SPM® 2 Inch Relief Valves Manual
Contents
1. 8 END CONNECTION OPTIONS 8 SECTION Il INSTALLATION AND OPERATION 9 u unu E E E E E SA 9 CALIBRATION GUIDI E E 10 PRESSURE TEMPRATUR RATING uuu uuu iga a a la saal L a un 2 11 SECTION MAINTENANCE AND RFPAIR 12 ALWAYS REMEMBER uuu uuu 12 MAINTENANCE REQUIREMENTS u u l r r SR 13 ANIIDAE DE OEI x 15 PREVENTATIVE MAINTENANCE AND 5 55 19 PREVENTATIVE MAINTENANCE INSPECTING INTERNAL COMPONENTS 20 REPLACEMENT ANID ASSEMBLY Sa 25 SETTING S ADJUSTING SG V RA RAN 30 TROUBLESHOOTING GUIDE 33 AND SUPPORT 34 SERVICE CENTER ORDER INFORMATION 34 VET uu 35 Document P N 2418192 Re2. 10 14 2014 Revision IR amp GAS SPM PRODUCT SAFETY GUIDE IMPORTANT SAFETY INFORMATION ENCLOSED READ THIS OPERATING AND MAINTENANCE INSTRUCTIONS MANUAL BEFORE OPERATING PRODUCT 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 SPM flow products contain elastomeric seals and are not intended to provide proper functionality when exposed to fire A 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 Personal Responsibilities 1 When working on SPM flow control products safety glasses approved safety shoes and hard hat must be worn 2 Personnel should never hammer on any component when pressure is present Hammering on any part or component may also cause foreign material or steel slags to become airborn
3. 6 17 19 20 21 15 Document P N 2418192 Release Date 10 14 2014 VER Revision IR OIL amp GAS Elastomer Seals 4122456 Buna Std Service P18152 18153 28332 1500 4122457 Viton Std Service 18131 24147 28332 3000 4124007 Buna Std Service PF18152 P18153 28332 4124008 Viton Std Service P18131 24147 28332 Relief Valve Pressure Part i icetype PSI Number Seal Seal 4124009 Buna Std Service 18152 18153 p28 7500 4124010 Viton Std Service 1 131 2414 7 28332 15000 41 20418 Buna Std Service 18152 P18153 28332 41 20419 Std Service P18131 2414 10000 25 Service P18131 24147 20000 4120422 Std Service 18152 P1815 P Expendable Items a 2 3 of Disk 17 Keeper Relief Valve PN Pressure Part 5 aes Description Adjusting Lock Service type 51 Number Nut 4124009 Buna Std Service 3P18148 P18151 3P18149 3P18139 P18919 AL24010 Viton Std Service 3P18148 P18151 3P18149 3P18139 P18919 15000 AL20418 Buna Std Service 3P18148 P18151 3P18149 3P18139 P18919 15000 4120419 Viton Std Service 3P18148 P18151 3P18149 3P18139 P18919 120420 Viton 25 Service 18151 216 3 18139 18919 5000 1 Viton 25 Service 18151 3P18149 16 3 18139 0421 Buna Std Service 3P18148 P18151 3P18149 3P18139 P18919 16 Document P N 241819
4. Excellent SPM Oil amp Gas Well Service Pumps amp Flow Control Products Solutions Full Flow Emergency Relief Valves Standard and 5 Service Models Spring Design 2 ERV s Operation Instruction and Service Manual Document P N 2A18192 Release Date 10 14 2014 Revision IR Copyright 2014 S P M Flow Control Inc All rights reserved S P M Flow Control Inc is the owner of the copyright 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 5 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 2418192 Release Date 10 14 2014 Revision IR OIL amp GAS THE FOLLOWING ICONS DENOTE IMPORTANT INFORMATION WITHIN THIS MANUAL W INFORMATION Onun AND OPERATION Won AND REPAIR 6 AND SUPPORT w NOTE A CAUTION WARNING DANGER Document P N 2418192 Release Date
5. 19 Spider 20 Seat 21 Seat Seal 22 20 Document P N 2418192 Release Date 10 14 2014 Revision IR Preventative Maintenance Inspecting Internal Components Body 10 Visually inspect the o ring groove area beneath the ball seat Location A This is a critical area If the groove shows indications of damage from either erosion corrosion the body should be replaced It is not repairable Visually inspect the fluid discharge surface for erosion or corrosion Location B Some wear in this area is expected Any damage to this surface that extends deeper than 10 renders the part unusable and it should be replaced Visually inspect the valve cap seal surface for erosion or corrosion Location C Damage to this area will allow fluid to leak past the cap during the relieving function If this surface shows signs of damage the body should be replaced Location B Location A Location C Adjusting Screw 2 amp Valve Cap 4 Visually inspect the cap body and cap spider seal areas for indications of damage or wear These seals keep valve fluid from leaking out of the valve past the body to cap threads and from leaking into the spring cavity lf these areas show signs of damage replace the Visually inspect the adjusting screw threads and mating threads the for indications of damage or wear Lubricate the adjusting screw and engage it into the cap by hand The action shoul
