1

GPS PIPELINE CURRENT MAPPER

Model “EPT/GCM-4000” Manual Instruction

Electronic Pipeline Technology 26 Palomino Drive, Richmond Hill, Ontario, Canada, L4C 0P8

Tel: (905) 918-0025 Fax: (905) 918-0033 www.ep-tech.ca

E-mail: sales@ep-tech.ca

2

Introduction: Cathodic Protection (CP) is applied to buried steel Pipelines to complement the protection provided by pipe coating. If the coating is damaged causing holidays, or if there is an electrical contact between the pipeline and another metal structure, it is necessary to increase the CP Current to compensate for the resulting losses. Excessive current can be detrimental to the pipe. The engineer responsible for the pipeline integrity must therefore achieve a fine balance between effective protection and acceptable Current consumption. If the current becomes excessive or the cathodic protection ineffective; the pipeline must be surveyed to search for the major fault location. EP-TECH GPS Pipeline Current Mapper (GPCM) has been specially designed to perform this function. An old traditional pipeline locator is used to detect an AC Current (typically 750HZ) applied to the pipeline. Large signal losses are assumed to be due to large fault. In fact, the losses are also due to capacitance losses along the pipeline, so fault are very often masked by the natural decay of signal. This current does not exactly mirror the CP D.C. Current. The effect can be particularly misleading at pipeline branches. Capacitance losses also limit the length of pipeline that can be surveyed in one operation. The Pipeline Current Mapper is designed to overcome the shortcoming of the existing techniques and now provides pipeline engineers with an accurate, cost effective product that can be used in all weather types and ground conditions. An extremely low “near D.C.” frequency (1HZ, 2HZ, or 4HZ) is used to mirror as closely as possible the D.C. current generated by the cathodic protection. It also avoids signal losses caused by capacitance so nearly all the signal loss is due to coating faults or shorts to other structures. Conventional pipe locators cannot partially detect such a low frequency. So the receiver is fitted with a precision high performance magnetometer. This detects and measures the (1HZ, 2HZ, or 4HZ) magnetic field. Advanced signal processing techniques filter and amplify the signal so that automatically current value (magnitude and direction) of the near D.C. signal can be seen in the LCD. Internal data logger function enables the storage of this data so that current or dB of current versus distance, or number of readings can be plotted.

3

GPCM Transmitter: This system is using the same cathodic protection current as power supply for Interruption. If there is not cathodic protection current available in the system, the operator can use external Car Battery for Interruption power easily. Only by installing a GPS current interrupter Model “EPT/CI-100” and program for 2 (200 ms OFF and 300 ms ON or 500 ms OFF and 500 ms ON) the CP current will change to a Transmitter signals with desired interruption program. Therefore; we do not use any extra transmitter except the GPS current Interrupter. The interruption program will be 500 ms or 1000 ms cycle and 200 ms or 500 ms OFF for 2 or 1 HZ interruption. In this system we don’t have any restrictions for the current and the operator may tune the Rectifier around 4-5 AMP (4000- 5000 ms) for this test.

4

GPCM Receiver: The hand held receiver with a search coil first locates the pipeline with using Flash Green light and LCD Bar graph even in heavily congested areas, and then provides the operator with a measurement of current magnitude and direction of the near D.C signal as applied by the systems transmitter. By pushing Keypad switch 1, all the LCD information such as current, number of readings, GPS coordinates, time, and tag for that position will be saved in the memory. By pushing 3 in survey mode, the operator can delete the last saved data reading. Receiver has the option to change the scale of the Bar graph in three positions for high and low sensitivity. This programmable unit has a large LCD with internal independent clock with date and time. The GPS coordinated for every point is visible in the LCD. This unit is provided with EP-TECH software which operates with windows base computer and able the export the data from the unit to the computer. Only by pushing a button it will automatically change to Current verses distance or number of readings. It is possible to export data to the computer by using EP-TECH software or sending the data to excel spreadsheet as well. Fault can be clearly identified with their position and imported in to a global information system so that pipeline maps can be generated.

