exl back pressure relief valves operation instruction and

Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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 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, 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 protected worldwide by patents pending and registered in the name of S.P.M. Flow Control, Inc..

SPM® Well Service Pumps & Flow Control Products EXL Back Pressure Relief Valves Operation Instruction and Service Manual



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THE FOLLOWING ICONS DENOTE IMPORTANT INFORMATION WITHIN THIS MANUAL.

GENERAL INFORMATION

INSTALLATION AND OPERATION

MAINTENANCE AND REPAIR

SALES AND SUPPORT

NOTE

CAUTION

WARNING/ DANGER



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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 PERSONNEL INJURY OR DEATH!

Most Weir 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.

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 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 airborne.

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.



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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 & Gas factory prior to installation.

4. A complete 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 & 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 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 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 used must match (according to size, pressure rating, etc.). These connections must also match the service of the designated string they are installed in.



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CONTENTS

SECTION I: GENERAL INFORMATION .............................................................................................................................................. 6

THIS SERVICE MANUAL COVERS: ............................................................................................................................................................. 6 REBUILD KITS/CRITICAL COMPONENTS: ................................................................................................................................................ 6 PRODUCT DESCRIPTION: ........................................................................................................................................................................ 7 GENERAL DESCRIPTION OF RELIEF VALVE OPERATION: ....................................................................................................................... 8 END CONNECTION OPTIONS: .................................................................................................................................................................. 8

SECTION II: INSTALLATION AND OPERATION .............................................................................................................................. 9

INSTALLATION: ......................................................................................................................................................................................... 9 METHODS TO OPERATE RELIEF VALVE ................................................................................................................................................. 10 EXL BACK PRESSURE RELIEF VALVE CONTROL PANEL SETTING GUIDE (OPTIONAL) ...................................................................... 15 PRESSURE/ 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 COMPONENTS ..................................................................................................... 36 ASSEMBLY: ............................................................................................................................................................................................ 38 VESSEL TEST PROCEDURES: ............................................................................................................................................................... 47 SETTING AND ADJUSTING PRESSURE: ................................................................................................................................................. 47 ERV STAND ASSEMBLY: ....................................................................................................................................................................... 48 TROUBLESHOOTING GUIDE ................................................................................................................................................................... 49

SECTION IV: SERVICE AND SUPPORT ........................................................................................................................................... 50

SERVICE CENTER ORDER INFORMATION: ............................................................................................................................................ 50 WEIR OIL & GAS LOCATIONS:............................................................................................................................................................... 51



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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



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Product Description: The SPM® EXL Back Pressure Relief Valve provides increased efficiency during service/maintenance; improved safety mechanism in the event of a blocked discharge port and increased longevity of service by design. The following components of the EXL Back Pressure Relief Valve have been re-designed from the Legacy Back Pressure N2 valve:

Threaded Body/Flange Overhaul of both Upper/Lower inner components Removable Packing Assembly & Nut

These modified components to the EXL will benefit in the following ways:

Eliminates the area of danger in the event the valve’s discharge port is blocked Aids in a quicker re-kitting in the field Reduces assembly time

The SPM® EXL Back Pressure Relief Valve provides over-pressure protection for reciprocating pumps, treating lines, pressure vessels, and other equipment operating under high pressure, high flow conditions. Compact and simple to operate, the valve is direct acting, relying on the system'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.” Manufactured to Weir Oil & Gas’s stringent Quality Assurance System, all pressure bearing components are made from high quality material. The forged body features an integral wing union male inlet connection, suitable for the pressure rating of the component. The low-pressure outlet is available with an integral wing union connection. Conforming to conditions of design and performance in API RP520, the SPM® EXL Back Pressure Relief Valve is intended for liquid service. It is not intended for elevated temperatures or as a safety device in case of fire. Available in 3”, this valve offers pressure ranges from 1,000 – 15,000 psi. The valve is best suited for over pressure protection in a “slick water” medium.

DO NOT USE FOR H2S SERVICE! Contact your Weir Oil & Gas representative for advice about sour gas service applications.



