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Weir SPM QWS 2500, Operation Instruction And Service Manual

The Weir SPM QWS 2500 is a high-performance pump designed for various industrial applications. To ensure optimal operation and maintenance, it is essential to refer to the comprehensive Operation Instruction and Service Manual. Easily download this manual for free from our website, and make the most of your Weir SPM QWS 2500.

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Document P/N:  2P136539 

Release Date:  05/25/2017 

Revision: F 

 

 

6 of 42 

 

 

SPM

®

 PRODUCT SAFETY GUIDE FOR WELL SERVICE PUMPS ....................................................................................... 2

 

SECTION I: GENERAL INFORMATION .................................................................................................................................. 7

 

U

SEFUL 

P

UMP 

D

ATA 

F

ORMULAS

: ............................................................................................................................................. 7

 

S

HIPPING AND 

S

TORAGE

: ........................................................................................................................................................ 9

 

SECTION II: INSTALLATION AND OPERATION ................................................................................................................. 10

 

SPM

®

 

QWS

 

2500

 

F

LUID 

E

ND 

D

ESCRIPTION

:

 ......................................................................................................................... 10

 

I

NSTALLATION 

H

IGHLIGHTS

: ................................................................................................................................................... 12

 

P

LUNGER 

L

UBE 

S

YSTEM 

R

EQUIREMENTS

: .............................................................................................................................. 15

 

R

ECOMMENDED 

P

LUNGER 

L

UBE 

O

ILS

: ................................................................................................................................... 16

 

R

ECOMMENDED 

P

LUNGER 

G

REASE 

L

UBE 

S

YSTEM

: ................................................................................................................ 17

 

P

LUNGER 

L

UBE 

C

IRCUIT 

D

IAGRAM

: ........................................................................................................................................ 18

 

S

UPERCHARGING 

S

YSTEM 

R

EQUIREMENTS

: ........................................................................................................................... 19

 

S

UPERCHARGING 

S

YSTEM 

O

PERATIONAL 

P

ARAMETERS

: ........................................................................................................ 21

 

S

TARTUP AND 

B

REAK

-I

N 

P

ROCEDURES

: ................................................................................................................................. 25

 

SECTION III: MAINTENANCE AND REPAIR: ...................................................................................................................... 28

 

R

OUTINE 

P

REVENTATIVE 

M

AINTENANCE

: ............................................................................................................................... 28

 

T

ROUBLESHOOTING 

G

UIDE

: ................................................................................................................................................... 31

 

SPM

®

 

QWS

 

2500

 

F

LUID 

E

ND 

R

EPAIR 

P

ROCEDURES

: ............................................................................................................ 33

 

S

UCTION 

V

ALVE 

S

TOP 

I

NSTALLATION FOR 

G

ROOVELESS 

F

LUID 

E

NDS

: .................................................................................... 37

 

S

UCTION 

V

ALVE 

S

TOP 

I

NSTALLATION FOR 

G

ROOVED 

F

LUID 

E

NDS

: .......................................................................................... 41

 

SECTION IV: SERVICE AND SUPPORT .............................................................................................................................. 42

 

G

ENERAL 

I

NFORMATION

: ....................................................................................................................................................... 42

 

 

 

 

 
 

 
 
 

TABLE OF CONTENTS

 

Summary of Contents for SPM QWS 2500

Page 1: ...has been provided without the prior written consent of the copyright owner SPM SAFETY IRON SAFETY HAMMER SUR DROP DESTINY STAMPEDE DURALAST and GLADIATOR are trademarks and or registered trademarks of S P M Flow Control Inc WEIR and WEIR logo are trademarks and or registered trademarks of Weir Engineering Services Limited Certain features of some of the products disclosed in this document may be p...

Page 2: ...de adequate guarding around the fluid end as well as the inlet and discharge piping to protect against burn injury A SPM well service pump operates at very high pressure and features some external moving parts It is the customer s responsibility to provide adequate warning and protection for personnel for when the unit is operated All images and drawings shown in this document are for representati...

