DC Voltage Gradient Pipeline Coating Survey Equipment OPERATIONS MANUALDC VOLTAGE GRADIENT TECHNOLOGY & SUPPLY LTD GLOBAL LEADERS IN DCVG / CIPS EQUIPMENT, ECDA & SURVEY SOFTWARE Suites 2 & 3, Ground Floor Tel: +44 (0)1942 522 180 / 522 153 Greenbank House Fax: +44 (0)1942 522 179 ‘Swan Lane, Hindley Green E-Mail: devg@devg.com Wigan WN2 4AR Web Page: www.devg.com United Kingdom Copyright And Patents All aspects of this DC Voltage Gradient Pipeline Survey Equipment are covered by International Copyright and Patent Laws and therefore cannot be copied, re-engineered, altered or modified without the prior permission in writing by DC Voltage Gradient technology and Supply Ltd. Contravention of these International Copyright and Patent Laws will be vigorously pursued by DC Voltage Gradient Technology and Supply Ltd. and will lead to Litigation and a Substantial Claim for damages. All literature, operating manuals including all diagrams in the manuals supplied with the DCVG equipment is covered by copyright to DC Voltage Gradient Technology and Supply Ltd. (CVG Ltd.), therefore, this literature cannot be copied or supplied to any third parties without the written permission by DCVG Ltd. Copyright © DCVG Ltd., 2012 Page 2 of 25SdiL 380d + 107 3SVO NI GAGNON! OSV TWANYW ONILYYadO +8107 SMBQTOH dit BEONd 8007 SdvL Sle 71107 SMSHSUM dit . STWLSA 380d SONSUSISY :6007 SLVHAINS HaddOO #9107 ‘v3 NOLLOSNNOO. ¢3OMVHO AMSLLV :£107 Sdv37 NOLLOSNNOO. 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Table Of Contents Introduction 7 Typical Applications © ofpc Voltage ¢ Gradient nt Technology 8 Principle Of The DCVG Technique... 8 Equipment Package. . a) Unpacking Your Equipment 10 Equipment Description 10 Survey Switch (Interrupter) . 10 Survey Meter. "1 Probes And Handles 12 Battery Charger... 13 Equipment Cases ..... 14 Preparing Equipment For Survey. 14 14 Battery Charging... Probes ..... Surveying...... Setting Up The DCVG Signal... 15 Assembling The DCVG Equipment. 17 Operating Instructions... osc atanaRIRRRES 7 Finding a Defect... Determining The Coating Fault Severity Measuring The Signal Strength At Test Posts Where The Coating Is Damaged ‘Surveying Where The Exact Pipe Location Is Uncertain Coating Fault Size Shape And Location On The Pipeline .......:srseonone 21 Calculating The Severity Of Coating Faults. Marking Coating Fault Locations ..... Deciding Which Coating Fault To Excavate And Repair......:s:cs 23 Detection Of Interference. wwnw.devg.com Copyright © DCVG Ltd., 2012 Page 6 of 25DC VOLTAGE GRADIENT PIPELINE COATING SURVEY EQUIPMENT OPERATIONS MANUAL 1 Introduction The Direct Current Voltage Gradient (DCVG) pipeline coating survey test equipment is version 9, and is the most technologically advanced version of the equipment that can be traced directly back to the original invention of the technique in Australia by John Mulvany. The suppliers of this equipment have been involved in the development of the technology almost since its invention, ‘and were responsible for more than 2500 excavations to validate coating fault indications identified by the technique. No other DC Voltage Gradient equipment is backed by the depth of expertise and understanding of the technology that stretches back more than 20 years not only in the development of equipment, but in studies to advance the interpretation of meter readings to provide a very powerful tool to use in the fight against corrosion. With the equipment described in this brochure, through experience in its use and interpretation, itis possible to gather with a reasonable degree of confidence the following information about the pipeline being inspected, 1. Coating fault epicentre location to within a 15cm circle, which means that excavation costs can be reduced. 2. The approximate severity of the coating fault can be established so that coating faults can be prioritised for repair. 3. The approximate corrosion behaviour of individual coating faults can be established to ease identification of those coating faults that do not have sufficient Cathodic Protection. The DCVG technique does not however, detect metal loss but identifies sites where metal loss is possible. 4, Identification of where a coating fault gets its Cathodic Protection (CP) from, so that the vulnerability of a coating fault to being unprotected if a CP source becomes inoperable can be established, Identification of those coating faults that are discharging or picking up DC Traction Interference so that more effective mitigation techniques can be implemented. Identification of interfering structures that robs CP from the pipeline. Establish the effectiveness of Insulating Flanges. Identification of defective Test Posts at which Pipe to Soil Potentials are routinely monitored Rapidly establish sections of pipeline that have a larger number of coating faults by studying the rate of decay of the DC Voltage Gradient Signal on the pipeline. It should be remembered that defining and understanding problems on buried pipelines using above ground non-contact techniques is complex. The data gathered by the DCVG technique is not absolute but relative and is influenced by a series of parameters such as soil resistivity, depth of burial etc whose effects must be taken into account to improve the accuracy of any data In order to understand the technique and improve interpretation it is strongly recommended that operators of the technique undergo the intensive DC Voltage Gradient Training Course offered by the manufacturers to maximise the technology transfer. See inside front cover of this manual and the DCVG Training Course Brochure for more information on the DC Voltage Gradient Training Course. s eene ‘wwww.devg.com Copyright © DOVG Ltd., 2012 Page 7 of 252. Typical Applications Of DC Voltage Gradient Technology Set out below are some typical examples of the application of DC Voltage Gradient Technology to evaluate the protective coatings and Cathodic Protection on buried pipelines. It has to be remembered that the protective coating on a buried pipeline is the premier corrosion protection mechanism but all coatings have coating faults in them. To control corrosion of steel exposed at coating faults, Cathodic Protection is used. Cathodic Protection is a supportive technique. The relationship between Cathodic Protection and the protective coating is important and since DC Voltage Gradient technology studies this relationship, the technique provides valuable information to control corrosion. ‘Typical applications are: Evaluate Pipeline Coatings to define Rehabilitation Requirements. Define weaknesses in the Cathodic Protection system. Validate that a pipeline has been constructed with minimum Coating faults. Investigate Interference Effects Establish effectiveness of Insulating Flanges and other methods of pipeline isolation Provides data for Operating License Validation. Surveying Complex Pipeline Networks not possible by other methods. Surveying under Concrete and Asphalt in City Streets. Capable of surveying under Overhead Power Lines. 10. Not affected by Tellurics so it is possible to survey affected pipelines. 