Wing Union or Safety Iron connections The nameplate will indicate the allowable cold working pressure for each assembly Wing union connections on the plug valve are interchangeable with other union connections of the same size and figure pressure rating Caution must be taken to avoid mixing different ratings of wing connections There are various sizes and figures that are capable of making marginal connections SPM Safety Iron connections are universal requiring no male or female as does the wing union Failure to observe good judgment may lead to failure of components and danger to life and limb Always verify working pressure ratings of each connection before use WARNING OBSERVE ALL INSTRUCTIONS CAUTIONS AND WARNINGS AS NOTED IN THIS MANUAL FAILURE TO DO SO CAN LEAD TO EQUIPMENT DAMAGE AND PERSONAL INJURY OR DEATH 14 Document P N 2P36784 9 Release Date 6 30 2014 SPM OIL amp GAS Revision B e SECTION II Installation and Operation Installation 7 1 x 2 172 and 2 Plug Valves SPM Plug Valves in these sizes are primarily installed in line of a flow back system on a fracturing site Manifold Assemblies or any other location that a plug valve with this rating and capacity is needed The important thing is to ensure that the size of the plug valve meets the correct application Figure below shows a SPM Flowline Manifold which consists of Plug Valves Tees Crosses and Chokes WARNING O
19. e Date 6 30 2014 SPM OIL amp GAS Revision B Preventative Maintenance and Disassembly WARNING ENSURE ALL PRESSURE IS RELIEVED PRIOR TO PERFORMING ANY MAINTENANCE OR DISSASEMBLY See ALWAYS REMEMBER Section on page 17 before assembly The reassembly of the valve is in approximate reverse order to the disassembly process Lightly lubricate all surfaces prior to assembly with assembly grease SPM p n P36791 WARNING OBSERVE ALL INSTRUCTIONS CAUTIONS AND WARNINGS AS NOTED IN THIS MANUAL FAILURE TO DO SO CAN LEAD TO EQUIPMENT DAMAGE AND PERSONAL INJURY OR DEATH A CAUTION Make sure there is no pressure on the valve 1 If valve has gear actuator assembly remove assembly 20 by removing bolts and lifting off assembly A hoist will be required to lift actuator assembly Always use proper ques W Bolts x4 25 Document P N 2P36784 Release Date 6 30 2014 Revision B 2 Remove the grease fitting 1 3 Remove Bolts 2 4 Remove top plate 5 5 Remove the plug 10 by lifting while twisting it back and forth Sometimes it is necessary to hammer slightly from the bottom to remove 26 sew OIL amp GAS Document P N 2P36784 ud Release Date 6 30 2014 SPM OIL amp GAS Revision B 6 Remove the side segments 12 and then the seal segments 11 7 Remove the segment seal rings 13 plug seal rings 8 and back up rings 9 body cap seal
20. embly Greases This will increase the amount of friction between internal components of the valve Contact Weir Oil amp Gas Engineering for other approved grease D 2 Any alteration of the SPM valve is prohibited D 3 Use only repair methods as outlined by SPM valve service literature Use only the proper SPM repair tools D 4 SPM Repair Kits should be used for repair Valve Body and all components must be clean and SPM assembly grease used as recommended Recommended Assembly Grease Val Tex 1502 SPM P36791 Weir Oil amp Gas does not recommend mixing competing types of assembly grease This may result in reduced tack at the interface between each grease and allow for an increase grease loss rate during pumping operations D 5 Weir Oil amp Gas does not allow weld repair to be attempted on its product Replacing worn components is a more effective and safe approach Document P N 2P36784 Release Date 6 30 2014 SPM OIL amp GAS Revision B CONTENTS SAFETY GUIDE FOR PLUG NEEE aN 3 SECTION F GENERAL INFORMA ION 7 THIS SERVICE MANUAL COVERS aa trett ostsee streets tre stres 7 3 E20 KITS 8 PRODUCT DESCRIPTION s ccseeccescccccccssccescccsccccsccescccuscccscccusccascccnssccuscecsescnseceucecsececssccasccaeceasccuscceuecensece 10