Page 3: ...s been pressured beyond its specified working pressure should be returned to Weir Oil Gas for disassembly inspection and recertification 6 Welding brazing or heating any part of the pump with the exception of driveline companion flanges is prohibited If accessories must be attached consult Weir Oil Gas factory prior to installation 7 The SPM pump suction supply flow and pressure minimums in the pu...

Page 4: ...are anticipated the fluid cylinder must be completely drained of any fluid Failure to do this may result in fluid cylinder damage from fluids which have hardened or frozen 3 All SPM threaded components are right hand threaded unless specifically designated otherwise Any turning counterclockwise will unscrew the assembly Always make sure any threaded component is made up properly with the proper to...

Page 5: ...ting in any area must be returned to Weir Oil Gas for repair and recertification prior to operating again 6 All fluid cylinders in operation must be disassembled and inspected for cracks Fluid cylinder inspection should occur on a monthly basis or every 100 hours of operation The operation of any pump with even small surface cracks in any area of the fluid cylinder can result in equipment failure ...

Page 6: ...D PLUNGER LUBE OILS 16 RECOMMENDED PLUNGER GREASE LUBE SYSTEM 17 PLUNGER LUBE CIRCUIT DIAGRAM 18 SUPERCHARGING SYSTEM REQUIREMENTS 19 SUPERCHARGING SYSTEM OPERATIONAL PARAMETERS 21 STARTUP AND BREAK IN PROCEDURES 25 SECTION III MAINTENANCE AND REPAIR 28 ROUTINE PREVENTATIVE MAINTENANCE 28 TROUBLESHOOTING GUIDE 31 SPM QWS 2500 FLUID END REPAIR PROCEDURES 33 SUCTION VALVE STOP INSTALLATION FOR GROOV...

Page 7: ...ches T Torque foot pounds Pump Data Formulas To calculate the HHP output when the volume and pressure are known GPM x PSI HHP 1714 To calculate the BHP input required when the volume pressure and mechanical efficiency are known GPM x PSI BHP 1714 x ME To calculate the maximum possible pressure when the BHP flow and ME are known BHP x 1714 x ME PSI GPM To calculate the maximum possible flow when th...

Page 8: ...city are known GPM x 3208 Internal Area Required FV To calculate the maximum allowable GPM through a specified hose or pipe at a specified flow velocity when the internal area of the pipe and the desired flow velocity are known FV x A Max GPM 3208 To calculate pinion shaft or driveline torque when the input BHP and pinion shaft RPM are known BHP x 5252 Torque Pinion Shaft RPM Conversion Factors Mu...

Page 9: ... When fluid ends are shipped by ocean cargo care should be taken to crate the fluid end in a watertight container and ship below deck to prevent salt water contamination Care should be taken to prepare the pump for possible long term storage New fluid ends are not prepared for long periods of storage and should be put in service as soon as possible Follow the SPM preservation guide for fluid end s...

Page 10: ...l service applications such as acidizing fracturing well killing etc Optional packing assemblies valve assemblies discharge flanges suction manifolds etc are available for a wide variety of unitization arrangements for the pumping of various specific fluids and for service in a wide range of ambient conditions The weight of the fluid end assembly will vary slightly depending on plunger size and ot...

Page 11: ...Tapered well service type valve seats w auxiliary seal ring Valve Springs Long lasting coil springs engineered for a wide range of well service applications Designed for spring rates installed spring loads and valve cracking pressures unique to well service pumps Suction Valve Keepers Low fluid restriction type keepers located out of the high stress plane of the fluid cylinder Discharge Flanges Du...