6. 6 Coat threads of the Valve Cap when installing it into Body The Cap should freely thread into the Body with only Seal Friction creating drag To fully tighten the Cap in the body it is recommended that a 36 wrench be used and that the cap is smartly snapped against the stop This will cause the bottom of the cap to bear against the spider holding the ball seat firmly against the seat seal The snapping action will guarantee a preload in the stackup of items threads Install brass tipped Set Screw 7 into the body and use allen wrench to tighten snugly against the valve cap f oy oe L F The Lock Nut 3 should be screwed onto the Adjusting Screw 2 then this assembly can be screwed into the Cap after a liberal application of grease The valve is now ready for pressure testing as discussed in Setting amp Adjusting Pressure section 28 Document P N 2418192 Release Date 10 14 2014 ISR Revision IR OIL amp GAS Optional Factory Seal Installation 29 Document P N 2418192 Release Date 10 14 2014 Revision IR OIL amp GAS Setting amp Adjusting Pressure Factory The 2 Emergency Relief Valve may be obtained from Weir Oil amp Gas as unset preset or preset and factory sealed Weir Oil amp Gas bench tests and sets every valve to verify accuracy and function before shipping If the valve is ordered as unset it will be tested for leaks and
7. Position the Ball 19 onto the Seat Install a new Keeper Seal 18 unto the Keeper 17 and position it between the Seat and onto the Ball 19 as shown below STEP 4 Stack Disk Springs 6 onto the Keeper 17 ensuring that the correct orientaiton and number of springs are used Reference Figure A for other configurations 26 Document P N 2418192 Release Date 10 14 2014 Revision IR OIL amp GAS Figure A Spring Disk Configurations Each Spring Relief Valve s designed pop off pressure is determined by the Spring Disk type and orientation Below represents the correct orientation of the Springs with its respective desired pressure Note Incorrect configuration of the springs may affect the spring rate and reduce the discharge capacity of the valve 3 000 PSI 2A23783 2A23783V gt 20 Disk 3 83V 20 Disks Single Stack Springs 1 on top 1 on bott 15000 PSI 2418192 2418192 16 Disks 119 500 PSI 223782 2A23782V _ 15 000 PSI 2A18138 16 Disks 10 000 PSI 2418544 16 Disks 20 000 PSI 2418796 16 Disks Coat the Springs 6 and Keeper 17 liberally with grease Install new Valve Cap Seal 5 into the o ring groove in the Valve Cap 4 Install the Valve Cap Assembly into the Valve Body 10 27 Document P N 2418192 Release Date 10 14 2014 1 _ bo l Revision IR OIL amp GAS STEP
8. full pressure capability The valve is then generally placed at a low less than 1 000 psi pressure setting for shipping For the preset and factory sealed configuration the valve is verified to full pressure capability and then set and locked at the required pressure The factory sealed option provides for wire to be fed through the lock bolt that must be cut before the valve may be re adjusted Field Shop For field situations where the valve must be adjusted after leaving the factory and a test facility is available the following procedure applies 1 Clamp the valve in a heavy duty vise as shown in Figure B Loosen the lock nut around the adjusting screw by rotating the nut counterclockwise L H 2 The set pressure can then be adjusted by rotating the adjusting screw either counterclockwise L H to lower pressure or clockwise R H to raise pressure Figure B Lower Pressure CCW Direction Adjusting Screw Locking Nut Valve Cap Raise Pressure CW Direction 30 Document P N 2418192 Release Date 10 14 2014 OIL amp GAS Revision IR It should be noted that this is a direct acting relief valve that uses the spring forces to balance the fluid pressure Consequently the forces needed to adjust the pressure can be quite high It is recommended that a wrench with a minimum handle length of 72 be used to turn the adjusting screw Setting and Adjusting Pressure Cont The pressure source should be a lo