21. ional No 245 Lote 09 Quadra W Loteamento Novo Cavaleiros Macae RJ Brazil 1 Ph 55 22 2106 8750 Fax 55 22 2106 8777 EUROPE Aberdeen Scotland Service Center Badentoy Industrial Park Portlethen Aberdeen AB12 4YD Scotland Ph 44 1224 783666 Fax 44 1224 7841 84 MIDDLE EAST Dubai UAE Service Center Oilfields Supply Center L T D Building 22 P O Box 1518 Jebel Ali Dubai UAE Ph 971 48836 368 Fax 971 48836 485 AUSTRALASIA Singapore Sales Office 15 Tukang Innovation Drive Singapore 618299 Ph 65 6302 0852 Fax 65 6302 0883 Australia Service Center Henderson Service Center 20 Stuart Drive Perth Western Australia 6166 Ph 61 8 9410 7500 Adelaide AUS Service Center 83 Rundle Road Salisbury South SA 5106 Ph 61 8 8285 3133 Fax 61 8 8285 3151 Toowoomba AUS Service Center Unit 4 24 Carroll Street Toowoomba QLD 4350 Ph 61 7 4633 7081 Fax 61 7 4637 7083 CHINA Shengli Oilfield Weir Highland Pump Co Ltd No 232 Nanyi Road Dongying City Shandong China 257091 Ph 86 546 7766997 Fax 86 546 7769899 MANUFACTURING Novatech 8388 C F Hawn Freeway Dallas TX 75217 Ph 1 214 398 1491
22. ision B Rebuild Kits Cont PARTS KITS 4L11982 4L16826 4114522 4120574 4113928 KIT PARTS PV 2 00 KIT PARTS PV 2 00 ACID SOLV NOT FOR 25 KIT PARTS PV 2 00 H2S KIT PARTS PV 2 00 H2S NO SIDE PORTS KIT PARTS PV 2 00 SP200 H2S SEAL KITS KIT SEAL PV 2 00 STD KIT SEAL 2 PV ACID SOLV NOT FOR H2S KIT SEAL PV 2 00 H2S SIDE PORTS KIT SEAL PV 2 00 H2S NO SIDE PORTS KIT SEAL 2 SP200 PV H2S ELASTOMER KITS KIT ELASTOMER PV 2 00 KIT ELASTOMER PV 2 00 H2S ACID SOLV O RING PACKING ASSY 4A11979 SEAL amp BKUP ASSY 2 PV 4A16825 SEAL amp BKUP ASSY 2 PV H2S 4A19829 SEAL amp BKUP ASSY 2 SP200 PV H2S PARTS KITS 2A30675 KIT PARTS PV 3 00 LT SD 2A33786 KIT PARTS PV 3 00 LT SD H2S 2A34110 KIT PARTS PV 3 00 LT SD LESS SIDE SGMTS SEAL KITS 2A30677 KIT SEAL PV 3 00 LT SD 3 2A33787 KIT SEALS PV 3 00 LT SD H2S 4113694 4116824 4114989 4120575 4119822 4120948 4120950 ELASTOMER KITS KIT ELASTOMER PV 3 00 LT SD KIT ELASTOMER PV 3 00 LT SD H2S O RING PACKING ASSY SEAL amp BKUP ASSY 3 PV SEAL amp BKUP ASSY 3 PV H2S 4 PARTS KITS KIT PARTS PV 4 00 SP100 KIT PARTS PV 4 00 SP150 2A30678 2A337 88 4A16827 4A20372 2A26353 2A26354 4 SEAL KITS KIT SEAL PV 4 00 SP100 KIT SEAL PV 4 00 SP150 2A26358 2A26359 4 ELASTOMER KITS KIT ELASTOMER PV 4 00 SP100 KIT ELASTOMER PV 4 00 SP150 2A26361 2A26362 4 O RING PACKING ASSY 2A26356 SEAL amp BKUP ASSY 4 PV Document P N 2P36784 9 Release Date 6 30 2014 SPM OIL
23. lean Clean body and components Re to open or close assemble Pins that hold detent spring may be interfering with actuator cap Re tighten pins in body Actuator cap is not SPM product or is worn Remove and install SPM actuator cap and felt gasket Always use SPM actuator caps on SPM valves NOTE IF PROBLEMS ARE NOT RESOLVED BY USING THE TROUBLESHOOTING GUIDE CONTACT WEIR OIL amp GAS FOR ASSISTANCE 34 Document P N 2P36784 9 Release Date 6 30 2014 SPM OIL amp GAS Revision B e SECTION IV Service and Support Service Center Order Information Weir Oil amp Gas stocks a large inventory of genuine original equipment replacement parts In order to expedite a parts order and avoid any delays please provide the following information with your order e model number and serial number e he part number and description refer to drawings and parts lists in this section of each item ordered e The quantity of each part kit or assembly ordered e Your purchase order number e Specify method of shipment complete shipping address complete billing address and telephone number at the destination of the shipment Parts and service may be ordered through the following locations Weir Oil amp Gas Excellent Oil amp Gas 601 Weir Way Tel 817 246 2461 Solutions Fort Worth Fax 817 246 6324 nU TX 76108 a USA www weiroilandgas com Copyright 2014 S P M Flow Co
24. mp 9 Periodic Inspection will include recertification of the Plug Valve which will include the following e Inspection of sealing surfaces evidence of wear and pitting of all components e Disassembly e New Kitting e Ultra Sonic Inspection Minimum Wall Inspection e Reassembly e Pressure testing to 100 the product s normal working pressure per SPM Specification 4512497 Section e Magnetic Particle Inspection Per Request 19 Document P N 2P36784 9 e Release Date 6 30 2014 SPM OIL amp GAS Revision B Recommended Re Greasing Procedure To maximize the valve s performance and longevity it is recommended that the lubrication maintenance procedure described below be followed Safety Note Always wear proper PPE equipment while performing work on any valves 1A After each job flush valve with clean water to wash away any contaminants in the valve 1B After each job grease with approved SPM valve grease to displace contaminants in between valve s internal components Engineering recommends using Val Tex 1502 Assembly Grease whenever disassembly of the valve is required Roll the plug to completely coat the O D of the plug Grease the O D surfaces of the seal segment Reassemble Valve using new seal components Grease Gun Assembly SPMP valve grease 2 Slide the grease gun fitting over the valve s grease fitting 3 Make sure the valve is in the OPEN position prior to pumping the grease 20
