Weir SPM SafeEdge ARC System Troubleshooting guide

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Release Date: 07/29/2019
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Copyright © 2019, S.P.M. Flow Control, Inc.. All rights reserved. S.P.M. Flow Control, Inc. is the owner of the copyright and all confidential information in
this document, which must not be copied in whole or in part, in any form or by any means, and the information in it must not be used for any purpose
other than the specific purpose for which it has been provided without the prior written consent of the copyright owner. SPM, SAFETY IRON, SAFETY
HAMMER, SUR-DROP, DESTINY, STAMPEDE, DURALAST and GLADIATOR are trademarks and/or registered trademarks of S.P.M. Flow Control,
Inc.. WEIR and WEIR (logo) are trademarks and/or registered trademarks of Weir Engineering Services Limited. Certain features of some of the products
disclosed in this document may be protected worldwide by patents pending and registered in the name of S.P.M. Flow Control, Inc..
SPM
®
Well Service Pumps & Flow Control Products
SafeEdge™ Automated Relief Vale Control (ARC) System
Operation Instruction and Service Manual

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WARNING: IMPORTANT SAFETY INFORMATION ENCLOSED. READ THIS OPERATING AND
MAINTENANCE INSTRUCTIONS MANUAL BEFORE OPERATING PRODUCT.
WARNING: THIS INFORMATION MUST BE AVAILABLE TO ALL PERSONNEL THAT WILL OPERATE
AND MAINTAIN EQUIPMENT. FAILURE TO READ, UNDERSTAND AND FOLLOW THE OPERATING
AND MAINTENANCE INSTRUCTIONS MANUAL COULD RESULT IN SERIOUS BODILY INJURY,
DEATH, OR PROPERTY DAMAGE.
Most SPM®products generate, control or direct pressurized fluids; therefore, it is critical that those who work
with these products be thoroughly trained in their proper application and safe handling. It is also critical that
these products be used and maintained properly!!
SPM®flow products contain elastomeric seals and are not intended to provide proper functionality when
exposed to fire.
WARNING: MISUSE, SIDE LOADING, IMPROPER MAINTENANCE, OR DISASSEMBLY UNDER
PRESSURE CAN CAUSE SERIOUS BODILY INJURY, DEATH, OR PROPERTY DAMAGE.
The following information is given in good faith and should aid in the safe use of your SPM® products. This
information is not meant to replace existing Company's safety policies or practices.
The internal components of the Arc 2.0 are a combination of both electrical and mechanical systems. It is
important to treat the system similar to a computer. In long use applications it is vital that the system be reset
every 1-2 days to ensure that its operation is optimal.
Personal Responsibilities:
1. When working on SPM®flow control products, safety glasses, approved safety shoes and hard hat must
be worn.
2. Personnel should never hammer on any component when pressure is present. Hammering on any part
or component may also cause foreign material or steel slags to become airborne.
3. It is a personal responsibility to use the proper tools when servicing the valve. It is a personal
responsibility to be knowledgeable and trained in the use and handling of tools for all maintenance of the
valve.
4. Hot surface may be present; it is a person’s own responsibility to protect against burn injury.
SPM
®
PRODUCT SAFETY GUIDE

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On Location:
1. Each valve is clearly marked with a maximum pressure rating. This pressure must not be exceeded or
SERIOUS BODILY INJURY, DEATH, OR PROPERTY DAMAGE MAY OCCUR.
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 product is prohibited. If accessories must be attached,
consult Weir Oil & Gas factory prior to installation.
4. A complete visual inspection of the product must be made prior to each use. Any leaking seals, broken
bolts, leaking hoses or improperly tightened parts must be remedied prior to using.
5. Any repairs or service (even routine maintenance) performed on the product must be performed by a
trained service technician who is qualified to work on high pressure flow control products. All such
service and repairs must be supervised by qualified management personnel or returned to Weir Oil &
Gas for service. Only SPM®replacement parts should be utilized. Failure to do so may result in loss
of warranty as well as SERIOUS BODILY INJURY, DEATH, OR PROPERTY DAMAGE.
Special Precautions:
1. The modifications to or unauthorized repair of any part of a SPM® product, or use of components not
qualified by Weir Oil & Gas , can lead to damage to or failure of equipment and SERIOUS BODILY
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.
5. Weir Flow Products are not intended for operation during fire, floods, earthquakes, tornadoes,
hurricanes, or other catastrophes, whether natural or man-made. Weir recommends immediate
depressurization of the equipment, followed by implementation of all customer specific safety protocols.
WARNING: OBSERVE ALL INSTRUCTIONS, CAUTIONS AND WARNINGS AS NOTED IN THIS
MANUAL. FAILURE TO DO SO CAN LEAD TO EQUIPMENT DAMAGE AND SERIOUS BODILY
INJURY, DEATH, OR PROPERTY DAMAGE.