9. generates a force on the ball lower than the spring force applied to its top the ball will remain seated However if the system pressure creates a force higher than the spring load the ball will lift off the seat and allow fluid to discharge 31 Document P N 2418192 Release Date 10 14 2014 Revision IR OIL amp GAS Setting and Adjusting Pressure Cont If the valve fails to hold pressure the problem is generally one of the following a Contamination between ball and seat holding the ball off seat b Damaged ball and seat c Damaged seat seal To correct the problem follow the instructions in Sections Il and II of this manual Installation and Operation and Maintenance and Repair Generally at the start of a pressure pumping job the customer will want to verify that the ERV will relieve at the intended pressure This maximum pressure may be arrived at by the condition of the wellhead or down hole equipment or it may be dictated by the limits of the treating iron It may also be arrived at for other reasons Consequently each job is likely to vary in the required setting of the ERV The valve can be initially set by counting the number of turns on the adjusting screw to get an approximation of desired set pressure The valve can also be pre set at the shop to the desired level The operator will then slowly bring his pump s on line and note at what pressure flow rate begins This is the set pressure I
10. genuine original equipment replacement parts In order to expedite a parts order and avoid any delays please provide the following information with your order The part number and description refer to drawings parts lists in this section of each item ordered e quantity of each part kit or assembly ordered e model number and serial number 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 Refer to location sheet on the following page Weir Oil amp Gas Excellent Oil amp Gas 601 Weir Way Tel 817 246 2461 Solutions Fort Worth Fax 817 246 6324 76108 USA www weiroilandgas com Copyright 2014 5 Flow Control Inc All rights reserved 5 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 5 Flow Control Inc WEIR is a trademark and or registered trademark of Weir Engineering Services Limited Certain features of so
11. 14 2014 ISR Revision IR OIL amp GAS SECTION III Maintenance and Repair A DISASSEMBLY UNDER PRESSURE CAUSE SERIOUS INJURY DEATH Always Remember Always wear PPE personal protective equipment Only qualified technicians should perform maintenance on SPM products Always use SPM supplied new parts kit for reassembly Clean all components thoroughly prior to reassembly Check sealing surface area of valve gate nozzle for pitting erosion or other flaws Failure sealing can result if these areas are not smooth Use only SPM parts on SPM valves 7 This device is intended to discharge atmospherically when it relieves A Required Tools Weir SPM f i Torque Wrench Contact Weir 5 or questions 600G Sandpaper 5 8 Allen Socket Hammer 1 2 Aluminum bar 1 2 Allen Socket Protective Screwdriver Gloves Safety Glasses 3 1 6 punch z lt amp L Moly Lithium Grease Vise with LPS Laboratories 02910 aluminum jaws copper based anti seize or equivalent 1 1 2 Open end wrench Standard Allen Wrench Set 12 Document P N 2418192 Release Date 10 14 2014 Revision OIL amp GAS Maintenance Requirements The SPM 2 Emergency Relief Valve is a well designed dependable valve that provides long term reliable performance Like any device however it requires routine inspection and servicing to guarantee th
12. 1W 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 1 20 Odessa 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 13055 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 5 9 Ph 1 250 785 6627 Fax 1 250 785 4501 Gran
13. 2 Release Date 10 14 2014 VIS Revision IR OIL amp GAS BOM 2A18192 BOM TABLE 2418303 SEAL INST RELIEF VA 2 3FF OPTION 1 eS a 3P10228 WING NUT 2 1502 18386 RIVET POP 13 DIA X 13 LG ALUMINUM 3 18139 RELIEF EMERG KEEPER 2 P18919 BALL 1 38 COBOLT 2 19460 SEAT 2 RLF VA 750 BORE COBOLT 4P10229 SEAL RNG UNION 2 17 OIL amp GAS Document P N 2A18192 Release Date 10 14 2014 Revision IR Exploded View H gt _ gt gt Saa lt 18 Document P N 2418192 Release Date 10 14 2014 Revision IR OIL amp GAS Preventative Maintenance and Disassembly STEP 1 ENSURE ALL PRESSURE IS RELIEVED PRIOR TO PERFORMING ANY MAINTENANCE DISSASEMBLY Close Isolation Valve to shut off fluid pressure Detach and remove Spring Loaded ERV from System Isolation Valve STEP 2 Secure the Relief Valve in a horizontal position on an appropriate workstation as shown 19 Document P N 2418192 Release Date 10 14 2014 Revision IR Preventative Maintenance and Disassembly Cont STEP 3 Remove the Factory Pressure Assembly 14 15 16 and Fact Seal Assembly 1 Loosen the Hex Lock nut 3 Remove the adjusting screw 2 with the Lock Nut 3 STEP 4 OIL amp GAS Remove Cap 4 Cap Seal 5 Springs 6 Keeper 17 Keeper Seal 18 Ball