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General Description of Relief Valve Operation: The SPM® EXL Back Pressure Relief Valve’s operation is a simple balance between the nitrogen acting on the piston and the inlet liquid pressure acting on the rod and wear sleeve. The equation is Pressure times Area equals Force (PxA=F). The ratio of areas is approximately 25:1 for the 15,000 psi rated valve. This means that nitrogen pressure of 100 psi can counter an inlet line pressure of 2500 psi for the 15,000 psi rated Back Pressure Relief Valve. Variations in this ratio in practice are due to friction of seals and will be discussed in setting and adjusting section on page 11.

End Connection Options: The SPM® 3” EXL Back Pressure Relief Valve is available with SPM® wing union connections. The nameplate will 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 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 must not be subjected to any significant backpressure; other than that generated by gravity or frictional losses on the discharge line. The choice of discharge connections is offered as a convenience for the user and does not imply high-pressure capability.

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!



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SECTION II: Installation and Operation

Installation: The SPM® EXL Back Pressure Relief Valve should be installed in a branch on the high-pressure pump line (Fig. 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”. Any application requiring localized protection of the high pressure pump is acceptable. However, this will require additional differential between the fluid pressure and set pressure of the valve to prevent “valve chatter”. Contact Engineering for additional recommendations. It is recommended to operate the valve in the upright position. This will reduce the tendency for proppants to accumulate around the sealing area and potentially affect the sealing performance. However, the valve will function within 90 degrees declination (Angle from vertical). 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 heavier liquids. Particulates, abrasives and contaminants will not preclude the valve from opening at the appropriate set pressure. However, abrasive materials will cause some wear between the wear sleeve, nozzle, and main seal. While these components feature wear resistant surfaces, their life will be reduced as the abrasives increase in the fluid.

WEIR OIL & GAS HIGHLY RECOMMENDS THAT AN ISOLATION VALVE BE PLACED BETWEEN THE PRESSURE LINE AND THE RELIEF VALVE. THE ISOLATION VALVE MUST BE IN THE OPEN POSITION DURING NORMAL OPERATION.

With the isolation valve installed, as shown in Figure 1, any time the pressure exceeds the set pressure at the EXL Back Pressure Relief Valve, the fluid will pass through the valve and out the discharge.

Figure 1



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Installation (Cont.): At low flow rates, the valve will discharge fluid at 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



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Methods to operate Relief Valve Weir’s SPM® EXL Relief Valve can be operated in the following ways:

1. Standard Gauges - This method uses the traditional regulators that are used to calibrate an adjacent

Relief Valve.

2. Legacy Control Panel – This method encompasses the standard gauges into a control panel that can be accessed away from the Relief Valve. Additional information can be found in “ SPM® Back Pressure RV Control Panel Setting Guide” and accessed via www.WeirInAction.com/downloads

3. Automated Relief Valve Control System (ARC System) – This system allows the operator to input a POP off and RESET pressure via an electrical control panel that automatically controls the Relief Valve by monitoring 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 valve is sequenced prior to each stage, than valve life decreases due to frequent exposure to abrasive fluids. The more the valve is exposed to abrasives, the greater likelihood that the valve will not reseat and possible washing may occur. The following information is to be used as a best practices guide, based on extensive field utilization, to assist the user in more convenient and accurate operation of the relief valve system. Refer to Figure 3 for N2 tank setting components.

WARNING: BLEED ALL PRESSURE FROM THE SYSTEM! (REFER TO DISASSEMBLY SECTION PG. 23)



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Standard Gauges – Calibration Guide Cont.

STEP 1 Turn the Black regulator counter clockwise all the way out as shown. (B) Open the valve on the nitrogen bottle (A). The inlet gauge should indicate the pressure in the Nitrogen bottle. Verify it is over 1,000 PSI.

STEP 2 Tighten the BLUE regulator fully by 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 clockwise until the Nitrogen line pressure reaches over 40 PSI over that desired pressure. The operator will hone in on that set pressure in later steps.



