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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

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..
Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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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Part Number: 2A33687

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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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Part Number: 2A33687

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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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Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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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Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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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Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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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Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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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Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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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Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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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Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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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Part Number: 2A33687

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Revision: B

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
counter- clockwise, 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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Revision: B

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 Required
Set Nitrogen (or gas)
Pressure Pressure
PSI 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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Revision: B

Pressure/ Temperature Ratings:


The SPM® 3” EXL Back Pressure Relief Valve is available in the following configurations at this time.

Part
Description Working Pressure (PSI)
Number
3-1502 Relief Valve Assembly EXL Back
2A33687 15,000
Pressure

Gas Side Specifications:


Low Pressure Working Range: 0 to 800 psi
Recommended Nitrogen Bottle: 2,500 psi, (1,000 min)

Operating Temperature:
-22F to 120F (-30C to 49C)

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Revision: B

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
DUMMY SEAT FOR TESTING RELIEF VALVE BODY,
5 1/2" ALUMINUM BAR 15
2P41038
6 SCREWDRIVER (FLAT TIP) 16 WRENCH EXTENSION, 2P24505
7 HOIST AND CHAIN - 500 LBS. RATING MIN 17 15/16” SOCKET 1/2" DRIVE
LPS LAB #02910 COPPER BASED ANTI-SEIZE OR
8 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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Revision: B

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:
PART
BOM ID QTY 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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Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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.

28
Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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).

29
Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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.

30
Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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.

31
Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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).

32
Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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.

33
Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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).

34
Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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.

35
Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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.

36
Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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.

37
Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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.)

38
Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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

39
Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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.

40
Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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.

41
Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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.

42
Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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

43
Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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.

44
Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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)

45
Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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.

46
Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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.

47
Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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.

48
Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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 a) System pressure hovering at a) Raise set pressure slightly


opening and closing) set pressure
b) Back pressure relief valve b) Relocate EXL Back Pressure Relief
located too close to pump’s Valve. Refer to service literature for
discharge information on proper location.
c) Valve installed before pressure c) Relocate relief valve behind pressure
dampener dampener

3. Loss of pressure (Valve a) Valve not set properly a) Set valve correctly.
does not seal or loses fluid
through discharge)
b) Damaged nozzle or valve gate b) Replace damaged parts
c) Damaged high pressure c) Replace damaged parts
cylinder connection
d) Contaminants trapped between d) Clean affected parts
valve gate and nozzle

4. Valve leaks through a) Damaged inner or outer or both a) Replace damaged seals
weephole or between flange seals
valve body and cap

5. Valve releases higher or a) Valve set incorrectly a) Reset valve to desired pressure per
lower than intended relief instructions in Section II
pressure

49
Part Number: 2A33687

Release Date: 8/27/2015

Revision: B

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..

50
www.weiroilandgas.com
www.weirinaction.com
Headquarters:
601 Weir Way | Fort Worth, TX 76108 | Ph: +1-800-342-7458 | Fax: +1-817-977-2508