11, Evaluation of Test Post Integrity 12. Electrical Continuity checking of Mechanically Jointed pipelines. DC Voltage Gradient Technology is an investigative technique that has wide application to the investigation of Coatings and Cathodic Protection, CONMMRONS 3. Principle Of The DCVG Technique When DC is applied to a pipeline in the same way as Cathodic Protection (CP) the current flow through the soil to steel exposed at coating faults generates a voltage gradient in the resistive soil The larger the current flowing, the greater the Soil Resistivity and the closer to the coating fault location, all give rise to a larger voltage gradient. In general, the larger the defect, the bigger the current flow and hence the voltage gradient, a fact that is used to size coating faults so they can be prioritised for repair. In order to separate the DC current flow being monitored from all other DC influences and hence to ease interpretation, in the DC Voltage Gradient technique, the DC signal impressed onto the pipeline is pulsed at a frequency of 1.25 Hertz. The DC signal can be impressed on top of the existing CP system of the pipeline, or the CP system itself can be utilised by inserting a special ‘switch or interrupter into one of the output cables from the nearest transformer rectifier. Only one transformer rectifier, the nearest to the survey area, needs to be interrupted at any one time, thus the limitations of other overline surveys where all DC influences have to be switched at precisely the same time does not apply for coating fault location. However, for more precise and intensive studies it is advisable to interrupt synchronously a number of rectifiers that are affecting the area being surveyed. For coating fault location the pulsing DC signal can even be imposed at a test post using batteries or a portable DC generator and temporary groundbed. Another unique feature of the DC Voltage Gradient technique is that the pulsed signal is irregular in shape. The DC is switched ON for 0.45 of a cycle and OFF for 0.8 of a cycle. The irregular pulse allows the direction of current flow to be determined and compared to all other DC influences at an individual coating fault, enabling the degree of protection against corrosion at individual faults to be determined at the time of the survey. wwew.devg.com Copyright © DCVG Ltd., 2012 Page 8 of 25To monitor the Voltage Gradient in the soil the technique utilises measuring on a sensitive and especially constructed millivoltmeter, the difference in voltage between two copper/copper sulphate half-cells placed in the soil at ground level. When spaced one meter apart in a voltage gradient, one half cell will adopt a more positive potential than the other which enables the direction of current flowing which caused the voltage gradient to be established. In surveying a pipeline, the operator walks the pipeline route testing for a pulsing voltage gradient at regular intervals. As a coating fault is approached, the surveyor will observe the mill-voltmeter needle begin to respond to the pulse, pointing in the direction of current flow which should always be towards the coating fault on the pipeline. When the coating fault is passed the needle direction completely reverses and slowly decreases in amplitude as the surveyor moves away from the defect. By retracing to the coating fault a position of the electrodes can be found where the needle shows no deflection in either direction (a null). The coating fault is then sited midway between the two electrodes. This procedure is then repeated at right angles to the first set of observations, and where the two midway positions cross is the location of the Voltage Gradient Epicentre. This is usually directly above the coating fault location. The coating fault epicenter location is then pegged. In order to determine various characteristics about a defect, such as severity, shape, corrosion behaviour etc various electrical measurements around the epicentre and from epicentre to remote earth are made for detailed interpretation. 4. Equipment Package The standard DC Voltage Gradient Equipment Package comes in two containers: - 1. A suitcase sized plastic case, which contains the survey meter, interrupter, battery charger, handles and spares. 2. Aleather case that contains the three probes only. A full list of all components that make up a standard equipment package is as follows: - ] Item’ Quantity DCVG Survey TIR interrupter (Non Synchronisable) I 4 DCVG Survey Meter | 4 Probe Handles (Bias) 2 Copper Sulphate Reference Probes 2 Right Hand Connection Leads 1 Left Hand Connection Leads 1 Reference Probe Tip Holders 2 Probe Tip Washers 4 Wooden Probe Tips - 4 PTFE Sealing Tape | 1 120/240 Volt Battery Charger 4 Battery Charger Connection Lead 1 Probe Filler Bottle 1 Copper Sulphate Crystals (JAR) 4 Equipment Carry Case 4 Probe Carry Case 1 DCVG Instruction Manual - 1 www dovg.com Copyright © DCVG Ltd, 2012 Page 9 of 254.1 Unpacking Your Equipment The DC Voltage Gradient Equipment Carry Cases when opened gives ready access to all components of the Equipment Package. Upon first receipt of the Equipment Package check that all components of the Equipment Package are present and in good condition. Contact the place of purchase immediately if any component is missing or damaged during shipment. 4.2 Equipment Description The DC Voltage Gradient Pipeline Coating Survey Equipment consists of a fast response, high input resistance analogue milivoltmeter, two probe electrodes and a switch to interrupt a DC source at 1.25 Hertz 4.3 Survey Switch (Interrupter) The survey switch utilises a solid-state device to switch the applied DC at one of two speeds determined by the position of the STD/SLOW switch. The STD/SLOW switch has two positions, which represents: - STANDARD (STD) Setting 0.45 seconds ON followed by 0.9 seconds OFF SLOW Setting 0.9 seconds ON followed by 1.8 seconds OFF The STD (STANDARD) setting of the switch is used for normal surveying to find coating faults. This speed of switching matches the typical response time of a survey operative. Surveying on the SLOW switch position, whilst possible, does mean that the operator is often waiting on the response from the analogue meter and hence is wasting time The SLOW switch position is used in conjunction with a digital voltmeter for Pipe to Soil Potential measurements, or Current measurements via an inline calibrated shunt. The solid-state switch is protected against damage caused by spikes or surges by means of a parallel-wired transorb. The effects of spikes on the pulse shape, etc is dealt with below. The status of the switch position is indicated by the colour of a tri-coloured LED and is as follows: - Switch ON (passing current). Switch OFF (no current passing). Low Battery or Battery on Charge. The Interrupter will cease to operate when the battery charge becomes too low. This prevents damage to components that make up the interrupter timing circuit. Under normal operation the Interrupter internal battery has sufficient capacity to work for one week without charging, but under surveying conditions it is recommended that the Interrupter be kept as fully charged as possible by charging every night. Battery