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CONTENTS
SPM®PRODUCT SAFETY GUIDE .......................................................................................................................................................2
TABLE OF CONTENTS ..........................................................................................................................................................................4
SECTION I: DEFINITIONS....................................................................................................................................................................5
1.1 SYSTEM COMPONENTS .......................................................................................................................................................................5
1.2 SYSTEM TERMINOLOGY .....................................................................................................................................................................6
SECTION II: OPERATION.....................................................................................................................................................................7
2.1 VENTING AND RESET..........................................................................................................................................................................7
2.2 USER MANUAL...................................................................................................................................................................................8
2.3 OPERATOR CONTROLS .......................................................................................................................................................................8
2.3.1 Keypad-entered Fields...............................................................................................................................................................9
2.3.2 Dump Switch..............................................................................................................................................................................9
2.4 GAUGES ...........................................................................................................................................................................................10
2.4.1 Wellhead Pressure ...................................................................................................................................................................10
2.4.2 Bottle Pressure.........................................................................................................................................................................10
2.5 INDICATORS .....................................................................................................................................................................................10
2.5.1 Manual Dump ..........................................................................................................................................................................10
2.5.2 Pop-off Active...........................................................................................................................................................................10
2.5.3 Dome Ready.............................................................................................................................................................................10
2.5.4 Warnings..................................................................................................................................................................................11
2.6 LOGGING..........................................................................................................................................................................................11
2.6.1 Logging File Format................................................................................................................................................................11
2.6.2 Constant Logging.....................................................................................................................................................................12
2.6.3 High-speed Event Logging.......................................................................................................................................................12
2.6.4 Transferring Files....................................................................................................................................................................12
2.6.5 Managing Files........................................................................................................................................................................13
2.7 ACCESSING WEBPAGE CONTROLS....................................................................................................................................................13
SECTION III: BASIC CONFIGURATION .........................................................................................................................................14
3.1 PREFERENCES...................................................................................................................................................................................14
3.2 DATE AND TIME ...............................................................................................................................................................................14
3.3 TIME ZONE.......................................................................................................................................................................................15
SECTION IV: ADVANCED CONFIGURATION...............................................................................................................................16
4.1 ADMINISTRATOR LOG IN..................................................................................................................................................................16
4.1.1 Management.............................................................................................................................................................................16
4.1.2 Weir..........................................................................................................................................................................................17
4.2 CHANGING ACCOUNT PASSWORD ....................................................................................................................................................17
4.3 SCALING...........................................................................................................................................................................................18
4.3.1 Nominal Min & Nominal Max..................................................................................................................................................19
4.3.2 Zeroing Scale...........................................................................................................................................................................19
4.3.3 Shunt Calibration.....................................................................................................................................................................20
4.3.4 Rebooting System.....................................................................................................................................................................21
SECTION V: INTEGRATIONS............................................................................................................................................................22
TROUBLESHOOTING GUIDE:...........................................................................................................................................................23
TABLE OF CONTENTS

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1.1 System Components
Suitcase – Combination of the control system, local interface, physical controls, and router. These components are enclosed in a
Pelican Case with a 70-pin DRC to connect to the Valve boxes.
Satellite Antenna
Network Antennas
Touchscreen Display
Manual Dump Valve Switches
Main Power Switch
70-pin DRC Connection for
Valve 1 & Valve 2
Power Supply
USB
Ethernet (LAN)
Ethernet (WAN)
SECTION I: Definitions