Page 12: ...der over the rods and install the nuts hand tight Nuts are tightened to 2000 lb ft for both styles The tightening increments are 1 3 2 3 and full value in the pattern outlined on the following page Inspection of the stay rods in the field can determine if a pump has damaged stay rods Weir recommends that when you replace one stay rod you replacement them all You will also find the nut loose if bro...

Page 13: ... be done in a cross bolting pattern sequence Use sequence shown below First torque to 1 3 of full torque then to 2 3 torque Repeat full torque sequence until bolts nuts cease to move ITEM SIZE 1 3 TORQUE LUBED 2 3 TORQUE LUBED FULL TORQUE LUBED 1 3 4 8NC HEX NUT 667 FT LBS 1333 FT LBS 2000 FT LBS ...

Page 14: ... THE SPM QWS 2500 PUMP OR QWS 2500 FLUID END ASSEMBLY WITHOUT USING EQUIPMENT RATED FOR THIS LOAD CAN CAUSE EQUIPMENT DAMAGE PERSONAL INJURY OR DEATH WARNING DO NOT HANDLE LIFT INSTALL OPERATE OR MAINTAIN THIS SPM FLUID END WITHOUT READING THIS OPERATION INSTRUCTION AND SERVICE MANUAL THOROUGHLY TRAINING IN THESE DOCUMENTS IS A MUST FOR PACKAGERS OPERATIONS AND MAINTENANCE PERSONNEL FAILURE TO DO ...

Page 15: ...d be installed so that the bottom of the pump is no closer than 1 to the bottom of the reservoir 3 Packing Lubricant Flow Lines Should be 1 4 I D 1250 PSI minimum fiber or wire reinforced hose to prevent crimping Should be a common line from the lubricant pump to the plunger pump at which point it will branch off to each individual packing lube port 4 Flow Control Needle Valves Should be a 1 4 nee...

Page 16: ...or use in various ambient conditions as shown General Service for ambient conditions above 32 degrees F Rock Drill 100 or equivalent Cold Temperature Service for ambient conditions below 32 degrees F Rock Drill 68 or equivalent NOTE LUBRICANTS WHICH DIFFER SIGNIFICANTLY FROM THOSE SHOWN ABOVE ARE UNACCEPTABLE AND MAY RESULT IN A MUCH SHORTER PLUNGER AND PACKING LIFE OR PREMATURE FAILURE OF THESE C...

Page 17: ...fe Failure to provide adequate or appropriate lube will cause the packing to fail and cause damage to mating components NOTE LUBRICANTS THAT FAIL TO MEET THE PACKING LUBRICATION SPECIFICATIONS AND ESPECIALLY USED CRANKCASE OILS ARE UNACCEPTABLE Recommended Plunger Grease Lube System If the end user is going to modify the lubrication system to use grease at their discretion the plunger packing wipe...

Page 18: ...Document P N 2P136539 Release Date 05 25 2017 Revision F 18 of 42 Plunger Lube Circuit Diagram ...

Page 19: ... wire reinforced combination vacuum discharge hose rated at 305inHg 150 PSI minimum If steel piping is used all piping runs must be installed so that they are level or progressively higher toward the plunger pump in order to prevent air traps in the system When used reducer fittings should be of the eccentric type and installed belly down in order to prevent air traps All welded connections must b...

Page 20: ... charge pump and the SPM pump unless the pressure wave is dampened out of the system A suction pulsation dampener is necessary to ensure adequate fluid acceleration when each suction valve opens which will help prevent cavitation and will result in a much smoother operating pump and longer lasting expendables Guidelines for using a suction pulsation dampener are as follows A pulsation dampener of ...

Page 21: ... 470 11 2 Three Up to 626 14 9 Four Up to 783 18 6 Five Up to 940 22 4 Six Up to 1096 26 1 Seven Up to 1253 29 8 Eight Up to 1409 33 5 Nine Up to 1566 37 3 Ten Steel pipe size required to maintain 4 feet per second maximum fluid velocity in gravity feed portion of the system GPM FLOW BPM FLOW PIPE SIZE REQ D Up to 156 3 7 4 I D Up to 250 5 9 5 I D Up to 353 8 4 6 I D Up to 626 14 9 8 I D Up to 979...

