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SURVEY EQUIPMENT
PCS-2000
OPERATORS
MANUAL
This document remains the property of PCS-2000 (Aust) Pty Ltd.
No information contained within this document or copies of this document in part or full shall be made and passed
to unauthorised third parties without the written consent of PCS-2000 (Aust) Pty Ltd.
_______________________________________________________________________________________________________________________
OPERATORS MANUAL
PREFACE
Thank you for your selection of the PCS-2000 instrument for undertaking Direct Current Voltage
Gradient (DCVG) Coating Defect surveys.
PCS-2000 incorporates the latest corrosion detection and electronics technology into a compact,
international standard unit designed for easy use.
To effectively use PCS-2000 and to keep it in optimum service condition for a long period of
time, follow the operating and maintenance instructions in this manual.
Page 1
TABLE OF CONTENTS
Page No
PREFACE ..............................................................................................................................1
1.0
COMPONENT GUIDE ..............................................................................................3
1.1
RECEIVER - Figure 1 ............................................................................................3
1.2
PROBES - Figure 2.................................................................................................4
1.3
CURRENT INTERRUPTER - Figure 3 ..................................................................6
2.0
OPERATING INSTRUCTIONS.................................................................................7
2.1
Set-Up.....................................................................................................................7
2.2
Survey Procedure ....................................................................................................9
2.3
Centering Defects..................................................................................................10
3.0
RECORDING AND INTERPRETATION OF RESULTS ........................................13
3.1
Coating Repair Criteria and Cathodic Protection System Review ..........................16
4.0
CARE AND MAINTENANCE.................................................................................16
4.1
Maintenance..........................................................................................................16
4.2
Procedures ............................................................................................................16
4.3
Caution .................................................................................................................17
5.0
6.0
WARRANTY ...........................................................................................................19
7.0
8.0
9.0
PATENT PROTECTION..........................................................................................21
Page 2
1.0
COMPONENT GUIDE
1.1
RECEIVER - Figure 1
___________________________________________________________________________
Name
Function
___________________________________________________________________________
(1) Millivoltmeter
Used to turn the instrument ON and OFF and perform a battery test.
(4) Impedance
Used to plug in lead from probe. One located on each side of meter
housing.
Figure 1
PCS-2000 Operators Manual
Page 3
Drip tube inlet. Push tube to lock in. To release tube / plug,
push in outer ring (red) with fingers and withdraw tube / plug.
(4) Electrode
___________________________________________________________________________
*Notes:
1.
2.
Page 4
Figure 2
Page 5
1.3
___________________________________________________________________________
Name
Function
___________________________________________________________________________
(1) ON-OFF Switch
(3) Terminals
Figure 3
Page 6
2.0
OPERATING INSTRUCTIONS
2.1
Set-Up
2.1.1
Fill water bottles in back pack, check adequate levels of tap water (min. 4"/100mm
head) in probes.
2.1.2
Output from the system can be turned up without unduly polarising the pipe as current
is only ON for a third of the time. Do not exceed 30 amps DC output. Switching
outputs greater than 30 amps will damage the interrupter. A separate contractor must be
used in order to switch larger currents.
2.1.4
Where possible adjust current output to give a minimum potential swing of 500 600mV from ON to OFF. A swing of 1000 - 2000mV is desirable when testing over
high resistivity ground. 'Shift' of signal strength can be measured using the Pipe-CAMP
meter. One probe being placed on the structure monitoring cable and the other probe on
the ground. The pulsing signal also confirms operation of the equipment.
Page 7
2.1.5
Strap on meter, connect cables and drip tubing to probes. See Figures 5, 6 & 7.
Page 8
2.1.6
Turn meter ON through automatic battery test. Set impedance to 100 or 1000
megohms. Select 1000 megohms only for testing over bitumen / asphalt surfaces or
where ground is very dry (high resistivity). Set range selector to 100mV for survey to
maintain meter deflections on the scale.
Note:
Drip system only require for surveying over high resistance surfaces such as
bitumen, concrete or dry soil/sand.
2.2
Survey Procedure
2.2.1
Measure ON and OFF potentials at all test points, valves and risers to determine signal
strength i.e. difference between ON and OFF readings.
2.2.2
Walk along the pipeline route using probes as walking sticks ensuring that one probe is
in contact with the ground at all times. One probe should always be near the centerline
of the pipeline and the other held laterally by 1-2m. For short durations between steps
both probes must be simultaneously contacting the ground. Where there's no defect, the
needle will register no movement.
Page 9
2.2.3
2.2.4
An auto zero button is fitted at the top of the right hand probe. This button should be
depressed momentarily when the meter needle strays excessively away from the centre
position or to assist when taking readings at defects.
2.2.5
2.2.6
If signal strength becomes weak, say 100 - 200mV, consider relocation of signal
injection point to a closer location for increased strength as small defects may be
missed.
2.3
Centering Defects
2.3.1
Whilst traversing along the top of the pipe, maximum amplitude of swing will indicate
approximate location of defect.
2.3.2
At two or three locations, offset from the line by 2 - 4 metres (6 - 13 feet), place probes
along the voltage gradient to obtain a null on the meter. A right angle line through the
centre of the probe locations should pass over the defect epi-centre. This geometrical
procedure on opposite sides of the pipeline will locate the exact point above the defect.
See Figures 8 & 9.