25. ntrol Inc All rights reserved S P M Flow Control Inc is the owner of the copyright and all confidential information in this document which must not be copied in whole or in part in any form or by any means and the information in it must not be used for any purpose other than the specific purpose for which it has been provided without the prior written consent of the copyright owner SPM SAFETY IRON SAFETY HAMMER SUR DROP DESTINY STAMPEDE VERIBAND DURALAST and GLADIATOR are trademarks and or registered trademarks of S P M Flow Control Inc WEIR is a trademark and or registered trademark of Weir Engineering Services Limited Certain features of some of the products disclosed in this document may be protected worldwide by patents pending and registered in the name of S P M Flow Control Inc 35 Pressure Pumping Global Locations Revised 8 8 2013 Headquarters 601 Weir Way Ft Worth TX 76108 Ph 1 800 342 7458 1 817 246 2461 Fax 1 817 977 2508 www weiroilandgas com www weirinaction com UNITED STATES Houston TX Sales Office 363 N Sam Houston Pkwy E Suite 550 Houston TX 77060 Ph 1 281 847 7270 Fax 1 281 820 2972 GULF COAST Alice TX Service Center 2450 Business Hwy 281 North Alice TX 78332 Ph 1 361 661 0900 Fax 1 361 661 0909 Deer Park TX Service Center 920 Seaco Court Deer Park TX 77536 Ph 1 832 200 6220 Fax 41 832 200 6227 Lafayette LA Service Center 401 S
26. ody wall thickness falls below the minimums listed in Engineering Specification 1519644 for Standard Service and 1523257 for H2S Service flow products it must be removed from service Wall thickness may be measured by mechanical sonic or visual means 18 Document P N 2P36784 59 Release Date 6 30 2014 SPM OIL amp GAS Revision B Maintenance Requirements Cont Weir Oil amp Gas recommends that the valve be serviced during the following 1 Preventative Maintenance After every Frac and or stage job Re greasing the Plug Valve after every Fracturing and or stage job will increase the life of the Plug Valve Normal working operations will allow for grease loss if the plug valve is not maintained This can create voids within the assembly These voids will quickly accumulate sand and proppants thus increasing the force required to open close the valve Frequent greasing of the valve will ensure easier operation Reference Recommended Re Greasing Procedure beginning on page 20 2 Periodic Inspection Periodic inspections are required to ensure that all internal components of the valve are working properly and are to Weir Oil amp Gas Engineering s specifications It is imperative that a qualified Weir Oil amp GasTechnician follow the assembly disassembly inspection instructions beginning on page 25 Rebuild Kits are available through Weir Oil amp Gas Service Centers They are referenced on pages 8 a
27. ored or pitted Resurface with 400 grit sandpaper or replace segments and or body Plug scored or worn Replace plug ID of body or OD of seal segments not cleaned properly Remove parts and clean out any contaminants If the ID of the body is not cleaned properly this will not let the O ring or seal segments seat properly ID of body may be too pitted to reuse Segments seal left out not properly installed or damaged during assembly Remove segments inspect seals and reinstall or replace as necessary Wrong actuator cap installed forcing plug to tilt to one side Ensure actuator cap is from same manufacturer as body Always use SPM actuator caps on SPM valves B Valve will not fully open Worn or damaged actuator cap or not an SPM actuator cap Remove and install SPM actuator cap Always use SPM actuator caps on SPM valves C Valve leaks at body threads Body cap not tight Re tighten Cap should bottom out Body cap O ring scored or cut or no longer maintains seal Replace O ring Body cap damaged or worn Replace cap Always use SPM body caps in SPM valves On SPMP 2inch valves back ring not installed Install back up ring above the O ring with concave surface touching the O ring Seal area scored or pitted in body Clean up with 400 grit sandpaper or replace body D Seals swollen and softened or tacky Avoid solvents Bune N seals are not compatible with solvents such as toluene or x