Page 22: ...rally mounted horizontally See Fig 2 and fluid is usually provided to one end of the manifold This arrangement requires the fluid to travel horizontally and then make an abrupt 90 transition to enter the cylinder s suction valves While this is the most popular method for manifolding its limitations have become evident as rates and pressures have increased and liquid solids compositions have change...

Page 23: ...Document P N 2P136539 Release Date 05 25 2017 Revision F 23 of 42 ...

Page 24: ...Document P N 2P136539 Release Date 05 25 2017 Revision F 24 of 42 ...

Page 25: ...Document P N 2P136539 Release Date 05 25 2017 Revision F 25 of 42 Startup and Break In Procedures Please refer to the SPM QWS 2500 power end operation and service manual ...

Page 26: ...ing on your need Soft sets include Wiper Ring Peek Adapter Ring if applicable Pressure Ring s Header Ring Complete sets include Applicable soft set parts and Lantern Ring Adapter Spacer SPM Frac Pump Packing For use in the following SPM fluid ends in both legacy and SPM Duralast models TWS 2250 TWS 2400 TWS 2500 QWS 2500 QWS 2700 TEM 2500 and QEM 3000 Frac Pump Low Pressure This set includes a hea...

Page 27: ... NOT SERVICE THE FLUID END TO CHANGE PACKING PLUNGERS VALVE SEATS OR SEALS UNTIL THE PUMP IS LOCKED OUT TAGGED OUT AND ISOLATED FROM WELL BORE PRESSURE SUCTION INLET PRESSURE AND PRIOR TO RELIEVING THE PRESSURE WITHIN THE FLUID CYLINDER FAILURE TO DO SO COULD LEAD TO SERIOUS INJURY OR DEATH CAUTION REPLACING PACKING PLUNGERS VALVES VALVE SEATS REQUIRE OPENING UP THE FLUID PUMPING CHAMBER USE A VAL...

Page 28: ...ions usually 60 80 of suction inlet pressure Weekly Preventive Maintenance Check all items on daily list Check all valves inserts valve seats and springs Check all discharge and suction cover seals Check suction pulsation dampener for correct pre charge Monthly or every 200 hours Preventive Maintenance Check all items on daily and weekly lists Check all fluid cylinder mounting bolts to insure that...

Page 29: ...pendable Components A Expendable life improvement techniques a Valves and valve seats Valves and valve seats wear out faster than any other expendable due to valve seat wear and tear from frac sand and cavitation corrosion pitting Valve life can be extended by keeping valve flow through velocities below 12 feet sec and by using a properly sized correct style and properly installed pulsation suctio...

Page 30: ...NGING VALVES USE A MIRROR AND FLASHLIGHT TO CHECK FLUID CYLINDER FOR CRACKS AND WIPE ALL SURFACES CLEAN c Plungers Plungers should be replaced if the hard coating is worn if they have dents or dings spalling of the plunger coating or grooving d Packing Packing should be replaced prior to failure Packing failure can lead to washout of the packing gland Between stages check to see that all packing n...

Page 31: ... 2 Worn or damaged packing 3 Packing installed improperly 4 Mating seal surface not cleaned properly prior to packing installation 5 Damaged or corroded mating seal surface 5 Fluid being pumped is incompatible with the style packing being used 6 Wiper ring damaged or installed improperly D High pressure iron is jumping 1 Pump was not primed 2 Discharge valve s could be damaged 3 Discharge seat s c...

Page 32: ...ressure 5 Valve cocked open broken valve spring or valve stop 6 Worn or damaged valve valve insert or valve seat 7 Improperly charged or ineffective suction pulsation dampener G Low discharge pressure rough running pump 1 Worn or damaged valve assemblies 2 Insufficient supercharge flow or pressure 3 Air gas or vapor in fluid being pumped 4 Improperly charged or ineffective suction pulsation dampen...