Page 10
2.3.3
Page 11
2.3.4
With probes spaced approx. 2m (6 feet) apart, measure a succession of potential drops
from the defect epi-centre to remote earth at right angles to the pipeline. This would
typically be 10 - 15m (32 - 49 feet) when increments of potential drop reduce to 1mV.
See Figure 10.
2.3.5
Record summation of potential drop increments to obtain total overline to remote earth
potential drop for relevant defect.
Page 12
3.0
-1.45 volts
=
-0.95 volts
=
1.45 - 0.95 volts
=
0.5V or 500mV
Page 13
The electrodes are used in various geometric attitudes and spacings to confirm the
validity of the indication and exact defect location. Probes placed across voltage
gradient lines will indicate voltage deflections cycling at the same rate as the current
interrupter. Probes placed along equi-potential lines will result in the instrument
nulling. Tracing of the voltage gradients will rapidly locate the defect epicentre. The
defect should be marked and a record made. A sample record form is appended.
Signal strengths along a pipeline may be as per Figure 12.
Figure 12
Page 14
Percentage IR
=
=
25 + 15 + 6 + 4 + 3 + 1 + 1mV
55mV
55 x 100%
275
20%
In other words, a reduction in protection but still protected. If in fact the defect had a
50% IR, the potential would then be -775mV, i.e. under-protection.
There are a number of inherent errors in this technique. Polarisation effects are
overlooked, soils are assumed to be homogenous and potential drops between the
ground surface and defects are not allowed for.
Page 15
3.1
4.0
4.1
Maintenance
4.1.1
*When refilling, avoid spillage of tap water onto top end of probes.
4.1.2
*End caps must be replaced after use immediately to prevent drying out the porous
plug. Caps should contain a small quantity of water prior to being placed over porous
plugs to maintain moisture.
4.1.3
Side connector of shaft for water tube should be plugged after use to avoid fouling with
dirt.
4.2
Procedures
4.2.1
Although the equipment is constructed from robust materials, the meter, probes and
interrupter contain sensitive electronics requiring care in handling and transportation.
Always transport the equipment in the carry cases provided.
4.2.2
Both probes should be secured with sponge and straps at two locations before packing
into tube to avoid vibration damage during transportation.
4.2.3
When testing at test stations/points the range selector should be set at an appropriate
range, say 1000mV.
4.2.4
Ensure that rechargeable batteries in meter and interrupter are kept charged to avoid
delays during surveying. Use only charger supplied. Make sure that the correct voltage
supply is used i.e. 110V or 240V.
Page 16
4.2.5
Current at transformer rectifier to be interrupted MUST NOT exceed 30A. When 30A
or more, switching via a contractor is required. Switching of currents of 20A or less
will increase the relay life.
4.2.6
4.2.7
Static spike seats between two 'O' rings on the porous plug holder.
4.2.8
During surveying do not forcefully jab at the ground with the probes.
4.3
Caution
4.3.1
Protect the meter and interrupter from rain. Do not immerse probes in water.
Electronics components are housed in the probes.
4.3.2
4.3.3
*Absorbent paper / cloth should be placed around probes prior to filling probe with
water to catch any spillage which would contaminate the electronics.
4.3.4
The porous plugs at the ends of the probes will wear and will require replacement.
Remove brass fixing screws and lever out using pliers or grips.
4.3.5
Ensure that during unscrewing porous plug for refilling or replacement, the adjoining
end piece is held and not the transparent electrode.
4.3.6
4.3.7
4.3.8
4.3.9
Backpack bottles should be emptied of water and double capped after use.
4.3.10
4.3.11
Sponge tips must be kept moist at all times to avoid hardening up. Retain in sealed
bag.
Page 17
WARNING:
DO NOT clean the equipment with solvents as permanent damage may occur. If cleaning is
necessary, only use a damp cloth.
5.0
FAULT FINDINGS
PROBLEM
POSSIBLE REASON
Insufficient current output
ACTION
Increase current output.
Disconnect off other lines
not under test.
Change groundbed location.
Testing on pipeline
appurtenance which is
resistively connected to the
pipeline.
Put on charge.
Page 18
PROBLEM
Erratic Deflections of
Meter.
6.0
POSSIBLE REASON
ACTION
As above.
Low Battery.
Charge.
Replenish.
WARRANTY
Equipment carries a 12 month warranty against defective materials and workmanship from
date of shipment. PCS-2000 (Aust) Pty Ltd is not liable for damages resulting from
instrument failure. Goods must be returned to manufacturer with freight pre-paid by client.
The warranty becomes void if internals of the equipment are tampered with by unapproved
personnel unless specifically advised in writing by PCS-2000 (Aust) Pty Ltd.
Page 19
7.0
EQUIPMENT SET
A full set of PCS-2000 equipment consists of:
1. PCS-2000 receiver.
2. One pair of probes, cables and one auto zero switch.
3. PCS-2000 current interrupter.
4. Battery charger.
5. Backpack containing one pair of water bottles.
6. Two pairs of connecting drip tubes (one spare pair).
7. 50 defect location markers and holster.
8. Sponge and wood probe tips and fixing screws for testing over concrete and
asphalt/bitumen.
9. Receiver harness.
10. CD-ROM.
11. Operators manual.
12. Carry case and probe tube.
Page 20
8.0
9.0
PATENT PROTECTION
Worldwide patent protection under the International Patent Co-operation Treaty has been
registered.
Page 21