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Standard Gauges – Calibration Guide Cont. STEP 3 Perform a pressure test of pumping system to the desired “Pop-off” pressure (or opening of the valve). Hold at that pressure. The “Pop-off” setting in case of an over pressure incident must be at a minimum of 1000 PSI over the system operating pressure to prevent chattering and decreased life of the valve. As the system is holding pressure, calibration can begin by SLOWLY turning the BLACK (B) regulator now counterclockwise, at intervals of 5 PSI. A slight amount of fluid can be seen discharged 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 regulator (C) clockwise until the gas ceases to exhaust. The correct setting should be verified by manually pushing the Tattle-tale to the closed position. If it remains closed, the setting is correct. If the tattle-tale opens, then Nitrogen is still venting. This will require an additional clockwise rotation of the BLUE regulator (C) and closing of the tattle-tale to verify that Nitrogen is not venting.



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Standard Gauges – Calibration Guide Cont.

STEP 5 The use of the Tattle-tale will allow the user to indicate if there is a Nitrogen leak present during calibration. This 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 pushed in and remains closed.



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EXL Back Pressure Relief Valve Control Panel Setting Guide (Optional) The Nitrogen Relief Valve can be controlled remotely through the use of the SPM® Remote Control Panel. It regulates the flow of rig air or nitrogen to the relief valve and allows the operator to change pressure 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 page 11.

Additional information can be found in “SPM® Back Pressure RV Control Panel Setting Guide” and accessed via www.WeirInAction.com



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EXL Back Pressure Relief Valve Calibration Guide (Cont.) Values in this chart should be considered preliminary and if the predicted gas pressure does not produce the desired set pressure, you may have to adjust the regulator up or down. Some of the factors 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

10000 276 10500 290 11000 303 11500 317 12000 331 12500 345 13000 359 13500 372 14000 386 14500 400 15000 414



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Pressure/ Temperature Ratings: The SPM® 3” EXL Back Pressure Relief Valve 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: -22F to 120F (-30C to 49C)



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SECTION III: Maintenance and Repair

WARNING: DISASSEMBLY UNDER PRESSURE CAN CAUSE SERIOUS INJURY OR DEATH!

Always Remember:

1. Always wear PPE (personal protective equipment). 2. Only qualified technicians should perform maintenance on SPM® products. 3. Always use Weir Oil & Gas supplied new parts kit for reassembly. 4. Clean all components thoroughly prior to reassembly. 5. Check sealing surface area of valve gate and nozzle for pitting, erosion or other flaws. Failure in sealing

can result if these areas 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 SEAT FOR TESTING RELIEF VALVE BODY, 2P41038

6 SCREWDRIVER (FLAT TIP) 16 WRENCH EXTENSION, 2P24505

7 HOIST AND CHAIN - 500 LBS. RATING MIN 17 15/16” SOCKET 1/2" DRIVE

8 LPS LAB #02910 COPPER BASED ANTI-SEIZE OR EQUIVALENT

18 1/2” IMPACT ALLEN SOCKET

9 ASSEMBLY TORQUE TOOL, 2P39525 19 1/2” TORQUE WRENCH (10 – 100 FT LBS), P24509

10 NEEDLE NOSE PLIERS 20 IMPACT WRENCH



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Maintenance Requirements:

The SPM® 3” EXL Back Pressure 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 maintain its functionality. 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 & Gas recommends that the valve be serviced during the following: Preventative Maintenance (After 20 Fracturing Stages, or 1 Complete Frac Job) 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 or 1 frac job, whichever comes first. This should be done immediately following the completion of the current job. 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. The valve’s design allows for a quick and easy inspection of its internal components. The components that require inspecting are listed below and are referenced on the bill of materials on page 24. (Illustrated on pages 25-27) The components that must be replaced during a re-kitting are highlighted in yellow below.

Valve Gate Nozzle Assembly O-Ring Seal (under Nozzle Assembly) Spring Gate Bushing Spider

Disassembly/Inspection guidelines are on pages 24 through 32. The following kits can be ordered separately through Weir Oil & Gas Service centers:

P33637 Cartridge 2P39528 Spider 4L28050 Metal Seal Kit (Nozzle Assembly, Valve Gate) 2A37213 Full Kit

Annual Inspection

An annual inspection is required to ensure that all internal components of the valve are working properly and are to Weir Oil & Gas Engineering’s specifications. It is imperative that a qualified Weir Oil & Gas Technician follow the assembly/disassembly/inspection instructions illustrated on pages 33 through 36.



