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Weir SPM EXL, Инструкция по эксплуатации и руководство по обслуживанию

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Part Number: 

2A33687 

Release Date: 

8/27/2015 

Revision: B 

 

                         

5 

 

CONTENTS 

 

SECTION I: GENERAL INFORMATION

 .............................................................................................................................................. 6

 

T

HIS SERVICE MANUAL COVERS

:

 ............................................................................................................................................................. 6

 

R

EBUILD 

K

ITS

/C

RITICAL 

C

OMPONENTS

:

 ................................................................................................................................................ 6

 

P

RODUCT 

D

ESCRIPTION

:

 ........................................................................................................................................................................ 7

 

G

ENERAL 

D

ESCRIPTION OF 

R

ELIEF 

V

ALVE 

O

PERATION

:

 ....................................................................................................................... 8

 

E

ND 

C

ONNECTION 

O

PTIONS

:

 .................................................................................................................................................................. 8

 

SECTION II: INSTALLATION AND OPERATION

 .............................................................................................................................. 9

 

I

NSTALLATION

:

 ......................................................................................................................................................................................... 9

 

M

ETHODS TO OPERATE 

R

ELIEF 

V

ALVE

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

 

EXL

 

B

ACK 

P

RESSURE 

R

ELIEF 

V

ALVE 

C

ONTROL 

P

ANEL 

S

ETTING 

G

UIDE 

(O

PTIONAL

)

 ...................................................................... 15

 

P

RESSURE

/

 

T

EMPERATURE 

R

ATINGS

:

 .................................................................................................................................................. 17

 

SECTION III: MAINTENANCE AND REPAIR

 ................................................................................................................................... 18

 

M

AINTENANCE 

R

EQUIREMENTS

:

 ........................................................................................................................................................... 19

 

BOM

 

T

ABLE

:

 ......................................................................................................................................................................................... 21

 

P

REVENTATIVE 

M

AINTENANCE AND 

D

ISASSEMBLY

:

 ............................................................................................................................. 25

 

P

REVENTATIVE 

M

AINTENANCE

:

 

I

NSPECTING 

I

NTERNAL 

C

OMPONENTS

 ............................................................................................... 30

 

P

REVENTATIVE 

M

AINTENANCE

:

 

R

EPLACEMENT AND 

A

SSEMBLY OF 

M

ETAL 

S

EALING 

C

OMPONENTS

 ................................................ 32

 

A

NNUAL 

M

AINTENANCE

:

 

D

ISASSEMBLY AND 

R

EPAIR OF 

C

YLINDER 

C

OMPONENTS

 ............................................................................ 36

 

A

NNUAL 

M

AINTENANCE

:

 

I

NSPECTION OF INTERNAL COMPONENTS

 ..................................................................................................... 36

 

A

SSEMBLY

:

 ............................................................................................................................................................................................ 38

 

V

ESSEL 

T

EST 

P

ROCEDURES

:

 ............................................................................................................................................................... 47

 

S

ETTING AND 

A

DJUSTING 

P

RESSURE

:

 ................................................................................................................................................. 47

 

ERV

 

S

TAND 

A

SSEMBLY

:

 ....................................................................................................................................................................... 48

 

T

ROUBLESHOOTING 

G

UIDE

 ................................................................................................................................................................... 49

 

SECTION IV: SERVICE AND SUPPORT

 ........................................................................................................................................... 50

 

S

ERVICE 

C

ENTER 

O

RDER 

I

NFORMATION

:

 ............................................................................................................................................ 50

 

W

EIR 

O

IL 

&

 

G

AS 

L

OCATIONS

:

............................................................................................................................................................... 51

 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

Содержание SPM EXL

Страница 1: ...n 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 protecte...

Страница 2: ... Release Date 8 27 2015 Revision B 2 THE FOLLOWING ICONS DENOTE IMPORTANT INFORMATION WITHIN THIS MANUAL GENERAL INFORMATION INSTALLATION AND OPERATION MAINTENANCE AND REPAIR SALES AND SUPPORT NOTE CAUTION WARNING DANGER ...

Страница 3: ...roper functionality when exposed to fire 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 Weir SPM flow contro...