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Valve Box – Stainless steel enclosure with the static pressure regulator, electronic pressure regulator, solenoid dump valve, and
pressure transducers.
N
2
Relief Valve – Weir SPM's Emergency 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.
Dome – shorthand way to refer to the N
2
Relief Valve’s nitrogen filled chamber.
RIO – The National Instruments controller inside the suitcase. Runs all the logic and web pages.
Router – The main network hub inside the suitcase.
Touchscreen Interface – The touchscreen that displays the web page on the suitcase.
1.2 System Terminology
Wellhead Pressure – the pressure in the line or vessel that the relief valve is protecting. Also referred to as treating pressure.
Bottle Pressure – the nitrogen supply pressure, measured after the system’s internal regulator.
Dome Pressure – the nitrogen pressure in the dome that holds the relief valve closed.
Pop-off – Event where the pressure trip point is exceeded for the defined interval and the system opens the relief valve.
Reset – Event, after a pop-off event, where the system closes the relief valve and allows pressure to resume in the treating line.
Dump – When the user empties the dome with a physical or software switch allowing the relief valve to vent.
Auto – When the dump switch is in the Auto position the system maintains sufficient nitrogen pressure to hold the relief valve
closed until the pop-off conditions are met.
10-pin Connector to Suitcase
Nitro
g
en Line Ou
t
Event Indicator Lights
Pressure Transduce
r
Calibration Switch
Nitrogen Supply In

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Prior to operation, the user enters a Pop-Off Set point and a Reset Pressure. The Pop-Off Set point is the highest pressure that the
system will allow before actuating the relief system. If the wellhead pressure exceeds this value, the N2Relief Valve vents and relieves
pressure in the line until the reset conditions are met. The Reset Pressure is set below the Pop-Off Set point to ensure successful
reseating and protect the valve.
Example Operation Cycle
To prevent unintended pop-offs, a pop-off event occurs only when the treating pressure has exceeded the Pop-Off Set point for a period
of time. The time period is configurable and is referred to as Pop-Off Filter. It is typically set to 100 ms (see Pop-Off Detail).
Pop-Off Detail
2.1 Venting and Reset
When a pop-off event occurs, the relief valve’s nitrogen chamber is emptied so that the valve can open fully. Strobe lights on the valve
box alert operators that the valve is venting. Once a pop-off event has been triggered, the valve continues to vent until two reset
conditions are satisfied. Reset condition 1 requires the treating pressure to remain below the Reset Pressure for a minimum amount of
time. The time period is referred to as Reset Filter and is typically set to 100 ms (see Reset Condition 1 Detail). Reset condition 2
requires that, once the valve begins venting, it does not reseat for a minimum amount of time (referred to as Minimum Pop off Time
and typically set to 2 s). The reset conditions can be satisfied in either order.
Reset Condition 1 Detail
SECTION II: Operation

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2.2 User Manual
The system contains a local copy of this operator’s manual that can be found under the log in section shown below.
2.3 Operator Controls
The interface for controlling and viewing the system is a web page hosted by the controller. Any device with a web browser that is
connected to the controller via Wi-Fi or Ethernet can access the interface. Prior to operation, the user enters the desired Pop-off Set
point and Reset Set point.
Touch to enter the Pop Off Setpoint
Touch to enter the Reset setpoint
Touch to manually trip or resume Auto

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2.3.1 Keypad-entered Fields
Clicking or pressing in a text box launches a keypad or keyboard for user input. The previous value is loaded as the default so that
clicking outside of the keypad or clicking Accept without entering anything will cancel the action and close the keypad.
To apply a new value, type it in with the keypad and click Accept. The
input will be validated, and if it falls outside an allowed range it will be
coerced to the closest acceptable value. A warning box indicates user
entry errors. When a valid entry is made, a popup message confirms the change.
Limits are enforced when choosing set points. These thresholds are
configurable in the Settings page, with a login.
2.3.2 Dump Switch
The switch on the far right is the dump switch. It has two positions: Auto and Manual Dump. When the dump switch is in the Auto
position the system maintains sufficient nitrogen pressure to hold the relief valve closed until the pop-off conditions are met.
Toggle between Auto and Manual Dump by clicking or touching the on-screen switch. When Manual Dump is activated, any nitrogen
pressure in the dome is immediately vented and the relief valve opens to vent the process pressure. The user is prompted to confirm
before the action is taken.
The dump switch operates the same as the physical switch on the suitcase; however, when the physical switch is in the Manual Dump
position, the software dump switch is disabled as shown below.