charging, dealt with in more detail in Sections 4.6 and .1, is via a built in rectifying circuit within the Interrupter and hence only requires connection to a low voltage AC source. The connection to the AC source is via a two-pin charger socket sited just below the Standard /Slow switch, Using the large terminals and suitable 10mm wire, the Interrupter is connected in SERIES into either the negative or positive cables from the DC source being interrupted. The negative cable is preferred. This is setup so that the cable coming from the Transformer / Rectifier (T/R) is connected to the Black Terminal on the interrupter and the cable from the pipe is connected to the Red Terminal on the Interrupter. www.devg.com Copyright © DCVG Ltd., 2012 Page 10 of 25DANGER UNDER NO CIRCUMSTANCES SHOULD THE TERMINALS OF THE INTERRUPTER BE DIRECTLY CONNECTED ACROSS THE TERMINALS OF THE DC POWER SOURCE/ TRANSFORMER RECTIFIER AS THIS WILL SHORT OUT THE POWER SOURCE AND DO SERIOUS DAMAGE TO THE INTERRUPTER AND THE DC POWER SOURCE. ALSO DO NOT UNDER ANY CIRCUMSTANCE CONNECT THE DC INTERRUPTER TERMINALS TO AN AC SOURCE. A typical current to be switched by the interrupter is up to 50 amperes The interrupter will safely handle up to 80 amperes. Although the switch is rated at 100 amperes, when switching large currents the corresponding large cathodic spike of two times or more the normal when switching ON, will cause the switch transorbs to fuse making the interrupter switch inoperative. It is the large spike that causes the problem not the average level of current switched. To one side of the interrupter is fitted a large heat sink to dissipate heat from the solid-state switch. These normally do not get hot but have been observed to get warm when switching a 100 volt § ampere Transformer Rectifier (high resistance soil) where the ambient temperature was 30°C at midday. The silver handle on the black interrupter case is meant for passing a chain (not supplied) through so that the Interrupter can be padlocked to the Transformer Rectifier/DC power source to prevent theft. 4.4 Survey Meter The dominant visible feature of the Survey Meter is the analogue meter movement. The meter, which is manufactured for Military Use, has a centre zero needle position. This means that with zero voltage across the meter input, the needle rests at mid scale irrespective of the range switch Position. The Survey Meter has the following voltage ranges: - 10mV, 25mV, 5OmV, 100mV, 250mV, 1V, 2.5V, 4V. The voltage range of the meter can be selected using the voltage range switch sited on right hand side of the meter front panel. These range switches correspond to various ranges or multiples of the ranges on the analogue meter scale. The 10mV on the voltage range switch corresponds to the zero to ten millivolts full-scale deflection on the analogue meter, (plus or minus 5 mV about the centre rest position of the meter needle) The 25 mV on the voltage range switch corresponds to the zero to twenty-five mili-volt full-scale deflection on the analogue meter, (plus or minus 12.5 mV about the centre rest position of the meter needle) The 50mV on the voltage range switch corresponds to five times the zero to ten-millivolt full-scale deflection on the analogue meter. It would also correspond to two times the zero to twenty-five millivolt full-scale deflection. ‘Muttiplying factors, which are in need of no further explanation, also apply to the convert analogue meter readings to match the selected position on the voltage range switch When not in use the range switch should be turned to the 4-volt range to minimise any chance of meter damage. To the left hand side of the front panel there is a Survey Meter ON, BATTERY (check), OFF range switch wnw.devg.com Copyright © DCVG Ltd., 2012 Page 11 of 25The switch is set to the ON position for normal surveying, When not in use or when being carried long distances, the meter should be switched to the OFF position. This practice conserves the batteries and also stops random full-scale deflections of the meter needle when the electrodes are being carried and not in contact with the soil In the BATTERY position, the meter needle should show an almost full-scale deflection to the right. Any position other than this, particularly if the needle reads mid scale indicates that the meter battery is in urgent need of recharging. Battery charging is similar to that of the interrupter. A two pin-charging socket is sited on the right hand side of the instrument. This is connected to a small rectifying facility sited inside the meter to charge the large capacity nickel cadmium battery pack. A low voltage AC power source, (described in Section 4.6), the same as that used for the interrupter and Bias Handles is used and is connected via the two-pin socket. Battery charging is indicated by a LED sited alongside the battery two-pin charger socket. The LED indicates red when the meter battery is on charge. The input connection leads to the Survey Meter are sited to the topside of the instrument. The lead plugs that fit into the three pin sockets in the Survey Meter are either a left hand or right hand fitting. A Right Hand Lead Will Fit Into A Left-+Hand Socket And Vice Versa But There Is Not Enough Space To Fit Two Crossed Leads. It Is Advisable To Fit Only A Left-Hand Lead Into The Left-Hand Socket And The Right Hand Lead Into The Right Hand Socket. To remove a lead the spring -loaded silver lever at the side of each socket must be pressed and held in as the plug is withdrawn The registered and copyrighted electronic circuitry design has been engineered so that it has high sensitivity but is not affected by induced voltages from high voltage AC overhead power lines, wind induced static, and other spurious noise. ‘The meter is designed to be water-resistant but should not be used in very heavy rain, as ingress of moisture at the plug and socket of the input cables will influence the very high input resistance of the Survey Meter. After use in rain the meter should be wiped dry and stored in a warm dry place Adjustable leather straps at the top and bottom of the Survey Meter are used to locate the instrument at waist level for easy viewing, adjustment and operation. 