Страница 4: ...rvised by qualified management personnel or returned to Weir Oil Gas for service Only SPM replacement parts should be utilized Failure to do so may 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 SPM can lead to valve damage or failure and SERIOUS INJURY ...

Страница 5: ...E TEMPERATURE RATINGS 17 SECTION III MAINTENANCE AND REPAIR 18 MAINTENANCE REQUIREMENTS 19 BOM TABLE 21 PREVENTATIVE MAINTENANCE AND DISASSEMBLY 25 PREVENTATIVE MAINTENANCE INSPECTING INTERNAL COMPONENTS 30 PREVENTATIVE MAINTENANCE REPLACEMENT AND ASSEMBLY OF METAL SEALING COMPONENTS 32 ANNUAL MAINTENANCE DISASSEMBLY AND REPAIR OF CYLINDER COMPONENTS 36 ANNUAL MAINTENANCE INSPECTION OF INTERNAL CO...

Страница 6: ... 6 SECTION I General Information This service manual covers 2A33687 ASSY RLF VA 3 1502 FULL BORE THRD BP Rebuild Kits Critical Components 2A37213 Full Kit Metal and Seal kit 4L28050 Metal Seal Kit Nozzle Assembly Valve Gate P33637 Cartridge 2P39528 Spider ...

Страница 7: ... s hydraulic pressure to overcome a preset nitrogen gas force to relieve It is externally adjustable from zero pressure to maximum setting The SPM valve will reseat once the system pressure reduces Unlike many High Lift Valves which require a substantial drop in pressure before they will reseat the SPM Relief Valve exhibits little blow down and will reseat at or near the cracking pressure Manufact...

Страница 8: ...indicate the cold working pressure allowable for each assembly Wing union connections on the relief 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 Failure to observe good judgment may lead...

Страница 9: ...al The gas regulator and gas back pressure relief valve should be installed as close to the relief valve as possible The nitrogen filled high pressure cylinder must be secured to either a skid or trailer or by staking it to the ground All general Frac Fluids may be discharged through the valve The valve will tolerate clean liquids better than others and lighter liquids will flow greater rates than...

Страница 10: ... approximately the set pressure Fig 2 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 ...

Страница 11: ...a high pressure transducer that is installed on the main treating iron Additional information can be found in Automated Relief Valve Control A R C System and accessed via www WeirInAction com downloads Standard Gauges Calibration Guide This guide is to be used when calibrating the SPM EXL Back Pressure Relief Valve The valve should be set at a minimum of 1000 PSI above system fluid pressure If the...

Страница 12: ...y turning clockwise as shown Be sure not to over tighten C Review chart on page 15 to find the Line set pressure which is the pressure you want the valve to OPEN in case of an over pressure event To the right of that is the required Nitrogen pressure for the valve Field use has shown due to variables such as thermal compression and friction the best practice is the turn the BLACK B regulator knob ...

Страница 13: ...d from the outlet port of the valve Iron connected to the discharge port of the valve may need to be disconnected to see an immediate indication NOTE DUE TO THE SMALL AMOUNT OF DISCHARGE THE USER WILL LIKELY NOT SEE AN INDICATION IN THE DATA VAN STEP 4 Turn the BLUE regulator C counter clockwise until the gas starts to exhaust Tattle tale opens reference Step 4A Then slightly turn the BLUE regulat...

Страница 14: ...applies to both a stand alone Nitrogen Relief Valve and the Control Panel option The Tattle tale has two positions as shown To set the backpressure follow this procedure Slowly decrease the back pressure regulator BLUE dial C until the Tattle tale pops This is an indication that the Nitrogen is venting Slowly increase the back pressure regulator BLUE dial C until the Tattle tale is able to be push...

Страница 15: ...ure relief settings with the flow line The Remote Control Panel is also engraved with a quick reference chart for easy adjustment An as option available upon request is the Tattle Tale feature on the Control Panel This allows the user to have a visual indication when the N2 gas is venting during calibration Control Panel Components Setting and calibration is the same as previously described See pa...

Страница 16: ...s affecting performance include ambient and liquid temperature and the gas media used 3 EXL Back Pressure Relief Valve Set Pressure vs Nitrogen Pressure Performance Data Line Set Pressure PSI Required Nitrogen or gas Pressure PSI 350 0 500 14 1000 28 1500 41 2000 55 2500 69 3000 83 3500 97 4000 110 4500 124 5000 138 5500 152 6000 166 6500 179 7000 193 7500 207 8000 221 8500 234 9000 248 9500 262 1...

