Spm-Exl Plug Valve
Spm-Exl Plug Valve
Spm-Exl Plug Valve
Revision: A
Copyright © 2017, S.P.M. Flow Control, Inc.. All rights reserved. S.P.M. Flow Control, Inc. is the owner of the copyright and all 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..
Document P/N: 2A36659
Revision: A
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 products contain elastomeric seals and are not intended to provide proper functionality when
exposed to fire.
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.
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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. The 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 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 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.
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TABLE OF CONTENTS
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TOOLS
2A38435 PLUG PUSHER
2A37197 CAP WRENCH
2A42166 ACTUATOR BEARING INSTALLATION TOOL
2A34084 4” PLUG VA/GEAR WHEEL OP HAMMER UNION – WHEEL
2A38394 4” PLUG VA/HYDRAULIC HAMMER UNION – HYDRAULIC
®
4” PLUG VA/GEAR WHEEL SAFETY IRON – WHEEL
2A36870
OPERATED
®
2A38493 4” PLUG VA/HYDRAULIC SAFETY IRON – HYDRUALIC
4" 1002 REBUILD KITS
4” 10K 2A38414 KIT/PARTS/PV/4 SP150WU/EXL PARTS KIT – 4” 1002/10K & 4"1502/15K
2A38417 KIT/SEAL/PV/4 SP150WU/EXL SEAL KIT – 4” 1002/10K & 4"1502/15K
TOOLS
2A38469 PLUG PUSHER
2A37333 CAP WRENCH
2A42166 ACTUATOR BEARING INSTALLATION TOOL
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Product Description:
Dual static face seals incorporate a self-energizing design to allow for proper sealing in
both low- and high-pressure applications
Proprietary pre-loaded seal segments create initial seal between dynamic seal surfaces to
eliminate sand trapping and decrease washouts
Dual grease ports on each side offer easy access, uniform grease distribution and decreased
maintenance time
SPM® plug valves are designed to regulate the transport of fluid through a flow line. By rotating the
plug 90°, the flow can either be terminated, or allowed to flow through the plug valve bore. They
require minimum space, are simple to operate, exhibit a fast response, and add relatively little internal
disturbance to the flow.
Operation is accomplished by a 90° rotation of the plug. This can be performed manually or with
wheel/gear or with hydraulic actuators.
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General Description:
All SPM® plug valves are in compliance with the following regulations:
Wing union connections on the plug 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.
SPM® Safety Iron® connections are universal, requiring no male or female as does the wing union.
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.
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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Bill of Material (BOM) is based off of Hammer Union configuration. Descriptions on unions
connection components may vary for SPM® Safety Iron® (S.I.) connections. See S.I. technical
literature for additional information.
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Required Tools:
DESCRIPTION ID DESCRIPTION
1 SAFETY GLASSES 13 IMPACT WRENCH
2 SAFETY GLOVES (CUT RESISTANT) 14 SOCKET (3/4")
3 SAFETY GLOVES (NITRILE) 15 SOCKET WRENCH
4 SAFETY BOOTS 16 CRESCENT WRENCH
5 LOCTITE® 243 17 RUBBER MALLET
GREASE GUN (HAND PUMP) – (P40156) – VALTEX
6 SUPER LUBE 41050 18 VIPER 8-11 OZ CAPACITY
7 C5A COPPER LOCTITE® ANTI-SEIZE 19 PIN SETTER
8 ALLEN WRENCH SET (STD) 20 HOIST
GREASE MACHINE (2A39533) – VALTEX QS-5000-
9 ACTUATOR BEARING TOOL (2A42166) 21 C – 5LBS CAPACITY
10 VISE (MOUNTED) - VALTEX 1502 (FOR ASSEMBLY) - P36791
VALTEX 972 (FOR RE-GREASING)
PLUG BODY PRESS TOOL (2A38435) P32553 – 5 LBS GREASE FOR MACHINE
11 See Page 5 for other sizes - P40230 – 8 OZ. FOR HAND PUMP
CAP WRENCH (See Page 5 for correct
AIR AND OTHER SHOP TOOLS MAY BE PREFFERED
12 size)
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Assembly
Mount Body onto table with union connection & Use Seal Segment Pin setter to install pins
Backup ring
Groove up
O-ring Lubricate seals with super
lube
Backup ring
O-ring
Plug Adapter Installation: Install Plug Adapter/Spacer and seals. Apply Super Lube® 41050
Synthetic Grease or approved equivalent on the seals as shown.
Use vise to position Spacer on so that Plug Adapter can easily install.
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Assembly continued
Thrust Bearing Installation: Lubricate thrust bearing liberally. Install thrust bearing into bottom of
valve body. Verify that its groove is facing up as highlighted in yellow. This is not a press fit, so it
should drop right into position.