GPS Connector

Power ON/OFF

USB download Connector

Input Search Coil Connector

5

Main Manu: When the unit is turned ON, the main menu has the following features. Survey mode: By pushing keypad number 1 all the LCD Information will save on the memory. The Current Direction The Bar graph is proportional with Current readings. As the currents go higher, the bar graph length will be longer. There is an option for changing the scale of Bar graph.

EP-TECH Pipeline Current Mapper 1- Set up 2- survey 3- Select File 4- Quick menu S- Set date and Time G- GPS on O- GPS OFF E- Export data H- Erase File F- Erase data from File I- Graph J- Bar graph Scale 10: 48 20/10/09 BATTERY 7.9 4353.6221, N 07926.9788, W

Current 565 ma Number of readings 25

CD → 10: 59 20/10/09 → 4353.6221, N 07926.9788, W →

6

7

Optional GPCM DCVG Frame: Use of the GPCM will give the location of coating fault to within just a few yards. The addition of the DCVG Pogo sticks frame enables the operator to pinpoint the fault to within a few inches keeping the excavation to a minimum.

Keypad:

The GPCM priority is to measure, Current, Monitor time, GPS Engine Coordinates,

and to display all of this information on a LCD and record the information with

commands.

G: GPS ON

O: GPS OFF

E: Export Data

F: Erase Memory

1: Set up in the main menu and record information in survey mode

2: Survey

3: File Directory, in the survey mode, deletes the last reading from the memory

S: Set time and date,

Shift+S: Space for file name or tag information name

Shift + T: dash line for tag information

H: Erase File

F: Erase files information only

I: To show the graph of information in the field in the same active file only

J: to change the scale of Bar graph in the survey mode.

4: Back to main menu in survey mode, and Push 4 in main menu for tag information

for quick menu. Please wait in the main menu to complete the page include

the clock time and date then send a keypad command.

Shift: Before attempting to type an alphabet letter, you must push Shift. .

Before typing a number, you do not need to push Shift. If you already pushed shift

and want to type a number, push shift again and then type your number.

Save your work: In case the operator decides to choose 1, 2, or any number from

the menu, he needs to push “Y” to accept. If he decides to name your file containing

8

alphabets such as A, B, Albert, the operator has to push shift to type and when it is

typed press shift+ Y to accept.

Fn: If you push the Function key and Z, it goes directly to stand by and when you

push Z again, it will come back to the main menu.

When the operator wants to select the file name in the programming or tag

information in the quick menu, or if he wants to use alphabet letters, he must first

push the shift key and then type the name. If he wants to select a number such as 3

for the file name or tag, he does not need to push shift first.

Accessories:

3.1) Search Coil:

3.2) GPS Engine: GPS Engine will send the coordinates information to the LCD

unit.

3.3) Charger: is a constant current charger the will charge the 7.2 volt Nickel

Cadmium Battery. It will work for 24 Hours and it takes 10 Hours to fully charge it.

The operator can check the Battery voltage (BAT) in the main menu.

3.4) DCVG pogo stick Frame with Cable

3.5) USB communication Cable:

3.6) EP-TECH software: When this software is installed on the computer, the

operator can send information to the computer, only by clicking a finger you can

save this information, plot the graph, or export to Excel.

3.7) Manual Instruction: The instructions of how to program the unit and survey

the pipeline.

9

Making Files: To make a file for example named “A” push 3 in the main menu and select a number for example “0” and program your file. Then go to survey and collect some data and download the information. By pushing “1” in the main menu, the selected program and file name (active file) will appear on the LCD. If the operator goes to the main menu and pushes 3, he can see file A is allocate to the “0” The operator can make another file “B” by pushing 3 in the main menu and selecting a number from the file directory menu. By selecting a number (i.e. 1) the operator can accept and start programming, then by going to the survey mode collect some data. By making file “B” the file “A” will not be active any more. The last file is always the active file and in the main menu, only the active file can be surveyed, downloaded, or erased. To active file “A” again, the operator has to go to the main menu and push 3, then push the allocate number of that file (for A is 0) then this file will be active and all functions in the main menu will work for file “A” again. Pushing F will delete the active file information, but the file will still exist and the operator can continue his survey from the last reading. Pushing H will delete the active file. Pushing E will download (export) the information of the active file to the computer. When you want to download information from the GPCM to the computer, you may clear the data base or delete a file that already exists. You may delete the file from the data base by using the graph page and type the name of the file. By pushing 1 in the main menu, your active file will be displayed. Please only accept it and if you want to change the file, go back to the main menu and push 3 for the file directory and program your new file. The operator can reprogram the same file without deleting that file, but it is better to select another name.