4.5 Probes And Handles The standard probes used with the DC Voltage Gradient Equipment are especially adapted approximately one-metre long copper/copper sulphate reference electrodes. The probes are lightweight, high strength tubes fixed at one end to an insulated stainless steel stud that provides both electrical and mechanical connection to the probe handle. The other end of the Probe electrode contains a conductive wooden plug to make electrochemical contact between the soil and the copper sulphate solution/copper electrode. The wooden plug is a push fit into its plastic holder with PTFE tape used as a washer. The plastic holder screws onto the probe using a flat rubber washer as the seal, All component parts of a probe can be unscrewed for cleaning and maintenance. ‘Two probes are used for surveying. There are also spare washers, wooden plugs, plug holders and PTFE tape. Each probe screws into identical handles, which are then coupled by flexible cables to the Survey Meter. Only one probe handle is switched on and used at any one time during a survey. The other is used as a spare. Plain handles that have no bias are available since only one bias handle is used at any one time for surveying www.deyg.com Copyright © DCVG Ltd, 2012 Page 12 ofThe probe handle has a builtin bias that is controlled via an ON /OFF /Range Switch and a Adjustment Potentiometer. The Bias ON/OFF /Range Switch is the smaller of the two knobs and is sited one third of the way up the handle from the threaded end where probe screws in. When the white line on the knob corresponds to the white spot on the handle body, the bias is switched OFF. The knob turns clockwise through five positions. From The Off Position The Knob Does Not Turn Anti- Clockwise And Any Attempt To Do So Will Damage The Switch. Each Position Of The Switch When Turned In The Clockwise Direction Applies An Increasing Amount Of Bias, The smallest Amount Being With The Switch In The First On Cloc! Position From The White Spot Off Position. The Largest Amount Of Bias Is In Po: ‘On. A high scale range e.g. 250mV or 1000mV on the DCVG Survey Meter usually requires a high bias so the last (position 5) ON position would be used. A small-scale range i.e. 10mV or 25mV on the DCVG. Survey Meter usually requires a small bias so the first ON position would be used To adjust the amount of bias applied for each range switch position a potentiometer is used. This potentiometer applies from minus 1.3 volt to plus 1.3 volt on the fifth ON range switch position. The potentiometer is sited as the large knob at the top of the handle. For a particular range position on the handle and also DCVG meter, the bias is adjusted to bring either end of the DC pulse (both extremities of the needle flick) onto the DCVG meter scale. For location this can be any position on the scale so long as the full pulse can be observed. Sited below the range switch on the handle is a socket into which the lead connecting probes to the DCVG Survey Meter is plugged On the reverse side to this location is sited a battery charging socket, identical in shape and size to the battery charging sockets on the DCVG Survey Meter and also the Interrupter. Similar to the Meter and Interrupter, the handles are charged with a low voltage (18 Volts) AC source. When the battery in the handle is on charge a small LED sited 4cm above the battery socket, glows red to show the status of the charging. ‘The Handle contains a selection of electronics and whilst it is made robust it should nevertheless be treated with care and not dropped onto hard surfaces. 4.6 Battery Charger ‘The Battery Charger comes as a small black plastic box with a lead out of either end. At the rear of the Battery Charger is a cable for connection to mains electricity. At the other end, set in a silver coloured panel is a mains voltage range switch so that either 120 or 240 Volts AC can be utilised Please Check The Power Source Required Which Varies for Different Countries. There is also a one ampere fuse to protect the battery charger and a LED that glows red when the charger is operational. The Low voltage cable also comes out of the silver panel and has a two-pin plug sized to fit into the Handles, DCVG Meter or interrupter. So that more than one item can be charged at the same time a charger adaptor is provided into which the low voltage AC out put cable plugs, thus allowing three items to be charged simultaneously. WARNING .. .- WARNING. . WARNING... WARNING The Battery Packs In The Interrupter And DCVG Survey Meter Are Quite Large. If These Batteries Are Badly Discharged, Then When First Plugged Into The Battery Charger They Will Each Take Very Large Initial Currents, Which Will Blow The Fuse On The Battery Charger. If In Any Doubt It Is Best To Charge The Meter On Its Own Or The Interrupter On Its Own First And Then The Handles. Under normal operation where the equipment is charged on a daily basis every night such a problem should not occur and it is quite normal to charge any combination of pieces of the ‘equipment at the same time. www.devg.com Copyright © DCVG Ltd., 2012 Page 13 of 254.7 Equipment Cases The probes fit snugly into a real leather long tubular carry case. The case will carry two probes at the same time. To prevent discolouration by copper sulphate solution it is recommended that probes be emptied and cleaned before returning to the case. All remaining components of the DC Voltage Gradient Equipment Package fit into a specially designed plastic vacuum-sealed case, to which compartments have been fitted to accommodate each different component. The case is fitted with clip locks and carry handle. 5. Preparing Equipment For Survey 5.1 Battery Charging Before use it is advisable to always charge the equipment overnight. Generally the DCVG Meter and the Interrupter will require charging more frequently than the Handles. Each item of equipment will require separate continuous charging for two days if the batteries are entirely fiat If the equipment has not been used for a week or more then all items should be charged overnight as a minimum but preferably for a 24-hour period. During continuous use on long surveys the meter and interrupter should be placed on charge overnight, every night. The handles may go several days without charging. When operating several sets in order to ensure all component parts of the equipment sets are adequately maintained it is advisable to number each component and set up a charging register to keep a tally of what equipment has been charged, when and for how long, 5.2 Probes ‘A wooden probe tip should first be wrapped around its cylindrical section with white PTFE Tape applying sufficient to ensure the wooden tip is a firm push fit into the probe tip holder. Three tip holders should be prepared, All three holders and tips should then be soaked in potable water ‘overnight. Water uptake causes the wood to expand and give a liquid tight seal The Copper/Copper Sulphate probes, (two of the three available) are filled with copper sulphate solution using a squeezy bottle. The probe is filled almost full of copper sulphate solution through the probe tip holder end, The presoaked tip and holder plus washer are screwed onto the probe to make a liquid tight seal, the probe is then inverted to its correct position and the handle is screwed on. The copper sulphate solution can be prepared in a number of different concentrations depending upon the type of reference electrode required. For surveying where actual pipe to soil potential measurements are to be made the solution should be saturated and have crystals of solid copper sulphate present. For normal surveying as all measurements are made by difference, the actual strength of the copper sulphate solution used is not critical. Solutions of strength between 5% to 10% by weight are recommended. Distilled water should be used to make up the copper sulphate solution. Tip ware rates are usually quite low, a typical tip lasting 4 to 6 weeks of normal surveying. The tip can be used until it is worn down flat to the holder. A new tip may leak but as it is