14. Valve should be installed a branch on the high pressure pump line Figure 1 It is recommended that the valve be placed downstream away from the high pressure pumps This increased distance will reduce the likelihood of the valve seat s experiencing chatter However any application requiring localization protection of the high pressure pump is acceptable This will require additional differential between the fluid pressure and set pressure of the valve to prevent valve chatter Contact Engineering for additional recommendations The valve should be mounted in the vertical position as shown to reduce the tendency of contaminants and particles in the fluid from collecting at the throat of the ball seat Although any type of fluid may be relieved through the valve the slick water media will allow for reseating and therefore resealing whereas proppants may become trapped in the ball and seat sealing area and inhibit resealing This is also true of contaminants DOES NOT FULLY RESEAT AFTER IT HAS RELIEVED IN THE EVENT THAT THIS MIGHT PRESENT A DANGER TO PERSONNEL OR EQUIPMENT WEIR OIL amp GAS HIGHLY RECOMMENDS THAT AN ISOLATER VALVE BE PLACED BETWEEN THE PRESSURE LINE AND THE RELIEF VALVE IT IS IMPORTANT FOR THE USER CONSIDER THE CONSEQUENCES OF A VALVE THAT With the valve installed as shown in Figure 1 any time the pressure exceeds the pop off pressure of the Relief Valve the fluid will pass through the valve and
15. al wing union male inlet suitable for the pressure rating of the component The low pressure outlet is available with an integral wing union female connection Conforming to conditions of design and performance in API RP520 the SPM Emergency Relief Valves are intended for liquid service They are not intended for elevated temperatures or as a safety device in case of fire Available 2 3 and 4 sizes these valves offer pressure ranges from 0 PSI to 20 000 PSI The valves best suited for over pressure protection in a slick water medium See 3 4 Emergency Relief Valve Service Literature for information regarding the 3 4 E R V A WARNING STANDARD 2 RELIEF VALVES A SHALL NOT BE USED FOR H2S SERVICE A WARNING DO NOT BLOCK RELIEF VALVE A DISCHARGE Document P N 2418192 Release Date 10 14 2014 Revision IR OIL amp GAS General Description of Relief Valve Operation The SPM Back Pressure Relief Valve s operation is a simple balance between the spring loaded keeper which holds the ball in the seat and the inlet liquid pressure acting on the ball The spring pressure is set by tightening the Hex Bolt on top which pushes on the keeper which in turn compresses the Belleville springs that forces the keeper on the Ball When the inlet fluid pressure rises and overcomes the set spring pressure the ball is lifted off its seat thereby discharging fluid to the outlet end Once
16. at it is fully functional Due to the harsh field environment where this relief valve will be used it is imperative that maintenance of this valve be HIGH Priority to ensure repeatability Weir Oil amp Gas recommends that the valve be serviced during the following 1 Preventative Maintenance After 20 Fracturing Stages or 7 Complete Frac Job The life of replacement kits may vary considerably based on the application and operating conditions However Weir Oil amp Gas provides the following recommendations Any time the valve is sequenced in operation as a result of overpressure other than routine calibration with clean water prior to pumping operations it must undergo a teardown and the primary seal surfaces be inspected If no over pressure event occurs the valve shall be serviced after every 20 stages 1 frac job whichever comes first This should be done immediately following the completion of the current job Specific applications combined with implementation of best practice procedures may result in longer kit life and reduced service interval Contact Engineering for more details Not properly servicing the valve once it has discharged frac media including frac sand is a dangerous practice and increases the risk of leakage during the next operation Disassembly repairs and reassembly should be done in accordance with service manual instructions valve s design allows for a quick and easy inspection of it
17. ay result in loss of warranty as well as SERIOUS INJURY OR DEATH Special Precautions 1 The modifications to or unauthorized repair of any part of a SPM valve or use of components not qualified by 5 can lead to valve damage or failure and SERIOUS INJURY OR DEATH 2 All SPM threaded components are right hand threaded unless specifically designated otherwise Any turning counterclockwise will unscrew the assembly Make sure all threaded components are assembled to the correct torque value 3 All products should be properly cleaned greased or oiled after each use and inspected prior to each use 4 Each integral union connection 15 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 used must match according to size pressure rating etc These connections must also match the service of the designated string they are installed in Document P N 2418192 Release Date 10 14 2014 Revision 5 SECTION Il GENERAL INFORMATION 6 HIS SERVICE IMIAINUIAI COVERS u uu uuu 6 6 PRODUCT DESCRIPTION GENERAL DESCRIPTION RELIEF VALVE OPERATION