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Maintenance Requirements (Cont.): The SPM® EXL Backpressure Relief Valve incorporates both threaded and flanged connections within the design. These features are intended to provide easy internal access and maintenance-free performance. However, in the event the valve experiences leaking at either the threaded or 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 KEEP WEIR OIL & GAS SPARE PARTS ON HAND: ALL ELASTOMER SEALS SHOULD BE REPLACED REGARDLESS OF CONDITION. (28, 27, 11, 12, 8, 9, 17) Expendables: Valve gate (21), Nozzle assembly (26)



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BOM Table:

BOM ID QTY PART

NUMBER DESCRIPTION

1 1 P25003 LIFTING EYE

2 1 2P33647 CYLINDER

3 1 2P33754 HEX NUT

4 1 2P33645 BUMPER

5 4 P21181 SHCS

6 1 2P39369 HARD STOP

7 1 2P33855 PISTON

8 1 P23334 SEAL

9 1 P23303 SEAL

10 1 2P37763 SPACER

11 1 P23304 SEAL

12 1 P23333 SEAL

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 2P10257 WING NUT

32 1 P33001 CLEVIS PIN

33 1 2P40168 RETAINER SPRING

34 3 P23017 DOWEL PIN

35 4 P24708 SHSS

36 1 2P39527 BODY



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BOM/ EXPLODED VIEW



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FIGURE X



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FIGURE Y



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Preventative Maintenance and Disassembly:

ENSURE ALL 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.



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Preventative Maintenance and Disassembly (Cont.): STEP 3 Using the Assembly Torque Tool (9) loosen the valve’s top 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 ¼” NPT Bolts to push the Cylinder from Flange. Ensure that each bolt is evenly inserted and pushed to avoid a difficult disassembly.



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STEP 5 Once Cylinder has been removed with the crane, place it on the work table. Finish loosening the Top assembly 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).



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Preventative Maintenance and Disassembly (Cont.): STEP 7 Using the Flange Lifting Tool; position the assembly into the hole 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.



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STEP 9 Remove the Packing Nut (18) and Packing Assembly (16) from the 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).



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Preventative Maintenance: Inspecting Internal Components BODY (36): Visually inspect the O-ring groove area beneath the seal. This is a critical area. The body will need to be replaced if any indication of wear or damage is present. 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 the relieving function. The body should be replaced if any sign of damage is present.



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VALVE GATE AND NOZZLE: Spider (25): Visually inspect the fluid discharge areas for erosion and corrosion. Some wear is to be expected. If any damage extends deeper than .06”, then replace part. Valve gate (21) Nozzle (26), and O-ring (27): These are considered 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 may be conducted on new seals to increase performance. Contact Engineering for additional details.



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Preventative Maintenance: Replacement and Assembly of Metal Sealing Components 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.

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 nozzle assembly (26) and aligned with the discharge on the valve body (36). Install new union seal (28) in body (36).



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Preventative Maintenance: Replacement and Assembly Metal Sealing Components (Cont.) STEP 2 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.



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Preventative Maintenance: Replacement and Assembly Metal Sealing Components (Cont.) STEP 3 Install cylinder/ 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).



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Preventative Maintenance: Replacement and 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.



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Annual Maintenance: Disassembly and Repair of Cylinder 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.



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Annual Maintenance: Inspection of internal components (Cont.) FLANGE (15), PACKING ASSEMBLY/NUT (18): Visually inspect Flange (15) sealing surfaces for erosion/corrosion. Damage to this area will allow fluid to leak past the flange during the relieving function. If this surface shows signs of damage, the 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 (2): Visually inspect the inside surface of the cylinder for wear or damage. Damage to this surface renders this component unusable and should be replaced.



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Assembly:

WARNING: THIS MAINTENANCE SECTION IS TO BE ONLY PERFORMED BY A QUALIFIED Weir Oil & Gas SERVICE TECHNICIAN!

STEP 1: Install Set Screws (35) into Flange with a small amount of anti-seize. Ensure that Set Screws do not protrude opposite side of Flange (20). 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 Flange (15). Tighten Packing Nut (Coat Packing Nut, Packing and Flange Bore with Oil to assist in the installation.)



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STEP 2: Using the Flange Lift Tool, position the 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



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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.



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STEP 4: Secure the cylinder rod (20) vertical in a vise using flats at its length. 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.



