Automated Relief Valve Control (A.R.C.) System
Contents
1. 13 RP 13 Alarm Acknowledgement Screen 15 16 HIGH PRESSURE TRANSDUCER nenne nes sese aen 17 ARC D H G eee eee 18 Nen Ne 19 PPE OP 19 SETTING THE POP OFF AND RESET PRESSURES l I m hehe se eas segs seran 24 USING A R C SYSTEM WITH LEGACY BACKPRESSURE amp FULL UNLOADING RELIEF VALVES meme nne nne 25 USING THE A R C SYSTEM TO CONTROL MULTIPLE RELIEF mene ne 26 USING THE A R C SYSTEM WITH LEGACY N2 5 26 SECTION IV SPARE 27 FULL ASSEMBLY 2381 Lc sese na 27 DATA VAN COMPONENTS uuu uu u 28 SKID COMPONENTS 22383 71 29 NITROGEN HOSE ASSEMBLY 38118 seges reseau ana 30 ASSEMBLY HOSE REGULATOR BOX N2 TANK 58130 11111 31 SECTION V SERVICE AND SUPPORT 32 S2. SPM 5 PRODUCT SAFETY GUIDE A IMPORTANT SAFETY INFORMATION ENCLOSED READ THIS OPERATING AND MAINTENANCE INSTRUCTIONS MANUAL BEFORE OPERATING PRODUCT THIS INFORMATION MUST BE AVAILABLE TO ALL PRESONNEL THAT WILL OPERATE AND MAINTAIN EQUIPM ENT 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 WARNING MISUSE SIDE LOADING IM PROPER MAINTENANCE OR DISASSEM BLY UN DER PRESSURE CAN CAUSE SERIOUS INJURY OR DEATH The following information is given in good faith and should aid in the safe use of SPM products This information is not meant to replace existing user safety policies or practices SPM products contain elastomer seals and are not intended to provide functionality in the event of a fire Personal Responsibilities 1 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 2 DO NOT touch hot surfaces It is your own responsibility to protect against a burn injury 3 YOU MUST wear proper Personal Protective Equipment PPE when working on SPM flow control
3. Image 3 User Interface Panel 11 Part Number 2438151 Release Date 10 31 2013 SPAM Revision B Overall dimensions User Interface Panel 7 30 12 30 Image 4 User Interface Panel overall dimensions Bottom amp Side View 12 Part Number 2438151 Release Date 10 31 2013 SPM Revision B Main Menu Using the User Interface Panel Touch Screen LCD After powering up the ARC System s User Interface Panel the following screen will appear as shown in Image 5 below The Main Menu features three 3 buttons e Main This button will display the Main Screen as shown in Image 6 The Main screen will allow the user to input the desired Pop Off and Reset Pressures e Alarms This button will display the Alarm Screen as shown on Image 7 The Alarms Screen shows the current alarms and a button to silence Acknowledge the alarm e Admin This button displays a password protected Administrative section that is only to be used by a qualified Weir Oil amp Gas Technician OIL amp GAS Main Menu Image 5 User Interface Panel display 13 Part Number 2438151 Release Date 10 31 2013 SPM Revision Using the User Interface Panel Touch Screen LCD Cont Main Screen Easy Two Input Setup Pop Off Pressure amp Reset Pressure This feature eliminates the ERV calibration process which was once required with SPM s N Legacy Control Panel
4. SPM DIL GAS Revision lt Using the A R C System to control multiple Relief Valves The A R C System can be used to control multiple Relief Valves on location This is achieved by connecting the two Relief Valves to the Nitrogen Output Port Nitrogen of the Regulator Box A Tee can be used to split the Nitrogen hoses to each valve If Quick Disconnect QD hoses are used the use of a QD Tee Adapter will need to be used A Using the A R C System with Legacy N2 Setup Weir SPM s Legacy N Setup includes a Backpressure and Main Regulator as shown in Image 19 below The A R C System does not require either regulator Using the regulators will create a limit to the amount of Nitrogen Input going to the Relief Valve Image 19 Legacy Back Pressure M ain Regulator Setup 26 Part Number 1 Release Date 10 31 2013 LS SPIM Revision gt SECTION IV Spare Parts Full Assembly 1 N2 H Series Bottles HOSE P38130 TO N2 TANK CABLE P3815 TO CONTROL PANEL HOSE P38118 TO CONTROL PANEL CABLE P38149 TO TRANSDUCER HOSE P38118 TO N2 ERV 27 Part Number 2438151 Release Date 10 31 2013 Revision Data Van Components 9 04 1 P38128 CBL TRANSDUCER 1i P38152 ASSY CABLE COMMN 10 FT CNTL PANEL TO UIB 2 1 2P37881 UIB CNTRL PANEL N2 ERV 1 2P37883 CNTRL PANEL DATA VAN N2 ERV QTYREQD PART NUMBER NOMENCLATURE OR DESCR