used, bruising of the wood closes any large leaks. If this does not occur, then an alternative tip should be used. www.devg.com Copyright © DCVG Ltd, 2012 Page 14 of 256. Surveying 6.1 Setting Up The DCVG Signal The most important parameter in ensuring an accurate survey and in determining the survey speed is the amplitude of the DCVG pulsed signal. It is well worth spending adequate time during the setting up phase of any survey work to ensure the amplitude of the DCVG signal is at least 150mV and no larger than 1500mV. As the signal amplitude or strength will vary along a pipeline, the signal strength at the start (at drain point) should be 1500 mV and that at the other end, namely the next test posts the signal strength should be at least 150mV. A rapid decay of signal as described above measured at two locations say, one Kilometre apart would be an indication of a poor coating on the pipeline so the presence of many coating faults or some large drain on the CP system can be expected. A good coating would show very litle attenuation of signal amplitude with distance. The signal strength or amplitude is the difference between ON and OFF potentials measured on the pipe to remote earth, whilst the Interrupter is switching ON and OFF, the applied DC source. This amplitude is measured on the DCVG meter as the pulse size, the millivolts size of the pulse determined by measuring the difference in the extremities of the pulsing meter needle using the bias and range switches to bring the full pulse onto the meter dial The pulse amplitude at test posts measured to remote earth is not the same as the difference between ON and OFF pipe to soil potentials measured only at the test post. To get full value and meaning from the DCVG measurements, the ideal source is the pipelines CP system itself set at the same level of output as normal operation. Some adjustment to the transformer rectifier output might be required if signal levels are inadequate provided there is sufficient capacity available from the Transformer. Adjustment may also be necessary as the Interrupter has a resistance, which would need to be accounted for in its effect in reducing the natural setting of the CP system. Rectifier: If this is inadequate for a survey or if there is no CP system installed, then a temporary CP system must be set up. Ideally a maximum of 50 amperes should be switched, see Section 4.3. ‘A temporary groundbed may be steel poles inserted into the soil, or any steel structure such as a fencing post, overhead powerline earthing systems, scrap, steel pipe, etc. Because the resistance of temporary systems is not known, high currents could result. Caution Needs To Be Exercised In Order Not To Burn Out The interrupter. The interrupter should be connected into the electrical circuit as shown in Figure.1 utilising short wires of optimum 10 mm’ in cross section. The switch can be inserted into either the positive or negative output cables from the DC power source. The negative output lead is preferred. The black terminal of the interrupter should be connected to the negative terminal of the transformer rectifier and the red terminal of the interrupter should be connected to the cable going to the pipeline. The polarity of the connection is important, If Connected Around The Wrong Way The Interrupter Will Not Switch The DC Output. If This Happens Just Reverse The Terminal Connections On The interrupter. The Interrupter should be inserted with the transformer rectifier set in its lowest output setting and the transformer rectifier mains electricity switch in the OFF position. For Transformer Rectifiers with a known output that is less than 25 amperes, after the Interrupter has been inserted and the interrupter switch set to the ON position and interrupting speed switch to Standard, the Transformer Rectifier should be switched on and the output slowly increased to give normal output or higher to give an adequate DCVG signal level. To ensure adequate signal level, the amplitude of the signal at the extremities of the section of pipe to be surveyed are measured. If inadequate, adjustments must be made until an adequate signal level is obtained. www devg.com Copyright © DCVG Litd., 2012 Page 15 of 25Poor temporary anode set up is the usual cause of inadequate signal amplitude. With a temporary set up where the DC source are batteries, a welding set or rectifier with no ammeter it is important that the following procedure is followed in order not to damage the Interrupter by passing too much current The DC circuit is set up without the Interrupter in the circuit. At the lowest power source setting, the current is switched on and the actual amount of current flowing is measured by means of a DC clamp ammeter. Output should be no greater than 25 amperes. If less than 25 amperes the Interrupter is put in the circuit and pipe signal amplitude is measured. If signal level is inadequate then adjustments in output up to 25 amperes should be made. Adjustments beyond 25 amperes up to 60 amperes are possible but careful adjustment is necessary. A pipeline requiring more than 25 amperes to get a good signal level over a 1Km length is indicative of a very bad coating on the pipeline ‘Adjustment to ensure a good signal level requires trial and error and patience but extra time spent in setting up the signal will give greater confidence in the quality of the survey, which usually can be achieved at a greater speed than on pipelines with a poor signal Measurement of the signal level at test posts are carried out in exactly the same way as measurements made to Measure Pipe To Soil Potentials, except there are two measurements in this case: - 1. From the copper wire or test post terminal to the soil alongside the test post. 2. From the soil position alongside the test post to remote earth. This is dealt with in more detail in Section 7.2. Figure 1: Temporary T/R And Groundbed GROUNDBED TEMPORARY T/R TEST POST INTERRUPTER Om COATED PIPELINE UNDER SURVEY www.devg.com ‘opyrigh 3 Litd., 2012 Page 16 of 256.2 Assembling The DCVG Equipment The reference probes, previously filled with copper sulphate solution and fitted with tips are screwed onto the probe handles. The meter strap is placed around the neck and waist so that the meter fits snugly on the operator. The connecting leads are fitted into the meter and into the probes to interconnect the two probes to the meter. The meter function switch is then tured ON and the Range Switch adjusted from 4 volts to 1000mV. With the probe tips placed in the soil the bias to the right hand probe is switched ON. The bias to the left-hand probe is not switched on; it is a spare available if needed, also to increase the amount of bias available should that from one handle not be sufficient because of large background DC in the soil Move to the test point at which the signal is to be measured. With the right hand probe make contact with the soil and with the left- hand probe or with the plug end of the left-hand cable, make connection to the test point stud or wire. Adjust the right hand bias control knob and meter range switch until the full extent of the meter needle deflection is visible