10

FEATURES:

• The GPCM system accurately measures the distribution of an

impressed test current on a Pipeline network. It is a huge

achievement in troubleshooting and repairing defects.

• Direct Current Gradient technology is able to quickly

measure pipeline current flow.

• It is an accurate method of mapping and evaluating the loss

of cathodic protection Current.

• The GPCM Unit is able to measure the Current magnitude

and direction without the need of any connection.

• By only using the existing Rectifier and a current

interrupter, creates the easiest method to change the CP

potential to a transmitter signal.

• This unit is a Pipeline interruption locator and locates the

pipeline accurately by using the LCD Bar graph.

• Integral Data logger with 2000 Mb Flash Memory ( 2GB )

• USB interface Port allows data to be uploaded

• EP-TECH GPCM computer software has the ability to graph

and present saved data verses number of readings or distance.

• GPS Coordinates automatically will be saved for all reading

data. It is an easy way to map your pipeline by using ‘GPS

option’.

• Ability to export the data to Excel using any other software.

• Optional Frame Accessory as Direct Current Gradient for

finding accurately the fault location.

11

Technical Information:

1- Input voltage: 7.2 volt/ 4000MA

2- Large 240 x 64: LCD Display Graphics

3- Current consumption with GPS 120 MA

4- Memory Capacity : 2GB (2000 MB)

5- Ability to Tag information

6- Internal clock: separate Lithium Battery

7- Keypad : 7 x 4 tactile Switch keypad

8- AC Active filter : -73db for 50/60 HZ

9- Differential input with two separate channels for survey

10- Range of measurement: 5000 MA

11- Size of the unit: 182x 182 x 63 mm Aluminum box

12- EP-Tech computer software,

13- Ability to export data to Excel Spreadsheet

14- Universal Charger current: constant current 400 MA

15- Graph ability with GPCM “EP-Tech” Software

16- Graph Zooming ability with Graphic features

17- Precision magnetometer for Magnetic field measurements

18- LCD Bar graph for locating the pipeline and Current Direction

19- Use CP current without needing any extra Power supply

20- 100 AMP Current Interrupter Transmitter

21- Ability 1, 2, 4, HZ interruption program

22- Direct Current Gradient Frame Method for Fault location

23- Graph option for saved data information in the field

12

How to start operation: First the operator has to install the current Interrupter series with rectifier. The operator has to program the unit for 2 HZ or 1 HZ interruption as the followings:

1- Turn the Current Interrupter ON 2- Push 1 to go to the Program page and select 1

3- Push 2 on the next page to change for OFF time

4- Using D please select (200, or 500 ms) for OFF time then push A to accept it

5- Push 2 to change the cycle

6- By using D please select (500, or 1000 ms) for Cycle time and push A to

accept it

7- Please bypass the Start and Stop time and date

8- Select 2 to disable the GPS engine feature.

It will go to the main menu and will start interruption after a few seconds. The

operator can turn the unit off and when he turns it ON again, it will start with the

same last program too.

How to install Interrupter:

This installation must do with a certified technician.

1- First turn OFF the rectifier

2- Disconnect the negative of rectifier to Pipeline wire connection.

3- Connect the positive Cable of Current Interrupter to the Pipeline

4- Connect the Negative Cable to the Rectifier Negative Terminal.

5- Turn the rectifier and Current Interrupter ON.

Therefore, the rectifier power will interrupt with 200 ms OFF and 300 ms ON

This Interruption will create a magnetic field around the pipeline.

Start the interruption and tune the Rectifier current around 5Amp (5000 MA)

13

How to use receiver to start mapping:

First the operator needs to program the GPCM unit.