5. products 4 YOU MUST use the proper tools when servicing the A R C System It is a personal responsibility to be knowledgeable and trained in the use and handling of tools for all maintenance of the A R C System Part Number 2438151 Release Date 10 31 2013 Revision SPM GAS On Location 1 N EVER weld braze or heat any part of the system If accessories must be attached consult the Weir Oil amp Gas factory prior to installation N EVER allow anyone but a trained service technician who is qualified to work on the equipment perform any repairs or service even routine maintenance on the A R C System All such service and repairs must be supervised by qualified management personnel or returned to Weir Oil amp Gas for service NEVER use anything but SPM replacement parts Failure to do so will void the warranty as well put you in risk of SERIOUS INJURY OR DEATH DO NOT TAMPER WITH THE POP OFF PRESSURE SETTINGS Tampering could result in serious injury or death The A R C System has built in settings to ensure that the desired pop off pressure cannot exceed 15 000 PSI ALWAYS PROPERLY CLEAN AND MAINTAIN The communication lines and nitrogen hoses should be properly cleaned and maintained before and after every fracturing job This will ensure their longevity and effectiveness during operation ALWAYS REPLACE any worn or damaged cables and hoses ALWAYS DO A VISUAL INSPECTION of the A R C
6. All that is needed to set the ARC System is two user inputs Pop Off and Reset Once these values are inputted the system determines the amount of Nitrogen to send to the Relief Valve This value is based off of real world data and has been modified to eliminate chattering of the Relief Valve during operation There are only 2 user inputs needed to set ARC System N2 Valve Pop off PSI INPUT FROM USER This is the desired Pop Off pressure of the Relief Valve 2 Valve Pop Off PSI 2 Valve Reset PSI N2 Valve Reset PSI INPUT FROM USER This is the desired pressure the Relief Valve will Reset close This will occur when the system pressure is equal or less than the Reset pressure for two seconds Image 6 Control Panel LCD Interface The system will continuously monitor the high pressure transducer until it indicates an over pressure event exceeding the POP Off pressure for an amount of 100 ms by default Dampening of the system pressure signal has been added to the programming to avoid pressure spikes from prematurely opening the valve Once an over pressure event has occurred the ARC System will dump the programmed Nitrogen from the Relief Valve thus opening until the system pressure normalizes for an amount of two seconds After the system pressure has normalized at or below the RESET pressure for the two second increment the system will send the programmed amount of Nitrogen back to close the Relief Va
7. System before each use Fix any leaking seals broken bolts leaking hoses or improperly tightened parts before using it Special Warnings 1 2 MODIFICATIONS Modifications to unauthorized repair of any part of a SPM product and use of components not qualified by SPM can lead to damage or failure the A R C system and even SERIOUS INJURY OR DEATH THREADS All SPM threaded components are right hand threaded unless specifically designated otherwise Any turning in the counterclockwise direction will loosen the assembly CLEANING AND LUBRICATION All products should be properly cleaned greased or oiled after each use and inspected prior to each use Part Number 2438151 Release Date 10 31 2013 SPMI Revision TABLE OF CONTENTS SECTION 1 GENERAL INFORMATION 1 6 THIS SERVICE MANUAL COVERS coco rasa 6 REPLACEMENT PARTS 6 BRIEF B nc B rael FET mc tocata 7 BRIEF OPERATIONS 7 7 m 7 OVE 8 SECTION 11 COMPONENT DESCRIPTION nnnm nnn 9 CONTROL 5 sese sese sese seas sese aes ana 9 6 9 MOUNTING HOLE DIMENSIONS CONTROL PANEL gt eR eh uana 10 USER INTERFACE 11 OVERALL DIMENSIONS USER INTERFACE 12 USING THE USER INTERFACE PANEL TOUCH SCREEN 100 m m Rene ern