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2.4 Gauges
2.4.1 Wellhead Pressure
The wellhead pressure gauge has three indicator bands: red, yellow, and green. The green band is the region
between 0 psi and the Reset Pressure. The yellow band is between the Reset Pressure and the Pop-Off Setpoint.
The red band indicates the pop-off zone. When the Wellhead Pressure enters the red band, a pop-off event occurs.
Modifying the reset point or pop-off set point updates the wellhead gauge bands.
2.4.2 Bottle Pressure
The bottle pressure gauge indicates the pressure after the static pressure regulator inside the valve box. The regulator
is set to 1000 psi at the factory and is not adjustable. If the bottle pressure falls below 1000 psi, it may indicate that
the supply tank has dropped below 1000 psi and should be switched out. Low pressure may cause resetting the valve
to be very slow or prevent the system from reaching operational pressure.
2.5 Indicators
2.5.1 Manual Dump
When either a software switch or a physical switch is in the Manual Dump position, the Manual Dump
indicator flashes red. In order to resume operating, return all switches to the Auto position.
2.5.2 Pop-off Active
When the valve is dumped due to a pop-off event, the Pop-Off Active indicator flashes red. The valve
continues venting until the reset conditions are met.
2.5.3 Dome Ready
When the dome pressure is suitably close to its given control set point, the Dome Ready lamp lights,
indicating that the system is ready for operation.

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2.5.4 Warnings
The red text beneath the Pop-Off Active indicator is the list of current warnings for this valve. Warnings
include improper configuration of the system (e.g. disconnected sensors or low bottle pressure).
2.6 Logging
Log files are listed on the Log Files tab in the web interface.
2.6.1 Logging File Format
The system records data in the Technical Data Management Streaming (TDMS) file format. The binary TDMS file format is an easily
exchangeable, inherently structured, high-speed-streaming-capable file format. Each individual log is created each time the system is
rebooted, or every 12-hours at noon (1200) and midnight (2400). Each file contains individual tabs that record 30 seconds before and
after each pop-off event that occurs as shown below.
You can view the TDMS log files in Excel by downloading the Excel TDMS Add-in available to download from National Instruments.
POP OFF EVENTS
‐Each Pop Off Event is
recorded within each log
file as individual tabs.

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2.6.2 Constant Logging
While on, the system continuously records data at 1 sample per second. Log files are stored on the SD card in the controller. A new log
file is generated at startup, noon, and midnight so that each file contains a maximum of 12 hours of data. Once a file is closed, it is
compressed and archived on the SD card. A typical 12-hour log file is under 10 MB zipped. The standard SD card supplied with the
system is 32GB with room to store over 15 years of continuous data files.
2.6.3 High-speed Event Logging
Any time a pop-off event occurs and any time the operator executes a manual dump, the system logs at 200 samples per second from
30 seconds before the event to 30 seconds after the event. The high-speed pop-off data is stored in a separate tab in the TDMS log file.
2.6.4 Transferring Files
The suitcase has an external USB port. Log Files can be transferred locally or remotely as described below. A USB device must be
inserted, and the following icon will appear next to the Log Files tab, indicating a usable device is present and connected.
Local
The suitcase has an external USB port. To copy/transfer a Log File locally, a USB device must be inserted, and the following icon will
appear next to the Log Files tab, indicating a usable device is present and connected.
Once the selected files have been successfully transferred to the USB device, a confirmation dialog will appear. The system will
not overwrite existing files.

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Remote
Files can be downloaded remotely through the webpage directly to the user’s computer.
The Download Selected button will only appear through the webpage interface, not locally.
2.6.5 Managing Files
Log Files can be deleted from the system at any time. The SD card capacity is large enough to outlast the life of the SD card itself, but
it is still recommended to delete unneeded files periodically to make file management easier.
2.7 Accessing Webpage Controls
The user interface can be accessed remotely through the system webpage. It can be used to configure, monitor, and control the system
remotely.
To access the webpage the user must connect to the WiFi of the ARC system they wish to control. Once connected to the ARC
network, open a web browser (Internet Explorer, Chrome, etc.) and enter the URL of the ARC device (http://10.1.1.10:8080/ws/) into
the address bar as shown below:

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The settings tab allows the user to make changes to the system. By default, the system is logged in as Operator and does not allow any
administrative changes to be made.
3.1 Preferences
The basic configuration settings and information include:
Preferred Unit – Select PSI, MPa, or KPa. The setting does not affect logging or stream outs, only the interface on which you
change the unit.
Minimum Pressure Drop – The minimum allowed difference between the Reset Pressure and the Pop-Off Setpoint.
Cell, GPS, Satellite, WiFi – Check the boxes to enable the communication hardware. Uncheck to ensure that the radios are turned
off (whether or not that option is installed).
External IP – The external IP is the WAN IP address of the router inside the suitcase. If you plug an ethernet cable into the WAN
port, you can connect to the system on a local network using the IP address displayed here.
Date and Time – To change the date and time settings, click on the “Date/Time” section of the user interface.
3.2 Date and Time
To change the date and time, click on the area where the date and time are displayed.
SECTION III: Basic Confi
g
uration

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3.3 Time Zone
To adjust the time zone, select the drop-down button to the right of the area and select the correct time zone from the list that appears.
Click Apply to save the changes and the following dialog prompt will appear to confirm the changes to the system.