Important Notice: Do not change the rectifier current in survey time. This is a

reference current only. The current in the pipeline and all extension is proportional

with this reference current.

1- Push 3 and select a number such as 1

2- The push c for change

3- Push c again to change the name

4- Select your file name. To type a letter you need to push shift then type the

name. Then push shift again and press y to accept the file name. It will go to

the main menu again. To type a number you don’t need the shift key. Then

pus y to accept it

5- Connect the GPS engine and search coil to The GPCM unit in the field. Please

wait for the GPS Engine to be

locked and GPS coordinates appears

on the LCD. If the GPS is not locked

the information will not save in the

unit and the number of readings will

not change.

6- The search coil must be

perpendicular with the assumed

pipeline (not in the same direction

of the pipeline). To start readings

the operator has to use the search

coil to pin point the pipeline. When

the operator is on the pipeline the

14

Green flash light will start flashing with the same rate of the interruption of

Pipeline CP.

7- Please use the Bar graph feature in the survey mode (select the scale in main

menu) to find the MAX of Bar graph. When you have the Max Bar graph and

readings you are on the top of the pipeline. Put the search coil on the ground

and Wait for at least for 5-10 seconds to be balanced. The reading will refresh

every three seconds and it shows readings with a few MA differences.

The operator must select to save the middle one for best result.

8- By pushing 1 on the keypad the LCD information such as currents, GPS

Coordinates, date and time and number of readings will be saved on the

memory with a beeping alarm. If the operator made a mistake and saved an

irrelevant reading, by pushing 3 the last reading will be deleted.

9- For the next readings the operator can select approximately 100 Meter away

from the last readings (300 feet). The distance will accurately calculate

automatically by using GPS coordinates when the information will be

downloaded to the computer.

10- Continue locating the pipeline and save the information for the other

points for approximately around 30 Meter of each other. Do not worry

about the exact distance.

11- By pushing I keypad in the main menu you have option to see your

saved data graph verses number of readings in the field and check your saved

information arrangement.

15

How to use Pogo stick Frame:

To pin point the exact location of the faults, the operator may use pogo sticks frame.

Install the cable to the unit and the two other sides must be connected to the Pogo

sticks.

The operator must stand on the pipeline so that one pogo stick point is connected to

the top of pipeline soil and other pogo stick is connected to the soil vertically to the

pipeline around 1- 1.5 meter distance from each other.

As the operator walks on the pipeline, when the operator approaches the fault

location, the Green light will start flashing with the same Pipeline interruption rate.

Then the operator has to use a bar graph to find the exact location of the fault.

The operator must change the Graph sensitivity from high to low by going to the

main menu. When he approaches the fault location, the bar graph will get bigger and

bigger. In the top of the fault location, the Bar graph will be at the Max value.

\

16

How to download the information:

1- First the operator must install the EP-TECH software to their computer. (only

one time)

2- Connect The GPCM to the computer via USB cable and turn The GPCM ON. (The

USB software is on the EP-TECH set up CD. Please browse this file directory when

it asks for USB software to be installed.

3- Open the GPCM icon on the Desktop or go to:

C:\Program Files\Electronic PipeLine Company2\Eptech GPCM

Push The EP-TEC Icon and on the next page login and then following will appear:

4- Push the file Icon and select the port setting and the following page will appear.

Please open your computer device manager and find what com port is assigned

for this virtual RS232-USB converter. Normally it may be 3, 4, 5,

Port setting is very important and every time you have to select your port setting

to be able to download the information.

17

Please put that number in the place and save it. Then it will go back to the download

page.

Push E on the GPCM keypad unit, you will hear a beep and you will see a message

“Now receiving Data from GPCM ” is moving on the computer. When the downloading

the information is finished the moving will stop.

Then you have to push “Write to data base icon on the computer page”.

All downloaded information will save on the data base.

Push Plot and analysis Icon and the next page will appear.

18

Select your file name and then select distance or number of readings to graph.

If you check mark the Tag information, the Tag will appear on the graph too.