on the meter scale. Adjust the meter range until the deflection can be read accurately. If for example the meter is on the 1000mV range and the meter needle deflection is from 225milivolts in the OFF position to 850 milivolts in the ON position, the signal on the pipeline at the test post is 850 - 225 = 625 millivolts In measuring the signal the choice of probe handle to use is optional. Having measured the Pipe to Soil signal strength there is another measurement, that to remote earth which must be added to that from pipe to soil to give the full signal strength at the test post. In measurements to Remote Earth the probes are used like a set of dividers see Figure 2, by starting at the soil position at the test post and moving away at right angles, summing the voltages observed for each position of the half cells. Remote Earth is reached when two or more readings, small in size, are the same. THE SIGNAL STRENGTH IS RECORDED AS WELL AS THE DISTANCE APART OF THE TEST POSTS AS THESE ARE REQUIRED FOR COATING FAULT ASSESSMENT PURPOSES. The Signal Strength should be noted at every test post and all other potential monitoring points along the pipeline route. Measurements must be taken at either end of a section under survey as well as the distance apart, as these readings are required for calculating pipe to remote earth potential. Similar measurements to that described above are taken from the coating fault epicentre at ground level to remote earth at every coating fault and are used in calculating the coating fault severity 7. Operating Instructions 7.4 Finding a Defect Adjust the meter range switch to the 100mV range, and ensure that only one handle bias switch is ON adjusted to position 3. This is all that is necessary for normal surveying. It is recommended that in order to understand the instrument, on the first attempts at surveying, you walk directly over and along the pipeline route. Place the probes, one in front of the other. Contact the soil with the probes approximately at 1.5 to 2-metre spacing. Turn the bias control www.devg.com Copyright © DCVG Ltd., 2012 Page 17 of 25potentiometer to bring the needle of the meter onto the scale. Keep the needle on the meter scale the whole time the probes are in contact with the soil. Look for the meter needle to be flicking in response to the pulsed DC. Lift the probes; step out from the test point at which the signal strength was previously measured Move forward 2 paces and contact the ground with the probes. Use the bias if necessary to bring the meter needle onto the scale. Look for a needle deflection. If there is no deflection then step out another 2 paces and then bring the needle onto the scale with the bias control. If there is a deflection, observe the needle to see which direction the coating fault lies. If you are unsure either change to a lower meter scale or move the probe forward along the pipeline. The meter needle points to the probe, which is nearest to the defect. Figure 2: Overline To Remote Earth Potential Measurement x x x x COATING et Sf af ae — DEFECT OL/RE=15+8+3+1 =27mV Remember, The Interrupter Is OFF For Longer Than For What It Is ON And When It Is ON The Current Normally Flows Through The Ground Towards The Defect. It is the size and direction of the needle flick, or swing that you are interested in. It may be possible that the coating fault is small and lies behind you, so correct identification of direction of the needle swing is important. Recognising the direction of current flow as indicated by the needle flick will take a little time so be prepared to experiment to get used to the meter indications. If you have observed a deflection, lift the probe which is closest to the coating fault and move it 0.5 meter towards the defect. Bring the second probe forward and place it where the first probe used to be. Keep moving forward in this manner. ‘As you move toward the defect, the amplitude of the deflection will increase so there may be a need to change to a higher meter range as required. When the coating fault is passed, the needle deflection completely reverses and slowly decreases as you move away from the defect. Retrace your steps to the suspected coating fault position where the change in meter needle direction occurs. At the approximate null position, with the probes at about 1,5 metres apart observe any meter deflection. If the deflection is from left to right, move the left probe 15cm to the right and retest. Keep doing this until there is no deflection. It may be necessary to reposition the right hand probe. At the point of no deflection, the coating fault www.devg.com ‘opyright © DCVG Ltd., 2012 Page 18 of 25location lies midway between the two probe locations. Scratch a mark on the ground at the midway position. ‘The above process of nulling the meter is to place the probe tips on the same line of equipotential around the defect. Because it is an equipotential line there is no voltage difference between the probe tips and no meter needle deflection Tum through 90 degrees to work across the pipeline direction, Stand facing the mark in the ground and repeat the coating fault location process described above. At the new Null Position mark the midway position between the probes on the ground to cross the first mark. Recheck the first location by tuming back to the original position and checking for the null. Where the two lines cross is above the centre of the coating fault voltage gradient and is called the coating fault epicentre. As a final check that the location is correct, place one probe at the epicentre and the other about 1.5 metres away placed in turn at the four points of the compass. At each of the four locations the meter needle should indicate a direction towards the coating fault epicentre. If this is not the case then the epicentre has been incorrectly located or the coating fault location is at one end of a long crack in the pipe coating. Place a numbered peg, or some means of indication at the coating fault location. 7.2 Determining The Coating Fault Severity Coating fault severity, which is related to its geometric size although there are other influencing factors is determined from electrical measurements taken at the coating fault epicentre. Place one probe tip at the coating fault epicentre and the other at arms length at 90 degrees to the pipeline direction. Adjust the meter range if necessary and the bias control so that the full meter needie deflection is on scale. Read the amplitude of the meter deflection in millivolts, in the same fashion as that for taking measurements at a test post. For example if on the 100mV range and the deflection is from 10mV in the OFF position to 95mV in the ON position, the meter deflection is 85 mV. Remember this number. Put the epicentre probe where the other probe is and move the other probe out at right angles about 2 metres. Observe the meter deflection. Add this reading to the first reading. Continue ‘summing the deflections until the meter ceases to show any, or a small deflection, which indicates remote earth. During these measurements the bias control may need adjustment to keep the full meter needle movement on scale so that meter readings can be taken. The total millivolt drop made by summing all the individual readings to remote earth is referred to as the “Over Line To Remote Earth Potential’ (OL/RE) and must be entered into your note book against the appropriate coating fault number and distance. The Size/Importance or Severity of a coating fault titled %IR, is calculated by expressing the Overline To Remote Earth Potential as a percentage of the actual pipe to remote earth potential (the signal amplitude) on the pipeline at the defect. Refer to Section. 