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4.1 Administrator Log In
Click on the user icon and select Log In from the drop-down list shown below to access the advanced settings.
The following screen prompts the user for which account to log in to.
Note: Logging in to the Management and Weir accounts requires a password.
4.1.1 Management
The Management account enables administrative privileges that allow the user to configure advanced options throughout the system.
Once logged in, the user icon will display an Mconfirming the user is currently logged in to the Management account.
SECTION IV:
A
dvanced Confi
g
uration

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Additional parameters that are available while logged in as Management include:
Reset Filter – The Reset Filter is an interval of time, in milliseconds (rounded down to the nearest 5 ms). One condition for a reset
is that the wellhead pressure must be below the reset pressure for Reset Filter.
Pop Off Filter – Pop-off Filter is an interval of time, in milliseconds (rounded down to the nearest 5 ms). If the wellhead pressure
stays above the Pop-Off Setpoint for Pop-off Filter, the system triggers a pop-off.
Minimum Popoff Time – The minimum interval of time in milliseconds that the valve remains in the open/relief state once a pop-
off occurs. A reset will not occur until this interval of time has elapsed after a pop-off or manual dump.
4.1.2 Weir
The Weir account allows the user access to the same settings as the Management account but allows values that are for system test
mode only. Access to the Weir account is not required for operation of the system. Once logged in, the user icon displays a W
confirming the user is currently logged in as Weir.
4.2 Changing Account Password
The password for any account can only be changed if the current user is logged in with administrative privileges. Once logged in as an
administrator, the password can be changed by clicking the user icon in the top right corner of the screen and selecting the Change
Password option.

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The following prompt will appear allowing the user to select which account to change the password for.
Click Submit to save the changes to the system.
4.3 Scaling
The Scaling tab allows the user to calibrate input channels and scale the sensor values.
The following are available for the user to select and scale when logged in as Operator.

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When the user is logged in as an administrator under either the Management or Weir account, additional parameters are available to
select and adjust the scaling as shown below.
Click Apply at the bottom of the screen to save the settings to the system.
4.3.1 Nominal Min & Nominal Max
The Nominal Min value is the lower range (in engineering units, e.g. 0 psi) of the transducer being used to monitor the wellhead
pressure. The Nominal Max value is the upper range (in engineering units, e.g. 15,000 psi) of the transducer being used to monitor the
wellhead pressure.
4.3.2 Zeroing Scale
To zero the sensor, make sure no pressure is on the line (open to air). When the Raw Value reads approximately ~ 4 mA, click the
ZERO button to set the minimum scale of the sensor. If user attempts to zero the sensor with a Raw Value that is not close to 4 mA, the
following dialog will appear prompting the user to correct the issue before continuing.

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4.3.3 Shunt Calibration
This will set the upper limit of the calibrated input. Flipping the calibration switch on the valve box (shown below) will short the input
straight to 20mA to force a maximum value. Once the Raw Value stabilizes around ~20mA, click the SPAN button to calibrate the
maximum value scale.
NOTE: ONLY PERFORM SHUNT CALIBRATION WHEN THERE IS ZERO PRESSURE ON THE
LINE. IF SWITCH IS FLIPPED WHEN PRESSURE IS ON THE LINE, THEN THE CURRENT VALUE
WILL BE OVERRIDDEN WITH MAX VALUE AND POP-OFF EVENT WILL OCCUR.
NOTE: IF THE USER CLICKS THE SPAN BUTTON WHEN A VALUE THAT IS NOT CLOSE TO THE
MAXIMUM 20 MA VALUE THEN THE FOLLOWING ERROR DIALOG WILL APPEAR PROMPTING THE
USER TO CORRECT THE ISSUE BEFORE CONTINUING.
THE SPAN BUTTON MUST BE HELD TILL THE VALUE IS AT 20 MA
Calibration Switch