Страница 17: ...e is available in the following configurations at this time Part Number Description Working Pressure PSI 2A33687 3 1502 Relief Valve Assembly EXL Back Pressure 15 000 Gas Side Specifications Low Pressure Working Range 0 to 800 psi Recommended Nitrogen Bottle 2 500 psi 1 000 min Operating Temperature 22 F to 120 F 30 C to 49 C ...

Страница 18: ... are not smooth 6 Use only SPM Relief Valve parts on SPM Relief Valves 7 This device is intended to discharge atmospherically when it relieves ID REQUIRED TOOLS ID REQUIRED TOOLS 1 SAFETY GLASSES 11 STANDARD ALLEN WRENCH SET 2 PROTECTIVE GLOVES 12 VISE WITH ALUMINUM JAWS 3 2 LB HAMMER 13 BLUE LOCTITE 242 OR EQUIVALENT 4 600 GRIT SAND PAPER 14 FLANGE LIFTING TOOL 2A41047 5 1 2 ALUMINUM BAR 15 DUMMY...

Страница 19: ...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 The valve s design allows for a quick and easy inspection of its internal components The components that require inspecting are listed b...

Страница 20: ...r bolted external connections the valve must be immediately removed from operation and returned to the nearest SPM Service Center for inspection and repair Under no circumstance should the valve be allowed to continue operations with any visible external leak REGULAR MAINTENANCE SPARE PARTS NOTE ALWAYS KEEP WEIR OIL GAS SPARE PARTS ON HAND 19 21 22 26 27 ANNUAL MAINTENANCE SPARE PARTS NOTE ALWAYS ...

Страница 21: ...AL 13 10 P23863 SHCS 14 2 P29106 BREATHER VENT 15 1 2P33674 FLANGE 16 1 P33637 PACKING ASSEMBLY 17 1 P33757 ROD WIPER 18 1 2P39529 PACKING NUT 19 1 P16637 SEAL 20 1 2P39526 ROD 21 1 3P23880 GATE 22 1 P23879 SPRING 23 1 4P23875 BUSHING 24 1 P23878 PIN 25 1 2P39528 SPIDER 26 1 3P24314 NOZZLE ASSEMBLY 27 1 P28822 SEAL 28 1 4P10258 SEAL RING 29 1 P10261 RETAINER RING 30 3 3P10260 RETAINER SEGMENT 31 1...

Страница 22: ...Part Number 2A33687 Release Date 8 27 2015 Revision B 22 BOM EXPLODED VIEW ...

Страница 23: ...Part Number 2A33687 Release Date 8 27 2015 Revision B 23 FIGURE X ...

Страница 24: ...Part Number 2A33687 Release Date 8 27 2015 Revision B 24 FIGURE Y ...

Страница 25: ...LL PRESSURE IS RELIEVED PRIOR TO PERFORMING ANY MAINTENANCE OR DISSASEMBLY STEP 1 Remove any existing pressure on the valve Close high pressure N2 valve A Bleed down and remove N2 line to valve STEP 2 Secure valve in appropriate table with wing union connection Remove the two set screws 35 with Allen wrench ...

Страница 26: ...op assembly counter clockwise two 2 complete turns This will allow for easier access to all Top Flange Fasteners 13 With an Impact Wrench 20 and 1 2 Socket 18 loosen all fasteners 13 STEP 4 Remove Plugs 35 from bottom of the Cylinder Use NPT Bolts to push the Cylinder from Flange Ensure that each bolt is evenly inserted and pushed to avoid a difficult disassembly ...

Страница 27: ...ssembly from the Body as shown in a CCW manner Using the Flange Lifting Tool 14 lift the top assembly off of the Body STEP 6 Remove the cotter pin 24 with a Flat Tip Screw Driver 6 and Needle Nose Pliers 10 Tap the Clevis Pin 32 with a Hammer while holding bottom assembly Slide the Bottom Assembly away from the piston Gate 21 Spring 22 Bushing 23 Retainer Ring 33 ...

