Weir Safety Iron Manual

Document P/N: 2P42520
Release Date: 07/11/2016
Revision: D
Copyright © 2016, 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
Safety Iron
®
Operating and Maintenance Instructions

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WARNING: IMPORTANT SAFETY INFORMATION ENCLOSED. READ THIS OPERATING AND
MAINTENANCE INSTRUCTIONS MANUAL BEFORE OPERATING PRODUCT.
WARNING: 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 SERIOUS BODILY INJURY,
DEATH, OR PROPERTY DAMAGE.
Most SPM®products generate, control or direct pressurized fluids; therefore, it is critical that those who work
with these products be thoroughly trained in their proper application and safe handling. It is also critical that
these products be used and maintained properly!!
SPM
®
flow control products contain elastomeric seals and are not intended to provide proper functionality when
exposed to fire.
WARNING: MISUSE, SIDE LOADING, IMPROPER MAINTENANCE, OR DISASSEMBLY UNDER
PRESSURE CAN CAUSE SERIOUS BODILY INJURY, DEATH, OR PROPERTY DAMAGE.
The following information is given in good faith and should aid in the safe use of your SPM
®
products. This
information is not meant to replace existing Company's safety policies or practices.
Personal Responsibilities:
1. When working on SPM®flow control products, safety glasses, approved safety shoes and hard hat must
be worn.
2. Personnel should never hammer on any component when pressure is present. Hammering on any part
or component may also cause foreign material or steel slags to become 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.
SPM
®
PRODUCT SAFETY GUIDE

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On Location:
Each valve is clearly marked with a maximum pressure rating. This pressure must not be exceeded or
SERIOUS BODILY INJURY, DEATH, OR PROPERTY DAMAGE may occur.
1. 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.
2. Welding, brazing or heating any part of the product is prohibited. If accessories must be attached,
consult Weir Oil & Gas
factory prior to installation.
3. A complete visual inspection of the product must be made prior to each use. Any leaking seals, broken
bolts, leaking hoses or improperly tightened parts must be remedied prior to using.
4. Any repairs or service (even routine maintenance) performed on the product must be performed by a
trained service technician who is qualified to work on high pressure flow control products. 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 BODILY INJURY, DEATH, OR PROPERTY DAMAGE.
Special Precautions:
1. Modifications to or unauthorized repair of any part of a SPM
®
product, or use of components not
qualified by Weir Oil & Gas , can lead to damage or failure resulting in 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 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 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.
WARNING: OBSERVE ALL INSTRUCTIONS, CAUTIONS AND WARNINGS AS NOTED IN THIS
MANUAL. FAILURE TO DO SO CAN LEAD TO EQUIPMENT DAMAGE AND SERIOUS BODILY
INJURY, DEATH, OR PROPERTY DAMAGE.

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SECTION I: GENERAL INFORMATION .............................................................................................................. 5
THIS SERVICE MANUAL COVERS:........................................................................................................................... 5
SEAL RING KITS: .................................................................................................................................................5
OVERVIEW: .........................................................................................................................................................6
SAFETY IRON
®
–EXPLODED VIEW........................................................................................................................7
MAINTENANCE:....................................................................................................................................................8
IDENTIFICATION: ..................................................................................................................................................8
INSPECTION:........................................................................................................................................................8
ENGINEERING REFERENCE DOCUMENTS..............................................................................................................9
TEMPERATURE RATING........................................................................................................................................9
SECTION II: INSTALLATION AND OPERATION.............................................................................................. 10
INSTALLATION EQUIPMENT,ACCESSORIES &SPECIFICATIONS ............................................................................10
IMPACT WRENCH SPECIFICATIONS.....................................................................................................................11
SAFETY IRON
®
BOLT TORQUE VALUES................................................................................................................13
MINIMUM AIR REQUIREMENTS............................................................................................................................13
SECTION III: ASSEMBLY OF COMPONENTS.................................................................................................. 16
FLOW LINE INSPECTION .....................................................................................................................................19
SECTION III: DISASSEMBLY ............................................................................................................................ 20
TROUBLESHOOTING GUIDE ........................................................................................................................... 21
SECTION IV: SERVICE AND SUPPORT........................................................................................................... 22