18. d be free and easy Damage to the cap threads or adjusting screw render these components unusable and they should be replaced 21 OIL amp GAS Document P N 2418192 Release Date 10 14 2014 Revision IR OIL amp GAS Preventative Maintenance Inspecting Internal Components Cont Keeper 17 Visually inspect the keeper keeper stop and piston seal surfaces for wear Inspect the lock nut thread area for wear or galling Visually inspect the disk spring support area for damage due to the disk springs Inspect the ball mating area for unusual dents or damage from the ball or fluid lf damage or wear is evident the keeper should be replaced Ball 19 amp Seat 21 The ball and seat are considered expendable items and spares should be kept on hand at all times The life of these parts is dependent on the type and length of service to which they are exposed Visually inspect the ball and seat for indications of pitting erosion or corrosion damage These are critical components in the function of the valve Any indications of deterioration should be cause to replace these items Look for contaminants that while not damaging to the ball and seat will keep the parts from sealing Remove any foreign material found 22 Document P N 2418192 Release Date 10 14 2014 Revision IR amp GAS Preventative Maintenance Inspecting Internal Components Cont Disk Springs 6 Visua
19. de 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 2 0 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 Internacional 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 S
20. e 3 It is a personal responsibility to use the proper tools when servicing the valve It is a personal responsibility to be knowledgeable and trained in the use and handling of tools for all maintenance of the valve 4 Hot surface may be present it is a person s own responsibility to protect against burn injury Document P N 2418192 Release Date 10 14 2014 Revision IR OIL amp GAS On Location 1 Each valve is clearly marked with a maximum pressure rating This pressure must not be exceeded or SERIOUS INJURY OR DEATH CAN OCCUR 2 The valve discharge connections should be properly cleaned and lightly oiled before the downstream piping is attached Any worn damaged or missing seals should be replaced 3 Welding brazing or heating any part of the valve is prohibited If accessories must be attached consult Weir Oil amp Gas factory prior to installation 4 Acomplete visual inspection of the valve must be made prior to each use Any leaking seals broken bolts leaking hoses or improperly tightened parts must be remedied prior to using 5 Any repairs or service even routine maintenance performed on the valve must be performed by a trained service technician who is qualified to work on high pressure flow control valves All such service and repairs must be supervised by qualified management personnel or returned to Weir Oil amp Gas for service Only SPM replacement parts should be utilized Failure to do so m
21. f convenient can disconnect the discharge line of the valve and visually note at what pressure fluid discharges from the valve This is the set pressure If the valve is not at the preferred setting an increase or decrease in setting is accomplished by turning the adjustment screw Then the pump is brought on again to confirm the right setting By following this procedure the serviceman and company have confidence that an exact setting is affected and that the valve will perform as intended Weir Oil amp Gas pressure tests all Emergency Relief Valves prior to shipping Every valve is vessel tested to 150 of its rating to ensure safety and reliability This vessel test should not be repeated Field testing should be done at working pressure only It is still necessary to test each valve for leaks after they are refurbished To test for leaks follow instructions as previously described in this section Adjust valve to full working pressure and allow the valve to relieve To avoid damaging the ball and seat do not do this more than once or twice CAUTION DO NOT EXCEED WORKING PRESSURE With the valve near working pressure carefully examine for leaks If no leaks are observed the valve is now ready for service 32 Document P N 2418192 Release Date 10 14 2014 Revision OIL amp GAS Troubleshooting Guide TROUBLESHOOTING GUIDE Always follow existing Weir Oil amp Gas procedures concerning identifying equi