Страница 28: ... in the work table Pay special care to the threading of the Flange as it is placed into position Remove Hex Nut 3 Bumper 4 Hard Stop and Bolts 5 6 Piston and Piston Seal 7 9 and Spacer 10 from the Piston 20 STEP 8 Use a Hammer and rod to lightly tap the Cylinder Rod out of the Flange Hold hand in position as shown to guide and catch Cylinder Rod as it is removed from Flange ...

Страница 29: ...he Flange The Packing Assembly might require a small amount of force to remove This can be done by tapping it from the opposite side with a bar and hammer STEP 10 From Body Remove spider 25 from the valve body 36 Remove the nozzle assembly 26 Gently remove seal 27 from the valve body 36 Remove union seal 28 from body 36 ...

Страница 30: ...nt Visually inspect the fluid discharge surfaces for erosion or corrosion Some wear in this area is expected Any damage to this surface exceeding 100 renders the part unusable Thoroughly inspect the internal threads threads must be clean free of galling or damage Visually inspect the flange seal surface for erosion or corrosion Damage to this area will allow fluid to leak past the flange during th...

Страница 31: ...idered expendable items and spares should be kept on hand at all times The life cycle of these parts is dependent on the length and type of service Visually inspect the gate 21 and nozzle 26 for wear pitting erosion or corrosion damage These are critical components to the function of the valve Any indications of deterioration of sealing surfaces will require replacement of the component Lapping ma...

Страница 32: ...faces prior to assembly 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 STEP 1 Install new O ring 27 into O ring groove feature in valve body 36 Slip new or polished nozzle assembly 26 into the valve body Install spider 25 into the valve body aligning with dowel pins 34 ensuring it is flush to the noz...

Страница 33: ... Insert new or polished valve gate 21 into spring retainer 33 and fit over the wave spring 22 Install the bushing 23 into the spring retainer 33 Install assembly 23 21 22 and 33 onto cylinder rod 20 Then install clevis pin 32 into assembly then install cotter pin 24 Bend cotter pin 24 with pliers once installed to prevent pin from falling out ...

Страница 34: ...der flange assembly 15 into valve body 36 by gently lowering hoist and threading clockwise Use assembly torque tool SPM 2P39525 to tighten threads until they bottom out Use a hammer to strike the tool two times to ensure it is bottomed out Insert two set screws 35 into valve body to hold flange in place Install both breather vents into the side of flange 14 ...

Страница 35: ... Assembly Metal Sealing Components Cont STEP 4 If elbow fitting was removed apply Teflon tape and install Use shop air connect air to elbow fitting and stroke the piston up and down to ensure that it moves freely The valve is now ready for pressure testing as discussed in the vessel testing section ...

Страница 36: ...linder Components Repeat Steps 1 through 10 referenced on the Preventative Maintenance and Disassembly Section Pages 25 thought 29 Annual Maintenance Inspection of internal components ROD 20 Visually inspect the piston seal areas for damage or wear If damage or wear is evident the part should be replaced ...

Страница 37: ...body should be replaced Packing Assembly Nut 18 should also be visually inspected for wear or missing packing components that may have occurred during disassembly or usage It is unlikely that the Packing will be damaged due its robust design However if damage is seen during inspection it must be replaced with new packing Also inspect male threads for cleanliness and for damage or galling CYLINDER ...

Страница 38: ...0 Install Flange O Ring 19 on Flange O Ring Sealing pocket with small amount of oil Install Flange packing 17 into the Flange pocket inside the Flange Bore A small amount of oil as lubricant will assist the install Wrap Teflon tape over threads of Breather Vents 14 and install into the Flange Install Flange O Ring 11 Install Rod Wiper 17 into Packing Nut 18 as shown Insert Packing Assembly 16 into...

Страница 39: ...he Flange Assembly into a vise tightening it by the packing nut Rotate the Flange until it stops turning This should be sufficient enough rotation on the packing Install Flange PolyPack 12 into Flange as shown below Ensure that the Poly Pack O Ring side is facing down towards the Flange when installing ...

Страница 40: ...7 2015 Revision B 40 STEP 3 Install O rings 8 9 into around Piston 7 Position Hard Stop onto Piston 7 and secure with bolts 5 Apply Anti Seize over threads of Bolts Slide Bumper 4 into position as shown Lubricate ID OD of Piston with oil ...