10.1 for the % IR Calculation Once all information about a coating fault has been logged continue surveying along the pipeline route When leaving a coating fault location, keep the probe spacing at 0.5 to 1 metre, overlapping the probe locations until away from the voltage gradient and meter needle deflections cease. Close spacing is used to locate coating faults sited in close proximity to the first coating fault already located. ‘A special but common type of voltage gradient encountered during surveying has a long sausage shape, generated by longitudinal crown cracking in coal tar, ruffling in tapes, microporosity in asphalt coatings or where many small coating faults occur in close proximity. Whilst this type of coating fault is often missed during CIPS or Pearson surveys, their presence can readily be wwaw.devg.com Copyright © DCVG Ltd., 2012 Page 19 of 25recognised by DC Voltage Gradient Technology because such coating faults have strong lateral voltage gradients. The meter needle readings on the approach to a crack etc will be similar to those of a normal defect. The needle will defiect to the probe nearest the coating fault and will increase in size as the coating fault is approached. However, when past the epicentre a region of negligible needle deflection occurs before the needle swing reverses as the crack is passed. During the region of negligible needle movement, a check should be made of the voltage gradient at 90 degrees to the pipe direction, i.e. laterally, where a strong meter needle movement indicating a strong lateral gradient should be observed. The beginning and end of the null, which indicates the approximate length of the crack, should be marked and recorded. The overline to remote earth potential should be measured as normal but with readings taken at either end, if the crack is long. Measuring The Signal Strength At Test Posts Where The Coat Is Damage: ‘The measurement of signal strength at a test post is affected by the presence of voltage gradients generated by coating faults at the test post location. Often the coating fault is caused by inadequate recoating of the area where the test post cable was attached to the pipeline by thermit or stud welding. The presence of the coating fault will make the signal measured at the test post appear to be less than what it actually is. If a voltage gradient from a coating fault exists the two components that make up the total pipe to remote earth potential must still be measured. The pipe test post wire to soil potential must be measured as component one. Component two is from the soil location to remote earth measured by using the probes as a set of dividers as previously described. The two added together gives the signal strength (or amplitude). If no coating fault occurs at a test post the readings will be a large figure from pipeline wire/test post to the soil say 800mV and a small reading from the soil location to remote earth, say 70mV or less. If there is a coating fault then depending upon the severity of the coating fault it is common to find a smaller figure for the pipeline wire/test post to soil potential say 300mV and a much larger soil to remote earth potential say 570 mV. ‘As experience in the DC Voltage Gradient Technique increases interpretation of signal measurements and the attenuation of the signal strength (amplitude) between test posts will enable the surveyor to size the problems namely extent of coating damage to be identified in a section of pipe before the actual detailed survey is carried out. 9. Surveying Where The Exact Pipe Location Is Uncertain Sometimes it is necessary to survey pipelines, particularly old pipelines where the actual route is unknown, and there are inadequate pipeline waming marker signs or test posts. If the pips coating contains coating faults then the pipeline location can be easily found by locating coating faults. If there are no coating faults then a pipe locator must be used to ensure survey is carried out along the pipeline route to ensure accuracy. An AC machine such as Radio Detection equipment can be used for pipe location at exactly the same time as carrying out the DC Voltage Gradient Survey. The presence of AC on the pipeline does not interfere with the DCVG technique. If the pipeline coating is in poor condition then the pipe centerline can easily be located, Place the probes at a1.5 metre spacing down length of pipeline. A coating fault indication is given by the meter needle. Move two paces; check that still approaching the defect. Re-orientate the probes so they are 90 degrees to the pipeline axis. Observe for needle deflection and move wew.devg.com Copyright © DCVG Ltd., 2012 Page 20 of 25probes to follow needle deflection until there is a reverse in direction of the meter needle. Retrace to locate the null position, You are over the pipeline. Turn probes so parallel to the pipe axis and continue surveying, checking at 90 degrees for every third probe location. It may be necessary to double check over any section of pipeline that you may have missed by being off the pipeline route by 5 metres or more. Once several coating faults have been located and marked by wooden pegs line of sight can also be used keep the surveyor on the pipeline route. As an indication of the technique’s ability to detect coating faults, with a signal of 800 mV on the pipeline in 10,000 ohm om soil and a coating fault of severity 25-36%, then the meter will begin to respond to the coating faults voltage gradient when some 50 to 70 metres away from the actual coating fault location if that is the only coating fault around. The presence of other coating faults will suppress the distance the voltage gradient is visible from an individual defect. 