8. 5 Elk City OK Service Center 2111 S Main Elk City OK 73648 Ph 1 580 225 2385 Fax 1 580 225 3402 Fort Worth TX Service Center 7711 Wyatt Dr Ft Worth TX 76108 Ph 1 817 935 7900 Fax 1 817 246 3970 Kilgore TX Service Center 1102 State Hwy 31W Kilgore TX 75662 Ph 1 903 984 8153 Fax 1 903 984 8626 Searcy AR Service Center Searcy AR 72143 Ph 1 501 305 3296 Fax 1 501 305 3419 PERMIAN Odessa TX Service Center 2424 1 20 Odessa TX 79766 Ph 7 Fax 1 NORTH EAST Blairsville PA Service Center 1519 Route 22 Hwy East Blairsville PA 15717 Ph 1 724 459 4770 Fax 1 724 459 4771 Buckhannon WV Service Center 52 Norwins Drive Buckhannon WV 26201 Ph 1 304 472 9701 Fax 1 304 472 9130 Horseheads NY Service Center 36 Level Acres Dr Horseheads NY 14845 Ph 5 Fax 41 607 739 1314 Williamsport PA Service Center 76 Odell Road Muncy PA 17756 Ph 1 570 546 1005 Fax 1 570 546 2033 ROCKIES Fort Lupton CO Service Center 13055 Weld County Road 8 Fort Lupton CO 80621 Ph 1 303 535 5450 Fax 1 303 535 5455 Grand Junction CO Service Center 842 21 1 2 Rd Building A Grand Junction CO 81505 Ph 0 Fax 7 Williston ND Service Center 5073 Owens Industrial Park Williston ND 58801 Ph 1 701 572 0776 Fax 41 701 572 0784 CANADA Edmonton AB Canada Service Center 4737 97th Street Edmonton Al
9. A Singapore Sales Office 15 Tukang Innovation Drive Singapore 618299 Ph 65 6302 0852 Fax 65 6302 0883 Australia Service Center Henderson Service Center 20 Stuart Drive Perth Western Australia 6166 Ph 61 8 9410 7500 Adelaide AUS Service Center 83 Rundle Road Salisbury South SA 5106 Ph 61 8 8285 3133 Fax 1 Toowoomba AUS Service Center Unit 4 24 Carroll Street Toowoomba QLD 4350 Ph 61 7 4633 708 Fax 61 7 4637 7083 CHINA Shengli Oilfield Weir Highland Pump Co Ltd No 232 Nanyi Road Dongying City Shandong China 257091 Ph 86 546 7766997 Fax 86 546 7769899 MANUFACTURING Novatech 8388 C F Hawn Freeway Dallas TX 75217 Ph 1 214 398 1491
10. E Weir Oil amp Gas recommends setting the Pop Off Pressure to at least 500 PSI below the maximum pressure rating of the system Touch the N Valve Pop off PSI button as shown in Image 16 Once this is pressed a secondary screen will appear on the screen END 0 1 5000 0000 2 Valve Pop PSI N2 Valve Reset 2 Bottle PSI Average System 1 Lo LJ Image 16 User Input Screen Image 17 Pressure input screen On the secondary screen the desired pressure can be entered by using the number keypad on the screen as shown in Image 17 The A R C System will not allow the pop off pressure to exceed the maximum rated working pressure of 15 000 PSI Once the desired Pop off pressure is entered the Enter ENT button should be pressed which will return to the main screen Enter the Reset Pressure by pressing the N Valve Reset PSI Button This value cannot be more than the POP off pressure Once the desired Reset Pressure is entered the Enter ENT button will have be pressed which will return to the main screen At this point the system will release the programmed amount of Nitrogen Gas to the Relief Valve The system is now ready for use Field verification of the POP OFF pressure can be achieved by increasing the fluid pressure until the valve discharges The valve will automatically reset after the fluid pressure drops below the RESET pressure for an amount