NORTH AMERICA:
Houston, TX–Sales Office Rockies: LATIN AMERICA:
363 N. Sam Houston Pkwy. E., Suite 550
Billings, MT–Service Center Macae, Brazil–Service Center
Houston, TX 77060
255 Scott Str Rua Internacional, No 245,
Ph: +1-281-847-7270
Billings, MT 59101 Granja dos Cavaleiros
Fax: +1-281-820-2972
Ph: +1-406-256-2219 Macae, RJ Brazil
Deer Park, TX–Service Center Ph: +55-22-2106-8750
Fort Lupton, CO–Service Center
920 Seaco Court Fax: +55-22-2106-8777
13055 Weld County Road 8
Deer Park, TX 77536
Fort Lupton, CO 80621 Villahermosa, Mexico–Service Center
Ph: +1-832-200-6220
Ph: +1-303-535-5450 Bodega 3, Lote 8, Manzana 3
Fax: +1-832-200-6227
Fax: +1-303-535-5455 Sobre Calle San Lazaro
Mid Continent: Parque Logistico Industrial, Tobasco
Grand Junction, CO–Service Center
Villahermosa, Tabasco 86150
Bossier City, LA–Service Center 842 21 ½ Rd., Building A
Ph: +52-993-142-7083
2403 Grimmett Dr. Grand Junction, CO 81505
Shreveport, LA 71107 Ph: +1-970-243-4600 EUROPE, MIDDLE EAST, AND AFRICA:
Ph: +1-318-677-2422 Fax: +1-970-243-8027
Aberdeen, Scotland–Service Center
Fax: +1-318-677-5385
Williston, ND–Service Center Badentoy Industrial Park, Portlethen
Elk City, OK–Service Center 5073 Owans Industrial Park Drive Aberdeen AB12 4YD, Scotland
2111 S. Main Williston, ND 58801 Ph: +44-1224-783666
Elk City, OK 73648 Ph: +1-701-572-0776 Fax: +44-1224-784184
Ph: +1 580-225-2385 Fax: +1-701-572-0784
Dubai, UAE–Service Center
Fax: +1 580-225-3402
South and West Texas: Oilfields Supply Center, L.T.D., Building 18
Fort Worth, TX–Service Center P.O. Box 1518, Jebel Ali, Dubai, UAE
Odessa, TX–Service Center
7711 Wyatt Drive Ph: +971-48836-368
2424 E. I-20
Fort Worth, TX 76108 Fax: +971-48836-485
Odessa, TX 79766
Ph: +1 817-935-7964
Ph: +1-432-580-3887 ASIA PACIFIC:
Fax: +1 817-935-7365
Fax: +1-432-333-1351
Indonesia–Service Center
Kilgore, TX–Service Center
Pleasanton, TX–Service Center Jl. Mulawarman No.20 RT 20
1102 State Hwy 31 W
772 HWY 281 South Manggar, Balikpapan, Kalimantan Timur
Kilgore, TX 75662
Pleasanton, TX 78064 Indonesia 76116
Ph: +1-903-984-8153
Ph: +1-830-569-3571 Ph: +62 542 74 6098
Fax: +1-903-984-8626
Fax: +1-830-569-3643
Singapore–Service Center
Lafayette, LA–Service Center
Canada: 15 Tukang Innovation Drive,
401 S. Bernard Rd.
Singapore, 618299
Broussard, LA 70518 Edmonton, AB, Canada–Service Center
Ph: +65-6302-0852
Ph: +1-337-837-3161 4743 97th St.
Fax: +65-6302-0883
Fax: +1-337-839-1985 Edmonton, AB T6E 5W2
Ph: +1-780-438-1122 Perth, Australia–Service Center
Searcy, AR–Service Center
Fax: +1-780-437-5218 Henderson Service Center
2211 Taylor Road
20 Stuart Drive
Searcy, AR 72143 Grande Prairie, AB, Canada–Service Center
Perth, Western Australia 6166
Ph: +1-501-305-3296 8801 99th Street
Ph: +61-8-9410-7500
Fax: +1-501-305-3419 Clairmont, Alberta T0H 0W0
Ph: +1-780-567-3857 Adelaide (AUS)–Service Center
Northeast:
Fax: +1-780-567-2808 174 Cormack Road
Blairsville, PA–Service Center Wingfield
Medicine Hat, AB, Canada–Service Center
1519 Route 22 Hwy East Adelaide, SA, 5013
1202 Dirkson Drive N.E.
Blairsville, PA 15717 Ph: +61-8-8285-3133
Redcliff, Alberta T0J 2P0
Ph: +1-724-459-4770 Fax: +61-7-8285-3151
Ph: +1-403-504-8353
Fax: +1-724-459-4771
Fax: +1-403-504-8370 Shengli Oilfield
Buckhannon, WV–Service Center Weir Highland Pump Co, Ltd
Red Deer, AB, Canada–Service Center
52 Norwins Drive No.232 Nanyi Road, Dongying City,
Unit A, 8060 Edgar Industrial Crescent
Buckhannon, WV 26201 Shandong, China 257091
Red Deer, Alberta T4P 3R3
Ph: +1-304-472-9701 Ph: +86-546-7766997
Ph: +1-403-341-3410
Fax: +1-304- 472-9130 Fax: +86-546-77698
Fax: +1-403-341-3072
Williamsport, PA–Service Center MANUFACTURING:
76 Odell Road
Novatech
Muncy, PA 17756
8388 C.F. Hawn Freeway
Ph: +1-570-546-1005
Dallas, TX 75217
Fax: +1-570-546-2033
Ph: +1-214-398-1491

Updated: 7/22/15