22. lease Date 10 14 2014 IR OIL amp GAS Revision SECTION I General Information This service manual covers Connection Outlet Branch Configuration Service Type Number 2A18138 2 LPTL F Outlet 2A18192 2 1502F Outlet 2A18796 2 2002F Outlet 2A18544 2 1502F Outlet Low Temp Rebuild Kits Relief Valve Part Number Full Parts Kit Number Ball Seat amp Seal Kit Seal Kit Document P N 2418192 Release Date 10 14 2014 Revision IR OIL amp GAS Product Description SPM Emergency Relief Valve provides overpressure protection for reciprocating pumps treating lines pressure vessels and other equipment operating under high pressure high flow conditions Compact and simple to operate the valves are direct acting relying on the system s hydraulic pressure to overcome a preset spring force to relieve They are externally adjustable from zero pressure to maximum setting Unlike shear relief valves which use common nails to trigger the release the SPM valves will reseat once the system pressure reduces And unlike many High Lift Valves which require a substantial drop pressure before they will reseat the SPM relief valve exhibits little blow down and will reseat at or near the cracking pressure Manufactured to Weir Oil amp Gas stringent Quality Assurance System all pressure bearing components made from high quality material The forged body features an integr
23. lly inspect the surface of the springs for damage due to corrosion or mechanical failure This is a critical component in the function of the valve Any indication of deterioration should be cause for replacing these items Spider 20 Visually inspect the fluid discharge area for erosion or corrosion Some wear in these areas are expected Any damage in this area that extends deeper than 0 06 renders the part unusable and it should be replaced Visually inspect the keeper seal area and spider seal surface for signs of wear or damage Replace the spider if damage exists 23 Document P N 2418192 Release Date 10 14 2014 ISR Revision IR OIL amp GAS Preventative Maintenance Inspecting Internal Components Cont All Seals Elastomers All elastomer seals should be replaced regardless of condition 24 Document P N 2418192 Release Date 10 14 2014 Revision IR OIL amp GAS Replacement and Assembly STEP 1 Secure the Relief Valve Body 10 into appropriate workstation Install a new o ring seal 22 into body seal groove Figure A A small amount of heavy grease is useful to hold the seal in place Place Seat 21 into its pocket and press the seat against the seal 22 by hand Figure B STEP 2 Install Spider 20 into the body so that it sits on the Seat 21 20 25 Document P N 2418192 Release Date 10 14 2014 Revision IR OIL amp GAS STEP 3
24. me of the products disclosed in this document be protected worldwide by patents pending and registered the name of 5 Flow Control Inc 34 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 1 832 200 6227 Lafayette LA Service Center 401 S 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 3
25. out the discharge Figure 1 Disharge to atmosphere Isolation Valve To Document P N 2418192 Release Date 10 14 2014 ISR Revision IR OIL amp GAS Installation Cont At low flow rates the valve will discharge fluid at approximately the set pressure Figure 2 A through D At higher flow rates the valve will discharge fluid at levels above the set pressure API 520 defines the valve flow capacity as the rate that can be relieved at an over pressure of 25 When the fluid pressure falls to the set pressure level or below the valve will reseat and reseal Figure 2 Fluid pressure below set pressure Fluid pressure slightly above set gate is seated pressure Ball and Keeper off seat Fluid pressure substantially above Fluid pressure below set pressure set pressure Ball and Keeper off Keeper Ball Seat reseated of seat 10 Document P N 2418192 Release Date 10 14 2014 Revision IR OIL amp GAS Calibration Guide Pressure Temperature Ratings Inlet Low Pressure Pressure Range Int End NSCWP Service Temp Range Discharge 2 1502M 2 LPTL 0 15000 15000 30 C 110 C 2 1502M 2 1502F 0 15000 15000 30 C 110 C 2 2002M 2 2002F 0 20000 20000 30 C 110 C 2 1502M 2 1502F 0 10000 15000 H2S Sour 30 C 176 C 2 2202M 2 2202F 0 15000 10000 H2S Sour 30 C 176 C 11 Document P N 2418192 Release Date 10