11. ERVICE CENTER ORDER INFORM 32 WEB GAS LOCATIONS 33 Part Number 2438151 Release Date 10 31 2013 SPM Revision DIL amp GAS o SECTION I General Information This service manual covers 238151 Control Panel Assembly Top Level Assembly Replacement Parts See Section IV Spare Parts Part Number 2A38151 Release Date 10 31 2013 SPM OIL amp GAS Revision Brief Description Features The A R C System provides a simple method to operate SPM s Nitrogen Relief Valves and will supersede SPM s Legacy N Valve Control Panel It provides the following features Easy Two Input Setup Pop Off Pressure amp Reset Pressure Can be used with SPM s Legacy or next generation Back Pressure and Full Unloading Relief Valves with no or little modification Multiple Valves can be controlled with one system Remote Nitrogen Bottle Monitoring Backup Power System w auto re charge Dampening of the input signal to eliminate fluctuations of system pressure to avoid false overpressure events Emergency Shut Down Frac Site Ready Skid which provides easy installation and cable management Warning Alarm Indicators Brief Operations Setup Simple setup allows the user to quickly ready the system for use The following summarizes the simple setup requirements for the A R C WN Position A R C Skid no more than 150 ft between the Data Van and 25 ft from the Relief Valv
12. ION III OPERATION Pre Op Checklist The following steps shall be followed in order to prepare the A R C for operation YOU MUST complete the following checklist before powering ON the system l Position the A R C Skid in a position that is desired preferably between the Data Van and the Relief Valve The total distance must be less than 150ft from the Data Van and 25ft from the Relief Valve s a Rem ems dumm de mesi Gems ae A ME SS SS SSS ee CABLE P38150 TO CONTROL PANEL Data Van Components O CABLE P38149 TO TRANSDUCER HOSE P38118 TO N2 ERV 2A38159 KIT DATAVAN CNTRL PANEL N2 ERV 2A38143 ASSY SKID CNTRL PANEL N2 ERV D PART NUMBER NOMENCLATURE OR DESCRIPTION Image 11 Control System Assembly with Skid 19 z Part Number 2438151 Release Date 10 31 2013 Revision Pre OP Checklist Continued 2 Connect Nitrogen hose via the N reel Hose Part P38118 to the Nitrogen Relief Valve as referenced in Image 12 This is a Quick Disconnect connection 3 Connect the N hose from the Nitrogen tank to the INPUT PORT NITROGEN connection as shown in Image 13 One end of this hose is fixed to the Regulator Unit while the other is a Quick Disconnect going to the N Tank Visual inspection will determine if any Nitrogen connections are damaged or loose If necessary all damaged connections should be replaced before operation Ensure that 2 wrenches are used to av
13. IPTION 28 SPM 2A38151 Part Number Y c O N c m O ci Release Date Revision 2A38371 Skid Components NOLLATHISIO HO JYNLYTINIWON Awa ZN T3NVd THIND XS 00T XAW 13398 ANVL OLIN 01 52 01 e 1 350H ASSY _ XO 934 OL 138 8b 01 e 1 350H ASSV QL 91 b T 350H ASSV TALNO OL u2O0SNuL LJ 0S1 31892 A55 v T3NVd TALNI OL 938 14 OST 318v2 ASSV 29 V SPM 2A38151 Part Number m c O N c m O ci Release Date Revision Nitrogen Hose Assembly P38118 M 1 53 YO TYNLYTONIJWON XVI 154 0005 45 05 ST FC Ec 9T N T3398 8 T ASSW 12NNOSG 320 Sd 1XV 91 Sc ss sawa rLLdNE T GI E T 34SOH ASSV NVNN3g lLLdNE T X ALdN8 T 06 TT3 5 80 90 NVNN33g VLLdNZ T X ALdNE T WLdOV rli wma i Aga TN OL SPIM 2A38151 Part Number Y c Oo c m O c Release Date Revision NOLLdIN2530 YO V T0N3HWON 97 bz SS SQN3 J9ICE T GI p T 3SOH ASSV LdN 8 T ASSV LONNDSO LdNt L VA J3T133 4370NT1A2 YA 43038 Y3IONTIAD LAN NYNN3H8 MWOICE T X JOICB E NVNN338 HDIC H T X WLAN t T stdav NYNN338 ALdN8 T ALdN e T uldav 55 20 20 0005 t 4 C T31V2S V 11913 MNV l NIDOYHLIN OL 30 LNdNI P YOLVIN93IY O