Страница 41: ...ength Install the spacer 10 on the rod 20 Install Top Assembly as assembled in Step 2 Secure the piston 7 and bumper 4 assembly by the hex nut 3 with blue Loctite 242 or equivalent Lubricate cylinder rod 20 before inserting any components Tighten Bumper Nut 3 with Socket P39545 Once assembled remove from Vise and proceed to Step 4 ...

Страница 42: ... B 42 Assembly cont STEP 5 Insert Flange Assembly into Table hole to provide support Ensure that the Cylinder Rod is lubricated before attempting to enter the Flange Assembly The use of a rubber mallet may assist in installing the top to bottom assembly ...

Страница 43: ...the Cylinder 2 onto the Flange Assembly as shown Utilizing a Screw Nuts 5 8 11 UNC to assist in bringing the Cylinder flush with the Flange Body Once completed re install Flange Hex bolts into Flange and flip Assembly over to install the Fasteners 13 Apply Anti Seize to threads Use Impact to tighten all screws ...

Страница 44: ...e 21 into spring retainer 33 and fit over the wave spring 22 Install the bushing 23 into the spring retainer 33 Install assembly 23 21 22 and 33 onto cylinder rod 20 Then install clevis pin 32 into assembly then install cotter pin 24 Bend cotter pin 24 with pliers once installed to prevent pin from falling out ...

Страница 45: ...33687 Release Date 8 27 2015 Revision B 45 Assembly cont STEP 8 Install Dowel Pins 34 into Body 36 O Ring 27 followed by the Nozzle Assembly 26 and Spider 25 Ensure that the Spider 25 meets up with the Dowel Pins 34 ...

Страница 46: ... cont STEP 9 Using an overhead hoist position the Flange Assembly onto the Body as shown Once the Threads have been engaged use the Assembly Tool Wrench to tighten the top assembly onto the Body Once it has stopped turning ensure that the hard stops 35 are installed ...

Страница 47: ...mergency relief valve should NEVER be pressure tested with the outlet discharge port A FULLY ASSEMBLED EMERGENCY RELIEF VALVE SHOULD NEVER BE PRESSURE TESTED WITH THE OUTLET DISCHARGE PORT CAPPED OR BLOCKED OFF Below is an excerpt from 4S12497 regarding the proper vessel testing procedure on used emergency relief valves 1 Assembly valve body with threaded blanking dummy seat SPM PN 2P41038 as show...

Страница 48: ... A few attempts at working pressure may be required to confirm the set point Refer to Setting Guide for Calibration Procedure Page 11 WARNING BLEED OFF ALL PRESSURE FROM SYSTEM TRAPPED AIR WILL BECOME ENERGIZED AND MAY CAUSE INJURY TO PERSONNEL WHEN THE VALVE RELIEVES ERV Stand Assembly Weir provides an ERV Stand Assembly 2A41384 for easier installation and removal of the Relief Valve on a Fractur...

Страница 49: ...t set pressure a Raise set pressure slightly b Back pressure relief valve located too close to pump s discharge b Relocate EXL Back Pressure Relief Valve Refer to service literature for information on proper location c Valve installed before pressure dampener c Relocate relief valve behind pressure dampener 3 Loss of pressure Valve does not seal or loses fluid through discharge a Valve not set pro...

Страница 50: ...ir Way Fort Worth TX 76108 USA Tel 817 246 2461 Fax 817 246 632 www weiroilandgas com www weirinaction com Copyright 2015 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 ...

Страница 51: ...South Pleasanton TX 78064 Ph 1 830 569 3571 Fax 1 830 569 3643 Canada Edmonton AB Canada Service Center 4743 97th St Edmonton AB T6E 5W2 Ph 1 780 438 1122 Fax 1 780 437 5218 Grande Prairie AB Canada Service Center 8801 99th Street Clairmont Alberta T0H 0W0 Ph 1 780 567 3857 Fax 1 780 567 2808 Medicine Hat AB Canada Service Center 1202 Dirkson Drive N E Redcliff Alberta T0J 2P0 Ph 1 403 504 8353 Fa...

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