Weir SPM EXL Troubleshooting guide

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

Part Number: 2A33687
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

Part Number: 2A33687
Release Date: 8/27/2015
Revision: B
3
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.

Part Number: 2A33687
Release Date: 8/27/2015
Revision: B
4
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.

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 

Part Number: 2A33687
Release Date: 8/27/2015
Revision: B
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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

Part Number: 2A33687
Release Date: 8/27/2015
Revision: B
7
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.

Part Number: 2A33687
Release Date: 8/27/2015
Revision: B
8
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!

Part Number: 2A33687
Release Date: 8/27/2015
Revision: B
9
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

Part Number: 2A33687
Release Date: 8/27/2015
Revision: B
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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