14. L AIC B E C Ed1V2S d 1139 Assembly Hose Regulator Box to N2 Tank P38130 Part Number 2A38151 Release Date 10 31 2013 SPM Revision e SECTION V Service and Support Service Center Order Information SPM stocks a large inventory of genuine original equipment replacement parts In order to expedite a parts order and avoid any delays please provide the following information with your order e The part number and description refer to drawings and parts lists in this section of each item ordered e The quantity of each part kit or assembly ordered e The model number and serial number e Your purchase order number e Specify method of shipment complete shipping address complete billing address and telephone number at the destination of the shipment Parts and service may be ordered through the locations on the following page Weir Oil amp Gas Excellent 601 Weir Way Tel 817 246 2461 Oil amp Gas Solutions Fort Worth Fax 817 246 6324 ds USA www weiroilandgas com Copyright 2013 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 copy
15. S P M S Excellent Oil amp Gas Well Service Pumps amp Flow Control Products Solutions Automated Relief Valve Control A R C System j Operation Instruction and Service M anual OIL amp GAS Part Number 2438151 Release Date 10 31 2013 Revision B Copyright 2013 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 VERIBAND DURALAST and GLADIATOR are trademarks and or registered trademarks of S P M Flow Control Inc WEIR is a trademark and or registered trademark 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 2438151 Release Date 10 31 2013 Revision THE FOLLOWING ICONS DENOTE IMPORTANT INFORMATION WITHIN THIS MANUAL ERAL INFORMATION MN AND OPERATION e AINTENANCE AND REPAIR AND SUPPORT Q A CAUTION A WARNING DANGER Part Number 2438151 Release Date 10 31 2013 Revision
16. berta 765 5W2 Ph 2 Fax 1 780 437 5218 Fort St John BC Canada Service Center 10508 89th Avenue Fort St John British Columbia V1 5P9 Ph 1 250 785 6627 Fax 1 250 785 4501 Grande Prairie AB Canada Service Center 8801 99th Street Clairmont Alberta TOH OWO Ph 1 780 567 3857 Fax 41 780 567 2808 Medicine Hat AB Canada Service Center 1202 Dirkson Drive N E Redcliff Alberta 0 Ph 1 403 504 8353 Fax 1 403 504 8370 Red Deer AB Canada Service Center Unit A 8060 Edgar Industrial Crescent Red Deer Alberta TAP 3R3 Ph 0 Fax 2 OIL amp GAS INTERNATIONAL MEXICO Villahermosa Mexico Service Center Bodega 3 Lote 8 Manzana 3 Sobre Calle San Lazaro Parque Logistico Industrial Tobasco Villahermosa Tabasco 86150 Ph 52 993 142 7083 Poza Rica Mexico Service Center San Miguel Mecatepec Tihuatlan Veracruz Bodega C Ph 782 111 73 55 BRAZIL Maca Brazil Service Center Rua Internacional No 245 Lote 09 Quadra W Loteamento Novo Cavaleiros Macae RJ Brazil 1 Ph 55 22 2106 8750 Fax 455 22 2106 8777 EUROPE Aberdeen Scotland Service Center Badentoy Industrial Park Portlethen Aberdeen AB12 4YD Scotland Ph 44 1224 783666 Fax 44 1224 784184 MIDDLE EAST Dubai UAE Service Center Oilfields Supply Center L T D Building 22 P O Box 1518 Jebel Ali Dubai UAE Ph 971 48836 368 Fax 971 48836 485 AUSTRALASI
17. ble and High Pressure Transducer 7 Connect the Transducer Cable Blue via the cable reel to the High Pressure Transducer and the Control Panel Box in the Data Van a Unwind the longer side of the Blue Transducer Cable and connect it to the Transducer b Unwind the shorter side of the Blue Transducer Cable and connect it to the Control Panel which is located in the Data Van 22 Part Number 2A38151 Release Date 10 31 2013 SPM Revision Pre OP Checklist Continued 8 Open the connected N Bottle by turning the handle counter clockwise 9 Ensure the E Stop Button is disabled This can be verified by twisting the E Stop knob on the User Interface Panel Page 10 Item 2 and pulling it up If it does not pull up then it is disabled 10 Turn the power switch ON from the User Interface Panel A IM PORTANT All Communication cables and Nitrogen hoses must be connected before powering on the system Once the system is powered on the POP OFF and RESET Pressures can be entered by using the User Interface Panel As a built in system feature a continuous self check of each component will take place If a problem is indicated it will sound the following alarm e Nitrogen Levels less than 1000 PSI In this case the Nitrogen Tank will need to be replaced with another tank with at least 1000 PSI of Nitrogen e Nitrogen Level greater than 3500 PSI The Regulator internal components maximum pressure i
