Excellent Oil & Gas Solutions Sur-Drop® Ball Injector Operating and Maintenance Instructions SAFETY WARNING: IMPORTANT: All personnel must be thoroughly trained about operation and maintenance requirements. From this point on, insure that the screw does not turn until Ball Injector is ready for operation. Improper use, operation, or disassembly under pressure can cause serious injury or death. III. MANUAL OPERATION: Install lid (2). Make sure that screw does not turn while lid is being installed on housing (1). If necessary, use 3/8" open-end wrench to hold screw top shaft stationary. I. DESCRIPTION: Install manual handle (16). Reset counter to zero. Install locking pin in handle. Ball injector is ready for operation. The SPM Sur-Drop® Ball Injector is a positive feed ball injector which has a maximum non-shock cold working pressure based on the type of body and union connections on the housing base. With the following union connections, 2” Figure 1502 2” Figure 1502 H2S 3” Figure 602 3” Figure 1002 3” Figure 1502 3” Figure 1502 H2S - Remove locking pin, rotate handle clockwise to drop balls. Every complete rotation will drop four balls. The crank handle should always be locked when not in use. 15,000 psi NSCWP 10,000 psi NSCWP 6,000 psi NSCWP 10,000 psi NSCWP 15,000 psi NSCWP 10,000 psi NSCWP IV. REMOTE OPERATION: A.) Connecting Remote Actuator (see Fig. 2): Install lid. Make sure that screw assembly does not turn while lid is being installed on housing. If necessary, use 3/8" open-end wrench to hold screw top shaft stationary. The Sur-Drop® will handle perf balls from 5/8" to 1¼" by means of one of three interchangeable screw assembly cartridges. Each screw assembly is marked for easy identification. The manual Sur-Drop® comes equipped with an actuation handle which has a resettable counter that displays the total number of balls dropped. An optional Remote Control Assembly (see Fig. 1, Fig. 2, Fig. 3, and Fig. 4) is available for 12-volt remote operation from up to 150 feet away from the Sur-Drop® Ball Injector. Capacity of the Sur-Drop® is as follows: Install remote actuator (1) onto ball injector. The coupling on the actuator shaft has a mating hex that will fit the top shaft of the screw. Fit is accomplished by moving the screw shaft slightly with the 3/8" open-end wrench. The actuator will then slide over the lid handles. Engage the actuator by turning slightly counterclockwise and engage restraining device (may be detent pin or locking lever depending on model). Connect the control cable from the actuator (1) to the control panel (2). The externally wrapped cable on the reel connects to the actuator whereas the shorter cable end under the cover in the center of the reel connects to the control panel. The power cable is connected from the control panel (2) to a convenient 12V. D.C. power source (such as an automobile battery). Insure polarity of clips is as shown on the tags. Remote operation is now possible. Capacity of the Sur-Drop® is as follows: Ball Size 5/8” & 3/4” 7/8” & 1” 1-1/8 & 1-1/4” Qty 165 130 100 II. SETUP: WARNING: A.) Loading Manually (see Fig. 4): Connecting the clamps to the battery opposite to that shown on the tags will cause the actuator to run backwards which will result in malfunction of the equipment. Remove handle (16) and lid (2), or if the unit is rigged for remote operation (see 1A24334, item 1), remove the remote actuator by raising locking lever; turning the remote actuator slightly clockwise to disengage L slot and lifting. Then remove the lid (2) by releasing setscrews and turning counterclockwise. Insure that the correct size cartridge for