10. Coating Fault Size Shape And Location On The Pipeline A good indication of a coating fault size, shape and location around the circumference of a pipeline can be gained by plotting of the equipotential lines of the voltage gradient at a coating fault in the soil surface. Start by plotting at a point equivalent to 30% of the overline to remote earth potential Track the equipotential line by the nulling method around the coating fault epicentre all way back to the start point, placing markers on the way. The line will indicate the size and shape of the coating fault. The distance from the epicentre to the pipe centre line as determined by a pipe locator will determine whether a coating fault is on the bottom, side or top of the pipeline but this is an awkward way of determining this. A small discrete coating fault on the top of the pipe will appear as a circular isopotential shape. The same sized coating fault on the bottom of the pipe will appear as an ellipse, distorted to one side of the pipe centre line, Because the effect the pipe itself has in distorting the isopotential lines from the pipe centre line, it is easier to determine the location of a coating fault around the circumference of a pipeline on large diameter pipelines than on smaller diameter pipelines. Some typical examples of isopotential plots of coating faults of different shape on a pipeline are shown in Figure 3. An alternative way of determining the orientation of a coating fault is to carry out the four points of the compass readings at each location keeping the probe spacing the same for all four measurements. If the coating fault is on the top of the pipe all four readings will be of similar amplitude. If the two readings to the side are much larger than those taken down the length of the pipeline then the coating fault is on the bottom segment of the pipeline. If one side reading is larger than the other then the coating fault is on that side of the pipeline. www devg.com Copyright © DCVG Ltd., 20 Page 21 of 25Figure 3: DCVG SHAPE PROFILES SMALL COATING FAULT ON THE TOP OF THE PIPE SMALL COATING FAULT CONTINUOUS DEFECT ON THE BOTTOM OF PIPE 10.1 Calculating The Severity Of Coating The relative Severity of a coating fault is expressed by the term % IR, which is calculated using the following formula: - Fault Epicentre to Remote Earth x 100 Coating Fault Severity (%l — — Calculated Pipe to Remote Earth In short version:- %IR = OL/RE x 100 Calculation of the pipe to remote earth potential (P/RE) is an important figure needed to calculate the severity importance (%IR) value for a defect. To be able to caloulate the severity of defects it is necessary to know the distance of defects and the DCVG signal strengths at test posts either side of the sector being surveyed The Pipe to Remote Earth Potential (P/RE) is calculated as follows: - PIRE = S,- dX (S;~S,) D2 Dy Where: - 'S; = Signal at upstream Test Post: in example = 800mV Distance between Upstream Test Post and Defect: in example = 400m Distance of Downstream Test Post: in example = 1000m Distance of upstream Test Post: in example = Om Signal at Downstream Test Post: in example = 300mV wwew.devg.com Copyright © DCVG Ltd., 2012 Page 22 of 25In the example given in Figure 4 the severity (%4IR) is calculated as follows: Overline to remote earth from Figure 4 is 130 millivolts, Pipe to remote earth calculated above in 12.0 from figures given in Figure 4, then: - %IR= 130x100 =21.7 What does this figure mean? An interpretation is given in Section 12. 11. Marking Coating Fault Loca’ All coating fault locations will need to be marked by some method be it temporary or permanent so that the coating fault can be relocated for repair. Temporary marking with a flag or stick or marking the soil with marker paint poses little problems, allowing time for distance and electrical measurements. Permanent marking however poses problems especially if the survey is conducted in areas where traffic, people or livestock may damage, remove or destroy completely any forms of marking. Time and weather also have their influence, as it is not uncommon for 2 years to elapse from the time of finding a coating fault to its actual repair. In paved city streets the best means of coating fault marking is to use permanent pen identification on a white spray paint background. If accurate maps or drawings of pipelines are available for city areas, the coating faults can be indicated on those drawings by use of reference points such as corner of a building or edge of a gutter Many transmission lines run through rural areas, which are either stocked with cattle or planted with crops. Any pegs placed in such areas will soon be lost, or may ultimately damage farm machinery. Depending upon the degree of accuracy required in coating fault marking, the positions of coating faults may be referenced to the nearest test post or fence etc, Distances are usually measured with a surveyor's wheel, a tape measure or optical techniques. A method, which is becoming popular in some locations, is the use of a portable Global Positioning System (GPS). The GPS system is positioned over the coating fault epicentre and the coordinates recorded. The GPS system can be used to re-determine the coating fault location when the repair work is carried out. A work of caution is necessary, many cheap GPS systems are only accurate to 5 metres or more, so whilst the approximate location can be re-identified, the use of the DCVG equipment to accurately relocate the actual coating fault position to within 15 cm is recommended in order to minimise excavation costs. Sub metre accuracy GPS is recommended as the best method for logging coating fault locations 12. Deciding Which Coating Fault To Excavate And Repair Because the severity of a coating fault is calculated from electrical measurements of the voltage gradient, the results obtained are dependent upon the current flowing to each coating fault and soilfilm resistivity. The current flowing depends upon how large the coating fault is, how well protective films of magnetite have grown on the exposed steel surface, and how close the coating fault is to the CP drain point. Resistivity affects current flow and hence voltage gradient. By resistivity we mean a combination of soil resistivity and the resistivity of films of corrosion product on the exposed steel surface. The latter resistivity can be quite large, i.e. 100,000 ohm per sq cm of surface area, Ideally all measurements should be converted to a standard soil resistivity, we have chosen 5,0000hm om ight © DCVG Lid., 2012 Page 23 of 25 www.devg.comThis has allowed coating faults to be graded to determine those that should be repaired from those that it is possible to live with. ‘The Coating Fault Grading Is: 0-15 %IR- Characterised as small coating faults. Such coating faults can usually be left unrepaired provided the pipeline Cathodic Protection is good and there are not too many small coating faults in close proximity. 15-35%IR- Characterised as medium coating faults. These coating faults may need repair usually within normal maintenance activities. 35-70%IR- Characterised as medium large coating faults. These coating faults need to be excavated for inspection and repair in order to fix what could be considered a significant coating fault 70 - 100%IR- Characterised as large/important coating faults. These coating faults should be excavated early for inspection and repair. The characterisations of coating faults given above are only one input but a very important input to the excavation and repair decision. Other important factors are shape and method of coating failure, corrosion behaviour, soil pH and resistivity, presence of hydrogen sulphide in the soil, operating temperature, age, coating type, leak and metal loss history etc. etc. In fact there are ‘over thirty inputs to the repair decision. Figure 4: % IR Severity Of The Defect -800mV Om (81) 400m (5,) 1000m (83 COATING FAULT LEAST NEGATIVE VOLTAGE 1 GRADIENT -130mv wnww.devg.com Copyright © DCVG Ltd., 2012 Page 24 of 25