18. e Connect Nitrogen Hoses to Relief Valve and Regulator Box Connect Data Cables to Control Panel and User Interface Panel in Data Van Input desired Sequence Pop off and Reset pressure values The system is now ready for use SPM 2A38151 Part Number m c O N c m O c Release Date Revision Product Overview _ _ o _ _ _ _ _ _ 9 Y gt c 8 5 Bc 5 96 OU 0 9 oz 5 229 6 5 E yg CE 5 gt 2 7 a C c C gt lt S Q e 0 C 8 SE 7 n a 5 O Part Number 2438151 Release Date 10 31 2013 Revision 8 ax SECTION II Component Description Control Assembl The Control Assembly includes two units The Control Box and the User Interface Panel Each of these items should be located in the Data Van and require 110AC power All electronics of the A R C are UL listed and intrinsically safe By definition intrinsically safe components are designed to provide safe operation in hazardous areas i e a fracturing site Contr
19. eparately in Image 8 below Each port on the bottom of the Regulator Unit is labeled for convenience as shown in the Pre Op Checklist section Image 8 Regulator Unit 16 Part Number 2438151 Release Date 10 31 2013 Revision High Pressure Transducer The High Pressure Transducer is mounted on a 2 1502 connection on the High Pressure Frac Iron leading up to the Wellhead Image 9 shows the transducer mounted on a Tee with a 2 1502 connection This transducer monitors the system pressure for the A R C System and is resistant to fracturing fluid sand gels and acid Transducer mounted on 2 1502 connection Image 9 High Pressure Transducer mounted onto a Tee with a 2 1502 connection 17 Part Number 2438151 Release Date 10 31 2013 Revision A R C Skid The A R C Skid is designed to provide easy setup in the field and for convenient durable transport By using the skid it reduces setup time and provides a method of easy cable hose management The A R C Skid houses the Regulator Unit as well as the following vital system components 6 oo gt Regulator Unit Control Panel Cable Grey Cable 150 ft 3 Nitrogen Hose 150 ft 4 Skid Lifting Eye Upper N2 Bottle Retainer N2 Bottles Lower N2 Bottle Retainer 8 Transducer Cable Blue Cable 150 ft Image 10 A R C Skid 18 Part Number 2438151 Release Date 10 31 2013 Revision SECT
20. lve 14 Part Number 2438151 Release Date 10 31 2013 Revision B ror Wa SPM Using the User Interface Panel Touch Screen LCD Cont Other features displayed on the LCD Touchscreen are as follows Image 6 N Bottle PSI This feature remotely monitors the connected Nitrogen Bottle Pressure o Monitoring the Nitrogen bottles ensures that the required amount of Nitrogen needed to properly control the Relief valve is present during operation o If the Nitrogen pressure of the Bottle is below 1000 PSI the system will alarm and display that the Nitrogen levels are too low o If the Nitrogen pressure of the N is above 3500 PSI the system will alarm and display that the Nitrogen levels are too high Average System PSI Displays the treating line pressure from the 2 1502 transducer which is mounted on one of the high pressure lines leading up to the wellhead It is recommended that the transducer be installed in front of the Relief Valve and before the check valve Relief Valve Status Indicator This button is located in the lower right of the LCD screen It displays whether the valve is OPEN or CLOSED Alarm Acknowledgement Screen The User Interface Panel Screen features an Alarm Acknowledgement Screen that will display when any of the following alarms listed below are indicated by the A R C System The alarm can be disabled by acknowledging the alarm This is done by pressing the AcK Alarm butto