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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.



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STEP 6: Remove Flange Hex bolts (35) and position place 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



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Assembly cont. STEP 7: 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.



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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)



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Assembly 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.



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Vessel Test Procedures: Prior to shipment, product testing procedure 4S12497 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 4S12497. Emergency relief valves should always be vessel tested in accordance with product testing procedure 4S12497. A fully assembled emergency 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 shown here for testing purposes only.

2. Attach valve to testing pump. 3. Fill with water and bleed off all air from the system prior to test. 4. Hydrostatically test by pressuring to 100% of product’s designed working pressure. 5. Hold pressure for the duration of time specified in 4S12497 spec. 6. Reduce pressure to zero.



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Setting and Adjusting Pressure: The EXL Back Pressure Relief Valve is direct acting. The pressure set on the nitrogen regulator is directly related to the relief pressure. The higher the nitrogen pressure, the higher the relief set point. Use the following procedure to obtain the correct set point. 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 Fracturing location. As shown in the illustration below, it is recommended that an isolation valve and a 90 degree elbow be used when setting up the Relief Valve.



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Troubleshooting Guide

Always follow existing Weir Oil & Gas procedures concerning identifying equipment for inspection, and removing equipment from service. The following is intended as a general guide in helping resolve most problems encountered in repairing emergency relief valves. If problems not covered here are encountered, contact Weir Oil & Gas for assistance.

SYMPTOM PROBLEM SOLUTION 1. Rapid erosion a) Used as continuous bypass a) Use only as an emergency back

pressure relief device b) Used beyond rated capacity b) Install sufficient quantity of valves to

meet capacity requirements 2. Shuddering (Rapid

opening and closing) a) System pressure hovering at

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 properly a) Set valve correctly.

b) Damaged nozzle or valve gate b) Replace damaged parts c) Damaged high pressure

cylinder connection c) Replace damaged parts

d) Contaminants trapped between valve gate and nozzle

d) Clean affected parts

4. Valve leaks through

weephole or between valve body and cap

a) Damaged inner or outer or both flange seals

a) Replace damaged seals

5. Valve releases higher or

lower than intended relief pressure

a) Valve set incorrectly a) Reset valve to desired pressure per instructions in Section II



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SECTION IV: Service and Support

Service Center Order Information: Weir SPM® stocks a large inventory of genuine original SPM® 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 and parts lists in this section) of each item ordered. The quantity of each part, kit, or assembly ordered. The model number and serial number Your purchase order number. 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 & Gas 601 Weir 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 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, 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 protected worldwide by patents pending and registered in the name of S.P.M. Flow Control, Inc..

Updated: 7/22/15

NORTH AMERICA:

Houston, TX–Sales Office363 N. Sam Houston Pkwy. E., Suite 550Houston, TX 77060 Ph: +1-281-847-7270 Fax: +1-281-820-2972

Deer Park, TX–Service Center920 Seaco CourtDeer Park, TX 77536 Ph: +1-832-200-6220 Fax: +1-832-200-6227

Mid Continent:

Bossier City, LA–Service Center2403 Grimmett Dr.Shreveport, LA 71107

Ph: +1-318-677-2422 Fax: +1-318-677-5385

Elk City, OK–Service Center 2111 S. MainElk City, OK 73648

Ph: +1 580-225-2385 Fax: +1 580-225-3402

Fort Worth, TX–Service Center7711 Wyatt DriveFort Worth, TX 76108

Ph: +1 817-935-7964 Fax: +1 817-935-7365

Kilgore, TX–Service Center1102 State Hwy 31 WKilgore, TX 75662

Ph: +1-903-984-8153 Fax: +1-903-984-8626

Lafayette, LA–Service Center401 S. Bernard Rd.Broussard, LA 70518

Ph: +1-337-837-3161 Fax: +1-337-839-1985

Searcy, AR–Service Center 2211 Taylor RoadSearcy, AR 72143

Ph: +1-501-305-3296 Fax: +1-501-305-3419

Northeast:

Blairsville, PA–Service Center1519 Route 22 Hwy EastBlairsville, PA 15717

Ph: +1-724-459-4770 Fax: +1-724-459-4771

Buckhannon, WV–Service Center52 Norwins DriveBuckhannon, WV 26201

Ph: +1-304-472-9701 Fax: +1-304- 472-9130

Williamsport, PA–Service Center76 Odell RoadMuncy, PA 17756

Ph: +1-570-546-1005 Fax: +1-570-546-2033

Rockies:

Billings, MT–Service Center255 Scott StrBillings, MT 59101

Ph: +1-406-256-2219

Fort Lupton, CO–Service Center13055 Weld County Road 8Fort Lupton, CO 80621

Ph: +1-303-535-5450 Fax: +1-303-535-5455

Grand Junction, CO–Service Center842 21 ½ Rd., Building AGrand Junction, CO 81505

Ph: +1-970-243-4600 Fax: +1-970-243-8027

Williston, ND–Service Center5073 Owans Industrial Park Drive Williston, ND 58801

Ph: +1-701-572-0776 Fax: +1-701-572-0784

South and West Texas:

Odessa, TX–Service Center2424 E. I-20Odessa, TX 79766

Ph: +1-432-580-3887 Fax: +1-432-333-1351

Pleasanton, TX–Service Center772 HWY 281 SouthPleasanton, TX 78064

Ph: +1-830-569-3571 Fax: +1-830-569-3643

Canada:

Edmonton, AB, Canada–Service Center4743 97th St.Edmonton, AB T6E 5W2

Ph: +1-780-438-1122 Fax: +1-780-437-5218

Grande Prairie, AB, Canada–Service Center8801 99th StreetClairmont, Alberta T0H 0W0

Ph: +1-780-567-3857 Fax: +1-780-567-2808

Medicine Hat, AB, Canada–Service Center1202 Dirkson Drive N.E.Redcliff, Alberta T0J 2P0

Ph: +1-403-504-8353 Fax: +1-403-504-8370

Red Deer, AB, Canada–Service CenterUnit A, 8060 Edgar Industrial CrescentRed Deer, Alberta T4P 3R3

Ph: +1-403-341-3410 Fax: +1-403-341-3072

LATIN AMERICA:

Macae, Brazil–Service CenterRua Internacional, No 245,Granja dos CavaleirosMacae, RJ Brazil Ph: +55-22-2106-8750 Fax: +55-22-2106-8777

Villahermosa, Mexico–Service Center Bodega 3, Lote 8, Manzana 3Sobre Calle San LazaroParque Logistico Industrial, TobascoVillahermosa, Tabasco 86150 Ph: +52-993-142-7083

EUROPE, MIDDLE EAST, AND AFRICA:

Aberdeen, Scotland–Service CenterBadentoy Industrial Park, PortlethenAberdeen AB12 4YD, Scotland Ph: +44-1224-783666 Fax: +44-1224-784184

Dubai, UAE–Service CenterOilfields Supply Center, L.T.D., Building 18P.O. Box 1518, Jebel Ali, Dubai, UAE Ph: +971-48836-368 Fax: +971-48836-485

ASIA PACIFIC:

Indonesia–Service CenterJl. Mulawarman No.20 RT 20Manggar, Balikpapan, Kalimantan TimurIndonesia 76116 Ph: +62 542 74 6098

Singapore–Service Center15 Tukang Innovation Drive,Singapore, 618299 Ph: +65-6302-0852 Fax: +65-6302-0883

Perth, Australia–Service CenterHenderson Service Center20 Stuart DrivePerth, Western Australia 6166 Ph: +61-8-9410-7500

Adelaide (AUS)–Service Center174 Cormack RoadWingfieldAdelaide, SA, 5013 Ph: +61-8-8285-3133 Fax: +61-7-8285-3151

Shengli Oilfield Weir Highland Pump Co, LtdNo.232 Nanyi Road, Dongying City,Shandong, China 257091 Ph: +86-546-7766997 Fax: +86-546-77698

MANUFACTURING:

Novatech8388 C.F. Hawn FreewayDallas, TX 75217 Ph: +1-214-398-1491

www.weiroilandgas.comwww.weirinaction.comHeadquarters:601 Weir Way | Fort Worth, TX 76108 | Ph: +1-800-342-7458 | Fax: +1-817-977-2508

exl back pressure relief valves operation instruction and

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