the ball size to be run is installed. To change cartridge, remove inner housing assembly (30) and change screw (5) as desired. When replacing inner housing assembly (30), insure that the hole in the top ring of the assembly is fully engaged on the guide pin (27) in the ball injector housing (1). Load the desired quantity of balls in the screw assembly cartridge by placing balls in each of the four open slots in the top of the cartridge. Using the manual handle (16), rotate the screw one complete turn and load four more; and so on until the desired quantity are loaded or until the maximum capacity is reached. Rotate the balls to the bottom insuring that balls are not dropped until actual operation is desired. B.) Remote Operation (see Fig. 2 & Fig. 3): 2 To drop balls: 1. Turn power selector switch to ON. a. The counter should power up (if not, check Fuse 1). 2. Set counter preset value. 3. Push the green START button. a. The START button should light up. 4. Select the direction to run the motor. a. Motor will start and run until counter is done when running in the forward direction (FWD). 5. To rotate in reverse direction (REV), select with toggle and then push the REV. JOG button. a. Motor will only run while push button is pushed. 6. In the forward direction (FWD), once the counter is done, select the toggle switch to the OFF position and reset the counter. The ball injector will drop the preset number of balls. Each time the switch is actuated to the 'FWD' position the ball injector will drop the preset number of balls until the supply is exhausted. During this time the green color bulb will be on. One line on the counter will dynamically display the number of "balls dropped", while the other line shows the "balls to drop". If for some reason a ball does not drop, it may be necessary to reverse direction. For that, simply return the toggle switch to reverse position (REV) and then push the "Jog. Rev" button as many times as needed to loosen the ball jamming condition. Then return the toggle switch to the OFF position. When the toggle switch is turned back to the FWD position, the counter will not start re-counting until returning to the previous stopping point, thus avoiding double counting balls. The operation will then be resumed normally. If during the course of dropping balls it is necessary to stop, simply return the toggle switch to the "OFF" position, and then the power switch to the "OFF" position. When the power switch is turned back to the "ON" position, it will be as if starting the operation over from the beginning. For instance, when the toggle switch is actuated to the FWD position, the injector will drop the preset number of balls, if they are loaded. When the operation is completed, disconnect all cables, clean and wrap control cable onto reel. Re-install caps on all end connectors. The ball injector should always be flushed with clean water after each job. WARNING: Improper operation, use or disassembly under pressure can result in serious injury or death. V. MAINTENANCE: General Practice (see Fig. 4): For maximum safe operation, all seals should be checked for nicks and cuts and proper sealing after each job. To change seals, o-rings and back-up rings, removal of the appropriate components will be necessary. See the Troubleshooting Guide below. Make sure all seal surfaces are smooth (32 RMS), and free of any nicks or burrs. Lightly coat seals and back-up rings and seal surfaces with petroleum jelly prior to installation. All threads should be clean, free of any foreign material, and coated with anti-seize or moly coat prior to assembly. All ball injector