TABLE OF CONTENTS

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This service manual covers:
Parts List Item
Size
(in) Pressure (PSI) Assembly PN Bolt Bolt Retainer Clamp (Plain) Soft/Hard Seal Clamp (Threaded)
1 2 3 4&5 6
2” 15,000 2A25919 2P25242 2P25243 2P25918 2A39288 2P25916
3” 15,000 2A25917 2P25247 2P25248 2P25904 2A39290 2P25910
4” 10,000 2A25927 2P25247 2P25248 2P25921 2A39294 2P25922
4” 15,000 2A25402 2P25233 2P25234 2P24728 2A39298 2P25232
Reference Exploded View of Assembly on Page 7
Seal Ring Kits:
Seal Ring Kits
Size (in) Pressure (PSI) Kit Part Number Type of Seal Hard Seal Soft Seal
2” 15,000 2A39288 Buna 2P38948 2P28294
2A39289 Viton 2P38948 2P25702
3” 15,000 2A39290 Buna 2P38949 2P28292
2A39291 Viton 2P38949 2P25704
4” 10,000 2A39294 Buna 2P38947 2P27767
2A39295 Viton 2P38947 2P28020
4” 15,000 2A39293 Buna 2P38949 2P28292
2A39296 Viton 2P38950 2P25377
SECTION I: General Information

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Overview:
SPM
®
Safety Iron
®
products are designed as an alternative to the traditional hammer union products used within
the oil and gas industry. Safety Iron
®
products eliminate the safety hazard of swinging a hammer to make up
and break down a connection while providing stronger, more durable connections that are less fatiguing for the
user.
Available in a broad range of configurations for use in high-pressure applications, these products are built to
exact specifications and meet the most rigorous quality standards from third parties such as DNV. SPM
®
Safety
Iron
®
products are available in 2”, 3”, and 4” sizes with pressure ratings up to 15,000 PSI.
Cross Section View – SPM
®
Safety Iron
®
Assembly

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SPM® Safety Iron®– Exploded View
Parts List
ID Description
1 Bolt
2 Bolt Retainer
3 Clamp (Plain)
4 Soft Seal
5 Hard Seal
6 Clamp (Threaded)

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Maintenance:
SPM
®
Safety Iron
®
products generally are not maintenance intensive. Care must be taken so that the threads
on bolts and clamps and all mating surfaces are lubricated, free of burrs, dents, gouges and dirt. Otherwise,
products should be maintained as directed. Typical maintenance would include properly cleaning, greasing, or
oiling the product after each use.
Identification:
SPM
®
Safety Iron
®
products are permanently identified on each individual component. All metal components
have full material traceability and are identified by their VENDOR ID (SPM), PART NUMBER, SIZE,
PRESSURE RATING, HEAT CODE.
Top View – Non Threaded Safety Iron
®
Half (Showing identification markings)
Inspection:
SPM
®
Safety Iron
®
components are generally more robust than their hammer union counterparts. Since no parts
are being forced or struck on a regular basis, the parts do not wear very quickly. However, certain features
should be inspected prior to use. Qualified personnel should review the overall installation before every use.
a) Flange faces should be free of significant burrs, gouges, dents, dirt, and cracks. The outer surfaces
are precision machined to fit against the clamp inner faces and are an integral part of maintaining a
proper seal.
b) Flange inner sealing surfaces should be clean and free of dirt or debris. Failure to clean these
surfaces could cause the connection to leak.
c) Bolt threads should be clean and free of burrs, gouges, and cracks. Bolts with damaged threads
should be replaced immediately.
d) Clamp threads should be clean and free of burrs, gouges, and cracks. Clamps with damaged
threads should be replaced immediately.
e) Clamp inner mating surfaces should be free of burrs, gouges, dents, dirt, and cracks. Clamps with
damaged inner mating surfaces should be replaced immediately.

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Inspection Continued
f) Soft seals should be inspected for tears or cracks. Seals showing significant wear or damage of any
sort should be immediately replaced.
g) Any part with excessive rust or corrosion that prevents proper assembly or sealing should be
immediately replaced.
h) Parts showing signs of internal washing, corrosion, acid pitting, or rust should be replaced.
i) SPM
®
recommends magnetic particle inspection on SPM
®
Safety Iron
®
clamps during the periodic re-
inspection for all applications involving strong vibrations.
j) Strings, treating lines, and equipment are recommended to be inspected every six months. SPM
®
also recommends routine hydrostatic tests on all SPM
®
Safety Iron
®
connections and equipment
k) Weld repair is prohibited for SPM
®
Safety Iron
®
products.
Engineering Reference Documents
The following list of SPM
®
Engineering documents serves as guidelines when working with Safety Iron
®
products. It is important that all are adhered to and are completed by a qualified technician.
ENG-051 SPM
®
Safety Iron
®
Clamp Assembly & Union Inspection
ENG-052 SPM
®
Safety Iron
®
Seal Polishing Requirement
2P38163 Inspection and Maintenance
2P36604 Manifold Trailer Operations Guide
BLLT1668 S.I. installed on mobile fixed applications
BLLT1224 S.I. Torque Values
ENG-086 10 Station Manifold Trailer Assembly procedure
Temperature Rating
All Safety Iron
®
products are rated as low-temperature product. Accordingly, they are certified for the below
temperature range:
For other temperature applications, please contact Engineering.
Temperature Ratings
Seal Type Minimum Maximum
Buna -30C (-22F) 100 C ( 230 F)
Viton -30C (-22F) 160 C (350 F)