Lubricate with
Valtex 1502
Adapter/Spacer Installation Use Actuator Bearing Tool (SPM® part number 2A42166) to install
Adapter/Spacer sub assembly into Plug Valve Body. Verify Adapter/Spacer Flats are perpendicular
to the Plug Valve Body bore. Using a rubber mallet, lightly tap assembly into position.
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Assembly continued
Segment Installation: Install Seal Segment Inner & Outer Seals. Apply a
coat of Valtex 1502 grease (SPM® part number P36791) onto whole
segment assembly
Segment Installation: Line up slots on Seal Segments to match the Body’s pins inside Body.
Install Segment assembly
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Assembly continued
Plug Installation: Use Plug Body Press Tool (2A38435) to press Plug down into Body.
(See page 5 for part numbers) The use of a lifting eye will assist in lowering the plug to avoid
pinched points. Once Plug is in position remove the lifting eye and use Body Press Tool to
lower Plug into position. Apply small amount of Val-Tex 1502 grease (SPM® PN P36791) onto
the Plug before installing.
Service Centers may have alternative methods installing/removing plug. It is advised that it is
approved by Weir Engineering before implementation.
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Assembly continued
Apply Anti-seize to the threads of the Cap
Nut
Cap Installation: Place Back-Up Ring (Concave Up) and follow it with the O-Ring Seal as shown
into the Cap Seal pocket grooves.
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Assembly continued
Cap Installation: Use appropriate Cap Wrench referenced on page 5 to tighten the Cap onto the body.
Tighten cap by striking tool firmly with mallet until the cap ceases to rotate. No specific torque value is
required.
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Assembly continued
Retainer
ring
Retainer
ring
Wing nut
Retainer
segments
Retainer
ring
Wing nut Installation: Install retainer ring onto plug valve body end as shown, followed by the
Wing Nut and Retainer rings. A flat tip screwdriver to open the Retainer Ring will assist in
installing the retainer ring into grove. Rotate body 180 degrees to complete the actuator
assembly.
Note: Ensure that the retainer segments are all installed in the correct configuration and are
SPM® manufactured.
(Please see S.I. technical literature for instructions regarding S.I. unions)
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Assembly continued
D
C
®
Actuator Assembly Installation: Apply a small amount of Loctite 243 onto set screw before
tightening with a 1/2” Allen Wrench. Line up Actuator and install the two Actuator keys. Install
and tighten washer and Actuator Bolt with 1/2” socket.
SPM® SPM®
P10064 P39430
Grease Fitting Installation: Install both grease fittings onto valve body. Tightening by hand
first will prevent cross threading from occurring.
There are two versions of the grease fittings as shown above. (Please see page 21 for details)
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a. P10064 – Standard product offering. Incorporates a 3/8” tapered pipe thread profile and must be
installed using Teflon tape
b. P39430 – Only available in the initial release. This fitting incorporates standard ¾” straight
threads and does not require Teflon tape.
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TORQUE SPECIFICATIONS:
AMOUNT OF TURNS FOR OPEN/CLOSE OF VALVE: 12 TURNS
RATIO: 48:1
MECHANICAL ADVANTAGE: 16.3
OUTPUT TORQUE: 42,4000
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Required Tools:
1. Assembly tools specific to size referenced on page 5
2. 400 Grit Sandpaper
3. Soft Face Mallet
®
4. Grease Gun (SPM P13335)
®
5. Val-Tex 1502 (Temp Range -20F to 400F) SPM P/N P36791 (For assembly)
®
6. Val-Tex 972- (Temp Range -20F to 600F), SPM P/N P32553 (For Re-greasing)
7. Appropriate PPE for your company; Safety Glasses, Steel Toe Boots, Gloves, Protective Clothing
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Maintenance Requirements:
®
SPM plug valves are made from high quality materials selected to provide the best performance for the
customer. However, the application of this product subjects it to handling fluids which are by their very nature
corrosive and abrasive. These fluids operate at high velocities and usually at high pressures. Some fluids may
also require being conveyed at elevated temperatures. Combinations of any and all of these conditions will
speed up the deterioration of internal surfaces including seals and seal surfaces.
Without the benefit of scheduled maintenance to routinely service and inspect the condition of components,
premature failure of parts can occur. This can lead to unnecessary material replacement along with the danger
of injury to personnel.
Proper usage and maintenance of the plug valve is necessary for safe operation. It is recommended that a
®
routine maintenance include the following criteria (contact the local SPM Service Facility for additional details):
Weir Oil & Gas recommends that the valve be serviced during the following:
Re-greasing the plug valve after every fracturing job or 20 stages (whichever comes first) will increase the
life of the plug valve. Normal working operations will allow for grease loss if the plug valve is not maintained.