parts should be thoroughly cleaned and inspected during routine maintenance. Do not use parts with badly worn, cracked or missing threads. Inspect the housing (1) and housing base (3) for excessive wear and replace, if necessary. Make sure the screw assembly cartridges rotate freely and inspect stop plate in the bottom of the housing (1) for wear. 3 TROUBLESHOOTING GUIDE General Troubleshooting (see Fig. 4): Always follow existing company procedure 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 clapper check valves. If problems are not covered here please contact Weir SPM for assistance at (817) 246-2461. SYMPTOM CAUSE SOLUTION 1. Unit leaks around housing base (3), flange plate (4) or bottom of housing (1). Bottom housing seal (18) has failed. Replace seal (18) by removing the eight capscrews (17) holding flange plate (4) to base (3). Lift housing (1) out of base and replace seal (18). Reinstall housing (1) in base (3) and tighten capscrews (17) to 350 ft-lbs. torque. 2. Unit leaks around lower side of lid (2). Top housing seal (14) and back-up (15) have failed. Replace seal (14) and back-up (15) by removing lid (2). Replace seal (14) and back-up (15) and reinstall lid (2). 3. Unit leaks around top shaft of screw assembly cartridge (5) around threads of cap (12). Seal (10) has failed. Replace seal (10) by removing lid (2). Remove cap (12) using socket provided. Replace seal (10) and reinstall removed components. 4. Unable to install lid (2) completely. Hole in the top ring of inner housing assembly (30) is not fully engaged on the guide pin (27) in the ball injector housing (1). Reinstall screw assembly cartridge properly. 5. Screw assembly (5) will not turn. Possible jamming issues (see item 6 below). See item (6) below for remedies to jamming issues. Check drive stem and replace if broken or cracked. 6. Screw assembly (5) jams on operation. Incorrect ball size used with a specific cartridge. Dirt or other foreign particles accumulated in screw cartridge. Make sure the correct ball size is used with the appropriate cartridge. Clean screw cartridges as necessary after use to eliminate dirt and other foreign particles. VII. REPLACEMENT PARTS CONTENTS OF BALL INJECTOR KIT DESCRIPTION UNIVERSAL BALL INJECTOR KIT ITEM# QTY 1 10 1 11 1each 14 1each 15 1 18 1 21 1 26 PART # 2A28494 PART# P16636 P14354 P16637 and P101519* P16635 and P28365* P100230 P14378 2P27317 DESCRIPTION Polypak seal Bearing O-ring Back-up ring Polypak Seal Snap ring Drive stem * O-ring and back-up ring will vary depending on ball injector model in question (original/new). The part numbers in bold italic represent the components required for the new style ball injector assembly. This assembly is easily identified by the "fully machined" helical screw (within the external housing). The "original" style ball injector is identified by the welded helical screw. The service kit will include all necessary components for both the original and new style ball injector. The following drawings represent the various configurations available for the ball injector. Contact Weir SPM Sales for available sizes and mode 4 5 1A24334 ASSY NO. 1A24374 SLB PART NO. SPM a) TAG TO BEAR FOLLOWING DATA: SPEC. 4S24378 ASSEMBLY MUST CONFORM TO OTHER COMPONENTS ARE NOT TO SCALE. SCALE FOR ACTUATOR IS 1:2 APPLICATION 3 2. 