There are some plot features that operators can use it.

5- The operator can go to C:\Program Files\Electronic PipeLine Company2\Eptech

GPCM directory and open Hexlogger.mdb file. (Please be advised this is a

Microsoft ACCESS file and you need to have Microsoft ACCESS in your computer.

You can Install Microsoft OFFICE 2003 that ACCESS file already is included

All the data base information will be there in different columns. It is possible to edit

the data base and to plot the graph too.

6 – The operator can Push Export saved data to Excel and by selecting the file name

all information will export to excel all in different columns.

The operator can Zip with .rar the file Hexlogger.mdb (data Base) and send or e-mail

for his colleagues for consideration.

19

GPS SYNCHRONIZED CURRENT INTERRUPTER

OPERATING MANUAL

Model “EPT/ CI-100”

20

Table of Contents:

6- Welcome 7- Safety 8- Technical spec 9- Accessories 10- Theory of operation 11- Description of the GPS current Interrupter Model EPT/ CI-100 12- How to start operating 13- Latch night programmer

21

Welcome: Thank you for selecting our GPS Synchronized Current Interrupter. This equipment is a precise instrument and is designed to interrupt the current flow from your cathodic protection Rectifier on a cyclic Basis. The Current Interrupter should not be opened. There is no consumer serviceable part inside. Breaking the seal invalidates the limited one year warranty. The Installation of the GPS Synchronized Current Interrupter requires Electrical connections to the Rectifier. Only Personnel who are trained in electrical safety should undertake this job. This unit interrupts the DC output current supply to the Rectifier. Please use special Cable and observe the following safety precautions when installing the interrupter. Turn the AC supply to the Rectifier OFF The “EPT/ CI-100” should now be connected as a series switch with the DC supply to the Rectifier. Before connecting the “EPT/CI-100” to the Rectifier, charge the Battery overnight with the supplied Battery charger.

22

Technical specification: • 12 satellites visible and works all around the world • Magnet mounts GPS Antenna • GPS lock indicator • Programmable Interruption program • Manual and GPS synchronized mode, • Compatible with NACE standard Logic • Fastest Solid state electronic relay in the world without any delay in response • Rechargeable long life battery • Resynchronizes every 1-minute and remains synchronized • Waterproof and heavy-duty box • 5 program capability • Programmable start and stop time • Programmable start and stop date • Hold rectifier power ON when not interrupting • 1 year Warranty from the date of purchase against defective component and faulty workmanship Accessories: GPS Synchronized Current Interrupter Model “EPT/ CI-100” has the following accessories:

1- One pair of Interruption DC Cable for 100 AMP with Alligator and Supercon Connector

2- Universal Switching Charger 3- GPS Magnet mount Antenna 4- Manual

23

THEORY OF OPERATION: Current Interrupters need to turn ON and OFF the Rectifiers for cathodic protection sources. Measurement of the ON and OFF potential shows a good explanation of the level of the protection of the Pipelines. We have a number of Rectifiers for the Pipelines that supply current for the cathodic protection process. Therefore, for the interruption of the power, we need several current Interrupters that turn OFF and ON all Rectifiers at exactly the same time. To synchronize the Interrupters, we use GPS Engine technology that controls and communicates with 12 GPS satellites all around the word. Our experience in the field for more than twenty years and our understanding that we are in the field and not in the lab, has allowed us to manufacture equipment simply and accurately. This equipment is equipped with an option that you can easily change from GPS mode to non-GPS mode. In GPS Mode, the GPS engine works as a pulse generator and provides a synchronized pulse from the satellites. When the GPS is locked, the white led on the top of the GPS switch will start flashing. The Interrupter will be synchronized in the 00 second of every minute and will turn OFF the Rectifier in 00 second of minute and continue to be OFF up to the end of the OFF time. Therefore when the GPS is locked, we have to wait at least one minute for it to start synchronized interrupting. Notice: In GPS Mode, the Rectifier will not start interrupting unless the GPS Engine is locked. When the GPS is locked, it will take max 1 minute for it to be synchronized with satellites. In non GPS Mode, use a crystal controlled oscillator as a time base control, and this will provide a very accurate pulse for the Interruption program.