21. n lt Image 7 Alarm Acknowledgment Screen 15 Part Number 2438151 Release Date 10 31 2013 SPM Revision Alarm Acknowledgement Screen Cont N2 Input Low High Alarms Displays Alarms when the N bottle pressure is below 1000 PSI or equal to or greater than 3500 PSI System Pressure Lost Alarm Displays Alarms when the System Pressure Transducer cable is not plugged in or shows no signal This alarm will sound until the System Pressure Transducer indicates a pressure reading System Pressure High Alarm Displays Alarms when the System Pressure has exceeded the set Pop Off pressure Main Control Power Alarm Displays Alarms when main power is lost The backup battery continues to power the system for approximately 30 minutes Regulator Unit A No User interaction is necessary except for ensuring all cables are connected correctly NEVER tamper with the internal components All components have been preset at the time of manufacturing Tampering will result in erratic performance and void the warranty The Regulator Unit houses all necessary components needed to control the Relief Valve via the User Interface Panel and Control Box which are located in the Data Van is designed with intrinsically safe components and is UL listed The Regulator Unit is made from Stainless Steel to provide resistance to harsh environments It is mounted on the A R C Skid Image 10 but is shown s
22. of 2 seconds Care must be taken to limit the discharge rate of the fluid during verification testing Extremely high discharge rates may reduce the life of the intemal seal components 24 Part Number 2438151 Release Date 10 31 2013 Revision B gt Using A R C System with Legacy Backpressure amp Full Unloading Relief Valves Back Pressure Relief Valve SPM s Legacy Backpressure Valve is fully compatible with the A R C System and requires no modification L Full Unloading Relief Valve The Full Unloading Valve Figure 18 below includes a secondary N line to pressurize the underside of the internal piston Each of these parts must be plugged to allow proper operation of the A R C System Note Plugging the ports may affect the performance of the valve if used without the A R C System The following steps should be followed to prepare the Full Unloading Relief Valve for use with the ARC System Disconnect all hoses and Tees from Relief Valve Plug all four ports around Relief Valve Body with 14 MNPT Plugs Connect 90 degree elbow on top of valve with Quick Disconnect adapter Valve is now ready for use gt UN Tee Replace it with a 90 Degree Elbow Fitting Ya NPT Valve is now ready for use Remove all hoses and Tees Replace with Y4 NPT Plugs Image 18 Preparing Full Unloading Relief Valve for A R C System use 25 Part Number 2438151 Release Date 10 31 2013
23. oid loosening the internal parts when removing the fittings on the outside of the Regulator Box Image 12 Regulator Box Front View Image 13 Regulator Box Bottom View 20 Part Number 2438151 Release Date 10 31 2013 Revision Pre OP Checklist Continued 4 Connect the OUTPUT PORT NITROGEN hose to the N Cable Reel 5 Connect and turn the grey Control Panel Communication Cable P38150 to the Regulator Unit and to the Control Panel Box in the Data Van Ensure that the connection lines up and is turned till snug DO NOT OVER TIGHTEN a Unwind the longer side of the Control Panel Cable Grey to the Data Van and connect it to the Control Panel b Unwind the shorter side of the Control Panel Cable from the same reel and connect it to the Communications port on the back of the Regulator Unit SYSTEM PRESSURE TRAN EOUCE A E id W Mallaq Ir Pa BOX TE 54 Image 14 Control Panel Box Connections 21 Part Number 2438151 Release Date 10 31 2013 Revision Pre OP Checklist Continued 6 Connect the 10 ft grey Communications Cable Item 3 between the Control Panel and the User Interface Panel as shown in Figure 15 below 1 1 Pss ASSY CABLE COMMN 10 FT CNTL PANEL TO UIB gt 2 1i _1 i QTYREQD PART NUMBER NOMENCLATURE OR DESCRIPTION Image 15 Control Panel and User Interface Panel with 10ft Ca