1. NOTES: 'A' 2A28450 2A24373 R 3 2A24381 'B' 2A24335 - 'C' 2S25663 1 1 2 FIGURE 1 R R 4 1 R 3 3 SPM FIGURE 1 SLB FIGURE 2 R 4 %%UREEL %%UTO CABLE %%UACTUATOR TO %%UREEL %%UTO CABLE %%UCONTROL PANEL TO REV. DESCRIPTION 1 SEE ECN #3825 2 SEE ECN #4514 SEE ECN #4815 R 3 R R 4 SEE ECN #5225 R 2 BY JED JED Date 2003 03/20 2005 11/29 MMJ 2007 02/26 02/16 2 GMP 2009 R + .005 .XXX 125 surface roughness all machined surfaces .010 unless otherwise noted + 30' - + .01 .XX All diameters concentric to Angular tol linear tol fractional DIMENSIONS ARE IN INCHES + 1/32 - PART NO 'A' 'B' 'C' 4S24378 UNLESS OTHERWISE NOTED QTY 1 1 1 REF REF 2 %%UDC %%U12 VOLT 3 4 ITEM 2 Material: Description: Flow Control, Inc. SPM Date: Scale: DO NOT SCALE DRAWING DESCRIPTION ACTUATOR ASSY. REMOTE CONTROL UNIT ASSEMBLY ACTUATOR CALIBRATION SPECIFICATION PROCESS SPECIFICATION 7601 WYATT DRIVE FT WORTH TEXAS 76108-2587 Drawing No: Approved: Drawn by: MDM %%UREEL %%UTO CABLE 6 ASSEMBLY 3A16668 2A24335 PWR CABLE 'A' 3A24382 %%UACTUATOR TO ACTUAL PARTS MAY APPEAR DIFFERENT. FOR ILLUSTRATION ONLY. 2A24381 1. NOTES: LENGTH 'B' 20' 60' CONTROL CABLE 'C' 3A16667 3A16667 2 R LENGTH 'D' 150' 125' %%UCONTROL PANEL TO PART NO. 'E' P24371 P24383 3 R 1 1 REV. R R DESCRIPTION SEE ECN #3824 SEE ECN # 3 BY JED %%UDC %%U12 VOLT 03/20 Date 2003 1 1 2 1 Angular tol surface roughness all machined surfaces .010 unless otherwise noted 125 + 30' - + .005 .XXX All diameters concentric to + .01 - + 1/32 .XX fractional DIMENSIONS ARE IN INCHES linear tol 'A' 'C' 'E' PART NO UNLESS OTHERWISE NOTED QTY 1 3 ITEM 1 Material: Description: Flow Control, Inc. SPM Date: Scale: DO NOT SCALE DRAWING DESCRIPTION POWER CABLE CONTROL CABLE REMOTE CONTROL & REEL MOUNT %%UREEL %%UTO CABLE 7601 WYATT DRIVE FT WORTH TEXAS 76108-2587 Drawing No: Approved: Drawn by: MDM SERIAL NO. 15000 NSCWP b) c) ASSEMBLY %%C.88-%%C1.00 BALLS BALL INJ. PART NO. a) PART NO. 2A28452 NAME PLATE TO BEAR FOLLOWING DATA: SMALL I.D. FACING DOWNWARD. ITEM #8 MUST BE INSTALLED WITH 3 LOCATE ON FINAL ASSEMBLY. 1 2 'A' 2P27315 1 'B' 2P27340 5. 4. BALL QTY 130 B 7 REF D VIEW SCALE = 2:1 "B" 2 8 16 REF 2 REF D COUNTER LEVER TO BE POSITION SO THAT IT MAKES CONTACT WITH P(ITEM #19) ROLL PIN TO ACTUATE BALL COUNTER. ASSEMBLY TO BE PRESSURE TESTED TO 150% OF RATING PER SPEC. 4S12497 A 3 SCALE = 1:2 SECTION 23 24 A MFG DATE NSCWP NOTES: 7601 WYATT DR. FT WORTH, TX. 76108 SERIOUS INJURY OR DEATH. SEE MAINTENANCE GUIDE. "D-D" SPM SERIAL NO. ASSEMBLY NO. USE OR DISASSEMBLY UNDER PRESSURE CAN CAUSE INSPECT AND TEST PRIOR TO EACH USE. IMPROPER WARNING 7 R 3 (54.00) SCALE = 1:1 SECTION 17 "A-A" 19 18 REV. DESCRIPTION BY Date 2 1 1 4 1 1 1 1 1 1 17 16 15 14 13 12 11 10 9 8 'B' P22133 QTY ITEM .XXX .XX 125 surface roughness all machined surfaces .010 unless otherwise noted All diameters concentric to Angular tol linear tol fractional DIMENSIONS ARE IN INCHES + 30' - + .005 - + .01 - + 1/32 - PART NO 1 1 UNLESS OTHERWISE NOTED 2P28436 1 'A' 2P27319 2P10257 3P10260 P10261 P16636 P14354 3P13664 P14356 P16637 P16635 2A14371 P14949 3A24365 P14378 P16638 P10660 P10456 P101836 1P14968 3P14961 3P14871 P18055 2P27317 2 1 2 18 3 2 19 1 2 20 4 1 21 3 1 22 5 1 23 1 2 24 6 1 1 1 26 25 7 1 27 7601 WYATT DRIVE FT WORTH TEXAS 76108-2587 BALL INJECTOR ASSY LISTING Date: Scale: Material: 15000 NSCWP 3" FIG. 1502 MALE - MANUAL ACTUATOR Description: Flow Control, Inc. SPM DO NOT SCALE DRAWING DESCRIPTION BALL INJECTOR HOUSING SCREW ASSY LID WELDMENT WING NUT RETAINER SEGMENTS RETAINER RING POLYPAK BEARING CAP SEAL O-RING BACK-UP RING HANDLE ASSY ROLL PIN RISER CLAMP ASSY SNAP RING SCREW - 1/2"~13 x 2" LG. NUT - 1/2" LOCK WASHER SET SCREW LOADING TOOL (NOT SHOWN) HANDLING TOOL, SCREW ASSY (NOT SHOWN) NAMEPLATE DRIVE SCREWS DRIVE STEM ROLL PIN .250 x .75 INNER HOUSING Drawing No: Approved: Drawn by: BCW 2 1. NOTES: POWER TORK STYLE POWER TORK STYLE 8 SERIAL NO. 15000 NSCWP b) c) d) BALL QTY. 165 %%C.63-%%C.75 BALLS BALL SIZE 130 100 