28. sible signs of leakage or failure to maintain pressure at the gauge 3 Reduce pressure to zero and place valve in CLOSED position 4 With the valve in CLOSED position again air must be evacuated from valve and system apply pressure slowly to one side of the valve leaving the opposite side open to a pressure equal to the maximum non shock cold working pressure of the valve and maintain for a period of at least 3 minutes Reduce pressure to zero Open and shut the valve Re pressurize the valve to its maximum non shock cold working pressure and maintain for an additional 3 minutes Inspect the valve during this procedure for any signs of leakage Bleed the pressure off of the valve 5 Reverse the valve and reconnect the pressure source to the opposite side of valve and repeat step 4 making sure all air is evacuated from valve and system 6 Consult Weir Oil amp gas Engineering on any valve not performing properly during any phase of test or operation 32 Document P N 2 36784 eee Release Date 6 30 2014 SPM OIL amp GAS Revision B Troubleshooting Guide The following is intended as a general guide in helping resolve most problems encountered in repairing plug valves PROBLEM SOLUTION A Valve leaks through bore when closed 1 Seal segments from two different manufacturers have been installed ALWAYS REPLACE SEGMENTS IN PAIRS FROM THE SAME MANUFACTURER Sealing area of segments or body sc
29. ss 24 PREVENTATIVE MAINTENANCE AND 25 28 TEST PROCEDURES csscccseccceccccccccscccuscecsccccscccuscecueccnssceuseccuccecseceneccuseceusceaueceuseecusecsecensecuceceesecsecensecenes 32 TROUBLESHOOTING GUIDE 33 SECTION IV SERVICE AND SUPPORT cccccccccsceccsccccsccccsccccccccesccccscscescscescscescsccscscsscsccccsceccsceccsces 35 SERVICE CENTER ORDER INFORMATION 35 WEIR OIL amp GAS ETT u w 35 Document P N 2P36784 9 Release Date 6 30 2014 SPM OIL amp GAS Revision B SECTION I General Information This service manual covers 1 1 2 2 3 Document P N 2P36784 9 Release Date 6 30 2014 SPM OIL amp GAS Revision B This service manual covers Cont m Rebuild Kits 1 ELASTOMER KITS PARTS KITS 4112487 KIT PARTS PV 1 50 STD SEAL KITS 1 1 2 4114442 KIT SEAL PV 1 50 NOT FOR H2S ELASTOMER KITS 4123926 KIT ELASTOMER PV 1 50 O RING PACKING ASSY 4L11979 SEAL amp BKUP ASSY 1 50 PV Document P N 2P36784 9 Release Date 6 30 2014 SPM OIL amp GAS Rev
30. t to become dislodged and cause an accident B 2 Valve unions should be clean and lightly oiled prior to each use A visual inspection for damage should also be performed at this time Union seals should be checked and replaced when worn or damaged B 3 Each valve has a size and pressure code designated on the valve Use this code for proper mating and pressure limits CAUTION SINCE PLUG VALVES MAY BE REPAINTED IN DIFFERENT COLORS FOR VARIOUS APPLICATIONS DO NOT USE FACTORY COLOR AS PRIMARY MEANS OF IDENTIFICATION B 4 Valve usage should be monitored by a qualified supervisor or foreman Supervisory personnel must approve proper placement position and handling of all plug valves in the system Only specially trained personnel under direct supervisory instruction should actuate valves under pressure B 5 Prior to applying pressure valves should be greased in both the opened and closed position This should be done before each use If valve is excessively hard to operate it should be removed and not used until repairs are made B 6 It is sometimes necessary to turn valves when pressure is present It is recommended that remote control actuators be used for this purpose If this is not feasible then only experienced specially trained personnel under direct supervisory instruction should perform this task B 7 Venting flammable or explosive gases to the atmosphere through individual SPM plug valves must be avoided Choke manifolds are