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Installation Equipment, Accessories & Specifications
Installation of individual Safety Iron
®
components and systems should be done by persons qualified by Weir to
do so. WEIR
recommends training for all personal involved with installation and assembly of SPM
®
Safety Iron
®
.
Prior to installation, all SPM
®
Safety Iron
®
components should be inspected for improper or excessive wear,
insufficient lubrication, and general damage. Any damaged part should be immediately withdrawn from use.
In general, Weir suggests that customers adhere to the following principles:
a) Provided bolts should be clean and lubricated with an approved grease or lubricant. Stripped or worn
bolts should be immediately replaced with other SPM
®
-manufactured Safety Iron
®
bolts. These bolts are
specifically engineered for this application and are not to be replaced with unapproved bolts. Replacement
bolts must also have a SPM
®
-manufactured retainer ring installed (once bolt is inserted into a clamp) prior to
use in the field. Failure to install the retainer ring or replacing it (or the bolt) with non- SPM
®
parts can lead
to serious injury or death.
b) Provided clamps should be kept clean and lubricated on contact surfaces with an approved grease or
lubricant. Bent or worn clamps should be immediately replaced.
c) All bolted SPM
®
Safety Iron
®
connections should be initially made up with an approved power wrench.
d) All SPM
®
Safety Iron
®
connections except 4”15K should be torqued using a SPM
®
Torque Regulating
Bar. 4”15K Safety Iron
®
does not require regulating bar for assembly. This device should be verified by an
approved calibrated, manual torque wrench once during each job. This manual torque wrench should be
periodically calibrated to verify accuracy in the field.
Failure to follow Weir Oil & Gas suggestions for equipment, methodology, and verification may result in
improper installation of SPM
®
Safety Iron
®
components, possibly resulting in injury and even death.
Through product research and testing, Weir Oil & Gas has developed recommendations for the equipment and
products that should be used in the assembly and maintenance of SPM
®
Safety Iron
®
.
A) Bolt lubricant - To extend service life and ease of installation, SPM
®
recommends that all bolts be properly
lubricated. Using a general purpose anti-seize such as Loctite
®
C5-A is recommended.
B) Impact wrench – SPM
®
recommends the use of a pneumatic impact wrench for primary assembly of all
Safety Iron
®
connections. This wrench must be chosen to suit the torque requirements listed below and should
have a minimum drive of 1/2". However, a 3/4" drive impact wrench is recommended for larger sizes. If
required, an adaptor can be incorporated to allow the use of larger size impact sockets.
C) Seal pocket lubricant - SPM
®
recommends the use of Super Lube
®
41050 Synthetic Grease or approved
equivalent on all seals and Safety Iron
®
pockets.
SECTION II: Installation and O
p
eration

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Installation Equipment, Accessories & Specifications continued
Impact Wrench Specifications
C) Torque Regulating Bar (TRB) - Safety Iron® bolts must be properly tightened during assembly to preserve
the pressure and structural integrity of the joint. SPM
®
requires that all bolts be torqued such that they fall within
50 ft-lbs of the listed torque for each size of Safety Iron
®
. This is best achieved by employing the SPM
®
"Torque
Regulating Bar". (4” 15K does not require TRB)
Impact Wrench Specifications
Safety
Iron
®
Size
Pressure
Rating
(PSI)
Drive
Size (in)
Torque
Capacity
(ft-lbs)
2" 15K 1/2 50 to 400
3" 15K 3/4 300 to 1000
4" 10K 3/4 300 to 1000
4" 15K 3/4 300 to 1000
Torque Regulating Bar (TRB)
SIZE
(IN) PRESSURE (PSI) TORQUE (FT/LBS) PART NUMBER
2" 15K 130-230 P26641
3" 15K 300-400 P40935
4" 10K 300-400 P40935
4" 15K - CONTACT
ENGINEERING