24

Description of GPS Current Interrupter Model “EPT/ CI- 100” I- Seconds Cycle: is the sum of OFF and ON time for interruption. GPS Synchronized equipment must be resynchronized every minute, therefore the Cycle can be only 0.2, 0.5,1, 2, 3, 4, 5, 6, 10, 30, 60, 120 seconds. The green LED on the bottom is ON only when the Rectifier is ON 2- Seconds OFF: is the time the Rectifier is OFF and the red LED on the bottom is ON. The selectable OFF time are 0.1, 0.2, 0.3, 0.5, 0.7, 1, 2, 3, 4, 5, 6, 8, 10 seconds 3- GPS Antenna: the Magnet mount Antenna with a Metallic connector must connect to the unit to enable it to communicate with satellites. 4- Battery Charger: Battery is 12volt/ 2.2 Amp Lead acid rechargeable Battery. When the battery is fully charged, the unit will work for at least 18 hours continuously. When the operator connects the charger to the unit, the yellow LED beside the charger Jack must be turned ON. The charger is a universal switching power supply with a constant control current. The current charge for this Battery is 0.6 Amp. It takes 4-5 hours to completely charge the Battery. Before operation, the battery must be completely charged. When the battery is completely charged, the led on charger will turn Green and yellow led on the unit will flash.

25

How to Start Operation A) Selectable Interruption program model:

1- Turn your Rectifier OFF and disconnect one pole of output power and connect to the Interrupter with one cable. Please be careful about the polarity for DC interruption. If the operator connects the cable with reverse polarity it will not start interrupting.

2- Connect the other interruption cable to the Interrupter and the power pole that you have already disconnected. By doing so, you put your interrupter series with output DC power. According to NACE standards, it is better to connect the unit series to the negative pole of Rectifier. Do not use this interrupter for AC interruption

3- You have the option to connect the GPS synchronized current

interrupter as one of the following methods. A: series with anode Disconnect the positive output post of the Rectifier and connect it to the red cable. The black cable must be connected to the Anode side. B: Series with pipe Disconnect the negative output post of the rectifier and connect it to the black cable. The red cable must be connected to the pipe side.

4- Select your Interruption Program. Your cycle is the sum of the ON + OFF time, therefore; always OFF Seconds must be less than Cycle seconds. Normally operation OFF time is one third of the Second Cycle. For example if you want the Interrupt program 0.3 second OFF and 0.7 second ON, you must select the Second cycle for 1 second (1000 ms) and OFF time 0.3 second (300 ms).

5- Select your GPS mode (1 second cycle or more).

26

6- Connect your Magnet mount Antenna cable to the unit and attach

the antenna to a metal surface in an open area to lock the GPS Engine. When the GPS is locked, the white LED will start flashing and in this position has to wait for one minute to synchronize with the Satellites.

7- Put all Interrupter programs in completely similar Cycle and OFF

time. 8- Turn the Rectifier ON 9- Turn the interrupter ON. 10- In GPS mode, wait for the GPS to lock and then start

interrupting in the 00 second of the minute.

27

B) Programmable models: This model is sophisticated electronic equipment with capability to program with 5 different interruption programs. The only difference with the selectable model is the programming procedure. In main menu, by pushing number 1 the operator enters to programming page and then he must follow the LCD instruction. When the unit is working and interrupts the rectifier, by pushing 1 the operator can back to the main menu. In the main menu with number 3, the operator can adjust the time and date. Interruption program: The operator can program the interrupter by entering Cycle and OFF time. It is simple and easy, follow the LCD instruction. OFF time must always be smaller than Cycle time. For example 300 ms OFF and 700 ms ON (1 second cycle and 300 ms OFF) GPS mode: If the GPS is selected to be off, the unit will work as an individual unit without any synchronization. If the GPS is selected to be ON, then it will start interrupting when the GPS engine is being locked. After max 1 minute, its interruption will be synchronized with Satellites on the 00 second of every minute.

28

Latch night programmer: The operator can enter start, stop time and date.