This can create voids within the assembly. These voids will quickly accumulate sand and proppants thus
increasing the force required to open/close the valve. Frequent greasing of the valve will ensure easier
operation.
2. Periodic Inspection
Periodic inspections are required to ensure that all internal components of the valve are working properly and
are to Weir Oil & Gas Engineering’s specifications. All inspections must be completed by a qualified technician
®
following SPM approved procedures. It is imperative that technician follow the assembly/inspection instructions
beginning on page 12.
Rebuild Kits are available through Weir Oil & Gas Service Centers. They are referenced on page 5.
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Re-greasing Requirements:
During the manufacturing of the EXL Plug Valve it is in imperative that the following grease procedure
be followed. A hydraulic grease machine that is capable of delivering grease at pressures above 2,000
PSI should be used.
A. Assembly Valve and position on a secure table with the appropriate end connection (Hammer
®
Union or Safety Iron )
B. Ensure that the plug valve is in the OPEN position
C. Position grease end connection onto grease fitting on Side 1 of the plug valve
D. Pump grease till the gauge reaches 2,000 PSI (do not exceed 2000 PSI)
E. Rotate valve to CLOSED position then back to the OPEN position
F. Position grease end connection onto grease fitting on Side 2 of the plug valve
G. Pump grease till the gauge reaches 2,000 PSI (do not exceed 2000 PSI)
H. Rotate valve to CLOSED position then back to the OPEN position
I. Valve is ready for service
Side 2
Side 1
After each job, flush valve with clean water to wash away any contaminants in the valve. Upon completion of
®
the job, grease with approved SPM valve grease to displace contaminants in between valve’s internal
components. Engineering recommends using Val-tex 1502 Assembly Grease whenever disassembly of the
valve is required. To maximize the valve’s performance and longevity, it is recommended that the lubrication
maintenance procedure described below be followed:
1. Verify that the valve is in the OPEN position before pumping grease.
2. Using a hand pump grease gun (or grease machine), pump the lever in order to push the grease into the
®
valve. Val-tex 972 (SPM PN P32552) stick grease is recommended.
®
a. If using a pneumatic grease gun, SPM PN P28682 grease can be used.
3. Grease 1 side of the valve to 2000 PSI (do not exceed 2000 PSI)
4. Close and re-open valve
5. Ready for use
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Troubleshooting Guide:
PROBLEM: SOLUTION:
A.) Valve leaks through bore when closed 1. Seal segments from two different manufacturers have
been installed. (ALWAYS REPLACE SEGMENTS IN
PAIRS FROM THE SAME MANUFACTURER).
2. Sealing area of segments or body scored or pitted.
Resurface with 400 grit sandpaper or replace segments
and/ or body.
3. Plug scored or worn. Replace plug.
4. ID of body or OD of seal segments not cleaned properly.
Remove parts and clean out any contaminants. If the ID
of the body is not cleaned properly, this will not let the O-
ring or seal segments seat properly. ID of body may be
too pitted to reuse.
5. Segments seal left out, not properly installed, or damaged
during assembly. Remove segments, inspect seals and
reinstall or replace as necessary.
6. Wrong actuator cap installed forcing plug to tilt to one
side. Ensure actuator cap is from same manufacturer as
body. (Always use SPM® actuator caps on SPM®
valves).
B.) Valve will not fully open. 1. Worn or damaged actuator cap or not an SPM® actuator
cap. Remove and install SPM® actuator cap. (Always
use SPM® actuator caps on SPM® valves).
C) Valve leaks at body threads. 1. Body cap not tight. Re-tighten. Cap should bottom out.
2. Body cap O-ring scored or cut or no longer maintains
seal. Replace O-ring.
3. Body cap damaged or worn. Replace cap. (Always use
SPM® body caps in SPM® valves).
4. Install back-up ring above the O-ring with concave
surface touching the O-ring.
5. Seal area scored or pitted in body. Clean up with 400 grit
sandpaper or replace body.
D) Seals swollen and softened or tacky. 1. Avoid solvents. Buna seals are not compatible with
solvents such as toluene or xylene. If Buna seals are
used, replace with Viton.
E) Lower edge of plug chipped. 1. Always start plug into valve upon reassembly by hand to
align chambers on plug and seal segments. Hammering
plug before it is properly started can chip the plug’s
leading edge and often score or damage the seal
segments. Use only soft type hammers.
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The part number and description (refer to drawings and parts lists in this section) of each item ordered.
Specify method of shipment, complete shipping address, complete billing address and telephone
number at the destination of the shipment.
www.global.weir
Copyright © 2017, S.P.M. Flow Control, Inc.. All rights reserved. S.P.M. Flow Control, Inc. is the owner of the copyright and all 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..
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