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Installation Equipment, Accessories & Specifications continued
This device appears like a simple hex drive extension but is actually an engineered product that limits the
torque that an impact wrench can impart to a bolt. This functionality is achieved by a specific combination of
physical geometry and material properties of the steel. When the torque applied to the bolt reaches the rated
value of the extension, the shaft will flex. Before the next impulse from the impact gun can be applied, the shaft
will "spring" back. Any further attempts to tighten the bolt will only result in the shaft flexing in sync with the
blows from the impact wrench.
The extension is easily attached to the impact wrench using a 3/4” square male/female drive with a socket
retainer. The additional reach offered by the extension also helps to reduce worker fatigue.
The Torque Regulator Bar is capable of limiting torque to within +/- 25 psi of the rated value and is a function of
available air pressure. Due to this, SPM
®
requires that the extension be verified and calibrated before each job
(see Calibration Procedure).
TORQUE REGULATING BAR FOR ASSEMBLY ONLY.
DO NOT USE FOR DIS-ASSEMBLY

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Installation Equipment, Accessories & Specifications continued
Please note that over- or under-torqueing the bolts outside of the indicated range is detrimental to the
performance and safety of the assembly and may lead to leakage or even failure.
DO NOT USE TRB TO REMOVE BOLTS - FAILURE MAY
OCCUR.
Safety Iron
®
Bolt Torque
Safety
Iron
®
Size Pressure
Rating (PSI)
Torque
Capacity
(ft-lbs)
2" 15K 180 +/- 50
3" 15K 350 +/- 50
4" 10K 350 +/- 50
4" 15K 700 +/- 50
Safety Iron®Bolt Torque values
D) Minimum Air Requirements - In order for the impact wrenches and the TRB to function as intended,
minimum air requirements must be met. SPM
®
recommends 45 SCFM per impact wrench, with an air pressure
(measured at the impact wrench) of 90 psi. Failure to supply these minimum requirements will not allow the
wrench to achieve the rated bolt torque, and will increase assembly time do to starvation. In order to minimize
pressure drop from the compressor, it is recommended that the minimum hose size be observed.
Minimum Air Requirements
Safety
Iron
®
Size
Pressure
Rating
(PSI)
Air
Supply
(SCFM)
Air
Pressure
(PSI)
Minimum
Hose
Size
2" 15K
45 90
1/2"
3" 15K 1/2"
4" 10K 1/2"
4" 15K 3/4"
Minimum Air Requirements

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Installation Equipment, Accessories & Specifications continued
E) Manual Torque Wrench – SPM
®
recommends the use of a manual adjustable torque wrench to verify the
calibration of the Torque Regulating Bar. If this extension is not available, the manual torque wrench must be
used on each assembled Safety Iron
®
connection in order to verify the proper torque.
Each manual torque wrench has a 1/2" drive (or larger) in order to more easily match sockets used for the
impact wrench. The following pneumatic torque wrenches are recommended by SPM
®
for use in the assembly
of Safety Iron
®
:
Manual Torque Wrench Specifications
Safety
Iron
®
Size
Pressure
Rating
(PSI)
Socket Size
(in)
Torque
Capacity
(ft-lbs)
2" 15K 1/2" 50 to 250
3" 15K 1/2" or 3/4" 50 to 400 +
4" 10K 1/2" or 3/4" 50 to 400 +
4" 15K 1" 100 to 700
Manual Torque Wrench Specifications
F) Torque Regulating Bar Calibration Procedure - Due to variations in the operating characteristics of impact
wrenches, the torque level achieved by the torque stick should be verified before each job. It is important that a
regulator be installed on the compressor to allow for adjustments necessary to complete the calibration
procedure.
a. Adjust the air pressure delivered to the impact wrench so that the tool is operating at 90 - 100 psi at
the tool when the trigger is pulled. Note: the regulator may require a higher setting to maintain this
pressure.
b. Using the Torque Regulating Bar on the impact wrench, tighten a clamp bolt until the bar stops
turning.
c. Set a calibrated torque wrench to the maximum bolt torque allowed per the manual.
d. Check the clamp bolt with the hand torque wrench. The wrench should rotate before clicking is heard.
If clicking occurs without rotation, the torque is excessive and the system air pressure must be reduced.
e. Set a calibrated torque wrench to the minimum bolt torque allowed per the manual.
f. Check the clamp bolt with the hand torque wrench. The wrench should not rotate before clicking is
heard. If rotation occurs before the clicking, the torque is insufficient and the system air pressure must
be increased.