BALL QTY. 130 MFG DATE %%C.88-%%C1.00 BALLS %%C1.13-%%C1.25 BALLS 3" FIG. 1502 MxF - REMOTE BALL SIZE %%C.88-%%C1.00 BALLS 4" FIG. 1502 MxF - REMOTE PART NO. a) NAME PLATE TO BEAR FOLLOWING DATA: OTHER COMPONENTS ARE NOT TO SCALE. SCALE FOR BALL INJECTOR ASSY & ACTUATOR IS 1:2 ASSY P/N 2A28467 ASSY P/N 2A28466 P/N 'A' P/N 2A27422 'A' 2A28453 P/N 'B' P/N 1A24334 1A24334 1A24334 'B' 1A24334 1A24334 1A24334 2 2 1 3 %%UASSEMBLY %%UBALL INJECTOR TO REV. DESCRIPTION %%UCONTROL PANEL 2 BY Date QTY ITEM .XXX .XX 125 surface roughness all machined surfaces .010 unless otherwise noted All diameters concentric to Angular tol linear tol fractional DIMENSIONS ARE IN INCHES UNLESS OTHERWISE NOTED PART NO 1 1 + 30' - + .005 - + .01 - + 1/32 - 'B' 'A' 1 1 3 2 Material: Description: Flow Control, Inc. SPM 7601 WYATT DRIVE Drawing No: Approved: Drawn by: %%UREEL %%UTO CABLE FT WORTH TEXAS 76108-2587 ELECTRICAL ACTUATION Date: Scale: DO NOT SCALE DRAWING DESCRIPTION BALL INJECTOR ASSY REMOTE ACTUATOR ASSY BAND NAMEPLATE %%UDC %%U12 VOLT 3P17138 2 5. 4. SERIAL NO. 15000 NSCWP b) c) SCALE = 1:1 DETAIL "C" 18 REF 17 1 REF NSCWP MFG DATE "D-D" 7601 WYATT DR. FT WORTH, TX. 76108 SERIAL NO. SERIOUS INJURY OR DEATH. SEE MAINTENANCE GUIDE. USE OR DISASSEMBLY UNDER PRESSURE CAN CAUSE INSPECT AND TEST PRIOR TO EACH USE. IMPROPER SCALE = 1:2 SECTION SPM ASSEMBLY NO. WARNING COUNTER LEVER TO BE POSITION SO THAT IT MAKES CONTACT WITH P(ITEM #19) ROLL PIN TO ACTUATE BALL COUNTER. ASSEMBLY TO BE PRESSURE TESTED TO 150% OF RATING PER SPEC. 4S12497 PART NO. a) NAME PLATE TO BEAR FOLLOWING DATA: SMALL I.D. FACING DOWNWARD. ITEM #11 MUST BE INSTALLED WITH 3 LOCATE ON FINAL ASSEMBLY. 1 2 NOTES: 5 5 R REF 29 28 3 23 REF 18 9 REF 4 3 REF REF SCALE = 1:2 SECTION 20 "A-A" 24 22 D D A A C B 1 REV. 2 DESCRIPTION BY Date QTY ITEM + .005 - 125 surface roughness all machined surfaces .010 unless otherwise noted + 30' - + .01 .XXX + 1/32 .XX All diameters concentric to Angular tol linear tol DIMENSIONS ARE IN INCHES fractional REF PART NO UNLESS OTHERWISE NOTED 1 1 10 REF "B" DESCRIPTION BALL INJECTOR HOUSING LID WELDMENT HOUSING BASE FLANGE PLATE SCREW WING NUT RETAINER SEGMENTS RETAINER RING SEAL RING POLYPAK BEARING CAP SEAL O-RING BACK-UP RING HANDLE ASSY SCREW - 1"~8UNC SOCKET HEAD POLYPAK ROLL PIN SUPPORT CLAMP SNAP RING SCREW - 1/2"~13 x 2" LG. NUT - 1/2" LOCK WASHER SET SCREW DRIVE STEM GUIDE PIN NAMEPLATE DRIVE SCREWS INNER HOUSING ASSY SCALE = 2:1 DETAIL Material: Description: Flow Control, Inc. SPM Date: 2 REF REF 7601 WYATT DRIVE 21 11 FT WORTH TEXAS 76108-2587 000 NSCWP Scale: DO NOT SCALE DRAWING 5 ~ Drawing No: Approved: Drawn by: SPM® PRODUCT SAFETY GUIDE 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 PERSONAL INJURY OR DEATH! 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. 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 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. 10 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. 11 SAFETY INFORMATION ! WARNING IMPORTANT SAFETY INFORMATION ENCLOSED. READ THIS OPERATING AND MAINTENANCE INSTRUCTIONS MANUAL BEFORE OPERATING PRODUCT. IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PLACE THE INFORMATION IN THIS MANUAL INTO THE HANDS OF THE OPERATOR. FAILURE TO READ, UNDERSTAND AND FOLLOW THE OPERATING AND MAINTENANCE INSTRUCTIONS MANUAL COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH. Sur Drop® is a registered trademark of SPM Flow Control, Inc. Weir SPM 7601 Wyatt Drive Fort Worth TX 76108 USA © 2009 Weir SPM Tel: (817) 246 2461 Fax (817) 246 6324 www.weiroilandgas.com V.1 03/09
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