24. ol Box The Control Box houses all the electronics of the A R C System including a Back Up Battery System In the event of a power loss to the Control Box the Backup Battery System will provide approximately 30 minutes of power to the system which will keep the programming enabled This will allow the user sufficient time to determine if the Relief Valve should remain closed or be opened Once power is restored the batteries will begin to re charge The Control Box should be mounted at a convenient location in the Data Van where it can be accessible if needed All communication cabling connects from the Control Box to the following components as shown below l System Pressure Transducer Blue Cable 2 Regulator Unit Grey Cable 3 User Interface Panel Grey Cable Image 1 Control Box Part Number 2438151 Release Date 10 31 2013 SPM Revision Mounting Hole Dimensions Control Panel 18 19 19 69 19 64 Image 2 Control Box mounting holes and dimensions 10 Part Number 2438151 Release Date 10 31 2013 Revision User Interface Panel The User Interface Panel connects to the Control Box via a communications cable and can be mounted in the Data Van s workspace for easy control and availability The User Interface Panel features the following as shown in image 3 below TASA Nacecrnntinn Jescrniption aarti petra 6 Connector from Control Panel Cable
25. right owner SPM SAFETY IRON SAFETY HAMMER SUR DROP DESTINY STAMPEDE VERIBAND DURALAST and GLADIATOR are trademarks and or registered trademarks of S P M Flow Control Inc WEIR is a trademark and or registered trademark 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 32 Pressure Pumping Global Locations Revised 8 8 2013 Headquarters 601 Weir Way Ft Worth TX 76108 Ph 1 800 342 7458 1 817 246 2461 Fax 1 817 977 2508 www weiroilandgas com www weirinaction com UNITED STATES Houston TX Sales Office 363 N Sam Houston Pkwy E Suite 550 Houston TX 77060 Ph 1 281 847 7270 Fax 1 281 820 2972 GULF COAST Alice TX Service Center 2450 Business Hwy 281 North Alice TX 78332 Ph 1 361 661 0900 Fax 1 361 661 0909 Deer Park TX Service Center 920 Seaco Court Deer Park TX 77536 Ph 1 832 200 6220 Fax 1 832 200 6227 Lafayette LA Service Center 401 S Bernard Rd Broussard LA 70518 Mailing PO Box 82099 Lafayette LA 70508 Ph 1 337 837 3161 Fax 1 337 839 1985 Pleasanton TX Service Center 772 HWY 281 South Pleasanton TX 78064 Ph 1 830 569 3571 Fax 1 830 569 3643 MID CONTINENT Bossier City LA Service Center 2403 Grimmett Dr Shreveport LA 71107 Ph 1 318 677 2422 Fax 1 318 677 538
26. s 3500 PSI The Nitrogen pressure will need to be below 3500 PSI to silence this alarm o The use of a regulator may have to be used if the Nitrogen Pressure Source is equal to or greater than 3500 PSI e NO Power If the status warning states that there is no AC Power it is necessary to ensure that the Control Panel is receiving AC power The system will operate on its back up battery system only for approximately 30 minutes e Communications line not connected damaged or no system pressure is being indicated This alarm will continue to alarm until there is system pressure indicated e No System Pressure Once the transducer indicates system pressure on the lines this alarm will continue to alarm until it is acknowledged from the Touch Screen Panel 23 Part Number 2438151 Release Date 10 31 2013 Revision SPM B Setting the POP OFF and RESET Pressures In most field applications the customer will require that the Relief Valve be popped off before fracturing operations can occur This ensures the function of the Relief Valve in that it will provide protection of the wellhead casing and personnel in the event an overpressure in the system occurs Once the Pre Operation checklist has been completed the values at which the valve needs to Pop Off OPEN and RESET CLOSE can be entered into the system The following steps should be followed in order to properly set the A R C System 1 NOT
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