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Installation Equipment, Accessories & Specifications continued
G) Socket Size – SPM
®
Safety Iron
®
comes with specified bolt-hex head sizes. Sockets to tighten these bolts
are required to match perfectly. The following sockets should come (at a minimum) with a 1/2" drive:
Bolt Hex Head Sizes
Safety
Iron
®
Size
Pressure
Rating
(PSI)
Socket Size
(in)
2" 15K 1 - 1/2"
3" 15K 1 - 1/16"
4" 10K 1 - 11/16"
4" 15K 2 - 1/16"
Bolt Hex Head Sizes

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Repeated assembly testing has given Weir Oil & Gas the opportunity to determine the safest, fastest, easiest,
and most repeatable way to (dis)assemble SPM
®
Safety Iron
®.
The below instructions detail the suggested
steps in properly and successfully making up and breaking down SPM
®
Safety Iron
®
.
1. Verify the internal and external surfaces of the SPM
®
Safety Iron
®
flanges are clean and lubricated
with multi-purpose grease or heavy oil.
2. Verify that the seal ring outside surfaces are clean and lubricated with multipurpose grease. This will
ease removal at the time of dis-assembly. Insert the seal ring assembly into the bore of one of the SPM
®
Safety Iron
®
flanges.
3. Pull the two SPM
®
Safety Iron
®
flange faces together until they are touching each other (or as close
as possible).
SECTION III: Assembl
y
Of Com
p
onents

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Assembly of Components continued
4. Slide the threaded clamp half underneath the SPM
®
Safety Iron
®
flanges, pulling it snugly against the flange
outer faces. In the interest of eliminating a pinch point, it is best if the clamps are oriented at a 45 degree
angle (see bottom right photo). This configuration reduces the chance of a hand getting trapped beneath a
clamp or the piping assembly should it be dropped.
5. Set the plain clamp (with captive bolts) on top of the SPM
®
Safety Iron
®
flanges, orienting it so that the bolts
easily seat against the threaded holes in the threaded clamp. All fixed manifold applications will require
striking the top of the upper clamp with a dead blow hammer prior to tightening the bolts. This action will
ensure the clamp is fully seated and will reduce the "settling" of the clamp that may occur during initial
transportation of the manifold
6. Adjust the clamps as needed to get both bolts to engage easily. Rotate the bolts (by hand) roughly two full
turns to guarantee good thread engagement.

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Assembly of Components continued
7. Attach the Torque Regulating Bar to an approved power wrench. Care must be taken that bar has the
appropriate rating for the intended application. This is clearly indicated on the large end of the extension.
8. Tighten the bolts using an alternating pattern in which the bolts are incrementally rotated to ensure each
thread engagement length is similar. Continue this until the bolts no longer rotate.
9. Verify that the torque applied to the bolts is within the allowable range for each size. This is to be
accomplished by testing the first connection (see Calibration Procedure) using a standard torque wrench. If the
Torque Regulating Bar is not available, all connections must have the torque verified.

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Flow Line Inspection
Weir Oil & Gas strongly recommends performing a flow line inspection to verify that each clamp has been
assembled prior to pressurizing the line. This will require physically inspecting the underside of each clamp to
verify that bolt is within approximately 1/4" of the opening in the bottom threaded clamp. This action will provide
additional verification that any clamps that may have been loosened to allow for adjustment during the
installation process were properly re-tightened.
One way to ensure that an equal amount of torque is being applied to the assembly, the gap between the
clamp halves must be approximately the same on both sides as shown below. This is only to be used as
a sanity check after torqueing the assembly. If there is a significant difference in the gap between each side,
the assembly must be corrected per the discussed assembly steps covered in this manual. There is no gauge
for this operation, so it is vital that an experienced technician adhere to this manual and apply the correct
assembly procedure.

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Disassembly of components is roughly the reverse of the assembly. Do not use Torque Regulating Bar to
remove bolts - failure can occur. Care should be taken to loosen the bolts in a gradual manner.
The "two step" method of loosening the bolts is recommended.
1. Loosen one bolt to about its halfway point, then loosen the other the same amount
2. Loosen the first bolt all the way, followed by the other bolt.
Completely disassemble the connection and store the components as desired. It is recommended that clamp
halves be bolted together for storage to keep bolt threads from being damaged as shown below.
Care should also be taken to minimize damage to the metal seal rings by storing them such that they do not
come into regular contact (vibration) with other metal surfaces.
SECTION III: Disassembl
y