Page 33: ...on in the fluid cylinder Each valve seat must be installed dry never use grease oil or any other substance to coat the tapered portion of the valve seat After installing the valve seat hand tight in the taper hammer it down tight into the taper using an old valve and a heavy steel bar 9 When installing new valve inserts do not install one manufacturer s valve insert on another manufacturer s valve...

Page 34: ... the lube passage is unobstructed 11 Each packing bore must be thoroughly cleaned and lightly hand polished with a 220 to 240 grit emory cloth prior to packing reinstallation 12 Using new packing header rings and new packing pressure rings reinstall the packing assembly one piece at a time refer to the Packing Assembly diagram included in this manual Each ring should be installed with a coating of...

Page 35: ... proper torque refer to drawing package for torque values To Remove the Suction Manifold 1 Using a 15 16 wrench remove the 7 8 capscrews which secure the suction manifold to the fluid cylinder and drop the suction manifold away from the fluid cylinder 2 Inspect the suction manifold for internal erosion and corrosion Remove the five suction manifold O ring seals and inspect the seal grooves in the ...

Page 36: ...ads prior to reinstalling the fluid cylinder For two piece stay rods the inner rod should be bottomed out into the power end with no additional applied torque NOTE IF A HYDRAULIC POWERED TORQUE WRENCH IS NOT AVAILABLE HAND TIGHTEN EACH STAY ROD AS TIGHT AS POSSIBLE WITH A 2 END WRENCH THEN TURN THE STAY ROD ANOTHER 30 DEGREES CLOCKWISE WITH AN OPEN END HAMMER WRENCH 5 Reinstall the fluid cylinder ...

Page 37: ...he following instructions show the correct method of installing suction valve stops in the Grooveless style fluid cylinders first introduced in 2004 1 Insert the valve stop with its base opposite the eye pointing towards the power end The eye of the stop must be closest to the suction cover side of the fluid cylinder Figure 1 ...

Page 38: ...ward edge of the base pointing downward while compressing the valve spring Catch the base inside the bottle bore of the fluid cylinder as shown in Fig 2 Figure 2 3 Continue to press the stop into the bottle bore until the spring is fully compressed Use the valve stop wrench if needed to assist Figure 3 ...

Page 39: ...ition see Fig 3 A slight push after rotating the bar stock will help push the rear lip past the bore edge 5 Release the valve stop into the bore until the spring secures the valve stop in place 6 The forward edge of the base should be resting against the taper of the bottle bore pointing to the power end The eye should be closest to the suction cover side of the fluid end 7 At this point the valve...

Page 40: ...cover without verifying that the cover post inserts into the valve stop eye Inspect post engagement by looking through discharge bore 9 Check the clearance see table below between plunger and suction valve stop for correct installation 10 Replace the suction cap seal with a new unit Figure 5 NOTE Maintain a 3 8 1 2 B gap between the suction cover valve stop and the end of the plunger WARNING USING...

Page 41: ...operly seated in the grooves in the cylinder and that it is turned perpendicular to the plunger Fig 6 Figure 6 3 Follow To remove valves and seats section of this manual for prepping covers and fluid cylinder for installation 4 Reinstall the discharge covers and suction covers using the SPM slide hammer Care must be taken to keep the discharge valve springs aligned properly while installing the di...

Page 42: ...ed within 90 days of the original shipping date Returned parts must be shipped prepaid to the appropriate address including a copy of the original invoice or delivery ticket Weir Oil Gas 601 Weir Way Fort Worth TX 76108 USA Tel 1 800 342 7458 Fax 817 977 2508 www global weir Copyright 2017 S P M Flow Control Inc All rights reserved S P M Flow Control Inc is the owner of the copyright and all confi...

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