26. pment for inspection and removing equipment from service The following is intended as a general guide in helping resolve most problems encountered repairing emergency relief valves If problems not covered here are encountered contact Weir Oil amp Gas for assistance at 1 800 342 7458 SYMPTOM PROBLEM SOLUTION EU lu a lu s relief device U eet 7 meet capacity requirements aaa ka ea opening and closing nozzle b Relief valve located too close to b Relocate Pressure Relief Valve Refer pump s discharge to service literature for information Loss of pressure ere does not seal or loses fluid through discharge Fully install the cap Item 2 in the body ltem 1 by uniformly tightening the screw 22 Tighten evenly to 104 Ft lb lubricated A small gap must remain between the cap and body Replace damaged seals Valve leaks through Damaged inner or outer or a weephole or between both Spider seals valve body and cap Valve releases higher or Reset valve to desired pressure per lower than intended relief instructions in Section VII pressure b Disk sprinos not installed b Reinstall disk spring pack Reset valve correctly 33 Document P N 2418192 Release Date 10 14 2014 Revision IR OIL amp GAS SECTION IV Service and Support Service Center Order Information Weir Oil and Gas stocks a large inventory of
27. s internal components The components that require inspecting are listed below and are referenced on the bill of materials on page 15 Illustrated pages 16 18 The components that must be replaced during a re kitting are highlighted in yellow and shown on Page 14 e Disk Spring e Keeper e Bushing e Spider e Other Applicable Seals Disassembly Inspection guidelines are on pages 19 through 28 2 Annually Inspection An annual inspection is 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 Gas Technician follow the assembly disassembly inspection instructions illustrated on pages 19 through 35 13 Document P N 2418192 Release Date 10 14 2014 Revision IR OIL amp GAS Preventative Requirements Regular maintenance spare parts Item 19 21 22 BALL amp SEAT amp SEAT SEAL KIT Relief Valve Service type Part No Seal Type Description 19 21 22 Ball Seat Seat Seal AL18755 BUNA 18919 2P19460 28332 1 5K 3 0K 7 5K 15K Std 4L18756 VITON SS P18919 2P19460 P28332 14 Document P N 2418192 Release Date 10 14 2014 Revision IR OIL amp GAS Annual Requirements Annual Maintenance Spare Parts All elastomeric seals need to be replaced regardless of condition Items 5 18 22 Expendable Items 2 3
28. the pressure of the inlet fluid falls below the set spring pressure the ball will be pushed back on to its seat and the fluid can pass downstream End Connection Options SPM s 2 Emergency Relief Valves are available with SPM wing union and Safety Iron end connections The nameplate will indicate the cold working pressure allowable for each assembly SPM wing union connections on the relief valves 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 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 This device is intended to discharge to atmospheric pressure when it relieves It should not be subjected to any significant back pressure The choice of discharge connections is offered as a convenience for the user and does not imply high pressure capability FAILURE DO SO CAN LEAD TO EQUIPMENT DAMAGE AND PERSONAL INJURY OR DEATH WARNING OBSERVE ALL INSTRUCTIONS CAUTIONS AND WARNINGS AS NOTED IN THIS MANUAL Figure 0 Discharge Document P N 2418192 Release Date 10 14 2014 ISR OIL amp GAS Revision IR SECTION II Installation and Operation Installation SPM s 2 Relief
29. tuart 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
30. w volume liquid pump with sufficient pressure capacity to meet the set value requirement The medium should be water or inert hydraulic oil suitable for this purpose explosive under pressure should the valve fail THIS CAN CAUSE SERIOUS INJURY OF DEATH All air must be purged from the valve and lines prior to building pressure Trapped air becomes recommended practice is to adjust the valve to full open no pressure prior to reset The valve should be oriented with the inlet end slightly down and the discharge port turned up as shown in Figure C Adjusting Screw Discharge High Pressure Low Volume Pump Pressure By fully loosening the adjusting screw the fluid will pass from the pump to the valve and purge the system of air The valve pressure setting can then be raised by rotating the adjusting screw clockwise R H and monitoring the gauge reading until the desired level is achieved Once the pressure is set the lock bolt should be retightened against the top of the valve cap by turning it clockwise while holding the adjusting screw steady The procedure of rotating the adjusting screw acts to vary the load that the disk springs apply to the ball and seat With a given valve setting the springs will cause the ball to bear against the seat with a given force The hydraulic pressure of the system works against the bottom surface of the ball defined by the cross sectional areas of the seat throat If the system pressure
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