31. ted models optional e Remote control actuator available e Each valve is thoroughly tested prior to shipment e Inventory stock of complete valves spare parts and seal kits available Can be used in the following service e Fresh Water and Sea Water Lines e Drilling Mud Lines including Choke and Kill Lines e Well Service Lines for cementing fracturing acidizing and flow testing e Hydraulic Lines including BOP control lines e Crude Oil Production Lines e Utility Lines 11 Document P N 2P36784 eS Release Date 6 30 2014 SPM OIL amp GAS Revision B SPM 2 Light weight Plug Valve The SPM 2 Light Weight LW Plug Valve is engineered with one thing in mind Safety It provides the following advantages to the Oil and Gas Industry e Compact Lightweight Design e Meets HSE Lifting Requirements e Easy Assembly Disassembly e DNV Certification Available e CE Compliant 97 23 EC HSE compliant products offer a safe lifting weight of 55 lbs 25 kg or less to be lifted and carried by one person Like other SPM high pressure plug valves the 2 LW Plug Valve is able to provide the same dependable service for applications such as e Acidizing e Cementing e Coil Tubing e Fracturing e Sand Control e Well Kill Refer to SPM 2 Light Weight Plug Valve HSE Approved Operation and Maintenance Instruction Manual for further information on this valve 12 Document P N 2P36784 IMS
32. washers and bolts 27 28 and tighten 15 With valve in the open position pump valve full of grease Usually 15 to 20 pumps is sufficient The valve is full when grease flows from bore 16 Test valve per instructions included in every repair kit 31 Document P N 2P36784 9 Release Date 6 30 2014 SPM OIL amp GAS Revision B Test Procedures Prior to shipment product testing procedure 4512497 requires that each emergency valve pass a one time vessel test at 150 it s rated working pressure then when conducting subsequent vessel tests on used or re certified valves limit the pressure to 100 of rated working pressure as required by 4512497 Upon final assembly or reassembly of valve a pressure test is to be performed as follows CAUTION PRIOR TO ANY PRESSURE TESTING ALL AIR MUST BE EVACUATED FROM THE VALVE AND PRESSURE APPARATUS FAILURE TO DO SO COULD RESULT IN PERSONNEL INJURY OR DEATH AND OR SEVERE DAMAGE TO THE VALVE 1 Both ends of the valve are to be capped Both caps must have pressure access ports as shown in the figure below Valve is to be tested so as to have pressure applied to both sides of plug hence the need for pressure access ports at both ends of the plug Pressure Access Ports 2 With caps in place and valve in the OPEN position and filled with liquid all air must be evacuated from valve at this point pressure valve slowly to maximum working pressure and inspect for vi
33. ylene If Buna seals are used replace with Viton E Lower edge of plug chipped Always start plug into valve upon reassembly by hand to align chambers on plug and seal segments Hammering plug before it is properly started can chip the plug s leading edge and often score or damage the seal segments Use only soft type hammers 33 Document P N 2P36784 tea BMMA Release Date 6 30 2014 SPM OIL amp GAS Revision F Valve leaks out the bottom 1 Body cap not SPM product Remove and reinstall SPM body cap SPM bodies and body caps are designed differently to eliminate leaking cap problems Always use SPM body caps in SPM valves Actuator cap not SPM product Remove and re install SPM actuator cap Actuator caps from competitor valves will not work properly on SPM valves Plug seal O ring and back up ring on bottom of plug not seated properly Remove plug and reinstall O ring and Nylon back up ring C Valve leaks around plug top stem Top plug seal O ring and back up scored or not seated properly Replace or re install Body cap not properly tightened Re tighten snugly until it bottoms out Body cap damaged or worn Replace Body cap not SPM product Remove and re install SPM body cap SPM bodies and body caps are designed differently to eliminate leaking cap problems Always use SPM body caps SPM valves H Valve binding up Hard or impossible ID of body not c
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