DCVG COATING DEFECT

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.
_______________________________________________________________________________________________________________________

DEVELOPED & SUPPLIED BY:

PCS-2000 (AUST) PTY LTD
4 Judith Court
Aspendale Gardens Victoria 3195
AUSTRALIA
tel : +61 431 807033
fax : +61 3 9532 3963
web : www.solcor.com.au

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.

PCS-2000 Operators 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

FAULT FINDINGS ..................................................................................................18

6.0

WARRANTY ...........................................................................................................19

7.0

EQUIPMENT SET ...................................................................................................20

8.0

OPTIONAL SPARES, EQUIPMENT AND SERVICES ..........................................21

9.0

PATENT PROTECTION..........................................................................................21

PCS-2000 Operators Manual

Page 2

1.0

COMPONENT GUIDE

1.1
RECEIVER - Figure 1
___________________________________________________________________________
Name
Function
___________________________________________________________________________
(1) Millivoltmeter

Indicates the average steady-state signal voltage measured between the

two probes. Meter has three scales with a centre zero and battery
charge indicator. Scales are + or - 5 / 10 / 20.

(2) Mode Switch

Used to turn the instrument ON and OFF and perform a battery test.

(3) Range Selector

Used to select the meter range. Ranges are 10 / 20 / 50 / 100 / 200 /

500 / 1000 / 2000 / 5000 mV.

(4) Impedance

Used to select the meter impedance. Impedance values are 100 or

1000 megohms.

(5) Strap Post

Used to secure neck strap to meter box.

(6) Strap Bracket

Used to secure waist strap to meter box.

(7) Probe Socket

Used to plug in lead from probe. One located on each side of meter
housing.

(8) Charger Socket

Used to plug in lead from battery charger.
___________________________________________________________________________

Figure 1
PCS-2000 Operators Manual

Page 3

1.2 PROBES - Figure 2

___________________________________________________________________________
Name
Function
___________________________________________________________________________
(1) Lead Socket

Used to plug lead to meter.

(2) Drip Inlet

Drip tube inlet. Push tube to lock in. To release tube / plug,
push in outer ring (red) with fingers and withdraw tube / plug.

(3) Foam Grip

Soft hand grip for operator.

(4) Electrode

Used for potential measurement. Tube contains tap water.

(5) Drip Outflow Apeture

Permits flow of water to probe tip.

(6) Removable Plug Holder

*Permits replenishment of tap water by unscrewing.O ring

provides seal.

(7) Porous Plug

*Permits electrical contact between half cell and ground.

Removable by unscrewing of two brass fixing screws and
levering out. O ring provides seal.

(8) End Cap

Used to cover tips when probes are not in use. Prevents

leakage.

(9) Auto Zero

Automatically zeroes the meter. Used to maintain needle in

central location when taking readings at defects or when
excessive drift is noted. Activated by momentary thumb
pressure. On right hand probe only.

___________________________________________________________________________
*Notes:
1.

2.

Although the video / CD-ROM mentions the use of copper/copper sulphate

(Cu/CuSO4), it is recommended that tap water is used in the test probes.
Test Probes - Water can be used in preference to Cu/CuSO4 solution. Recent test
results obtained show that using water provides:
equivalent sensitivity;
easier maintenance;
less risk of damage if spilled on equipment.

PCS-2000 Operators Manual

Page 4

Figure 2

PCS-2000 Operators Manual

Page 5

1.3

CURRENT INTERRUPTER - Figure 3

___________________________________________________________________________
Name
Function
___________________________________________________________________________
(1) ON-OFF Switch

Used to activate interrupter to set switching cycle.

(2) Signal LED

Indicates operation of interrupter with audible switching

sound.

(3) Terminals

Used to connect interrupter in series with DC or AC circuit.

Two terminals permit use of banana plug, spade lug or bare
cable connections.

(4) Low Battery Indicator

Indicates low battery voltage when illuminated.

(5) Charger Socket

Used to plug in lead from charger. Facility also available for

connection of external 12 volt battery using optional
connector lead for extended period of operation.
___________________________________________________________________________

Figure 3

PCS-2000 Operators Manual

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

Install interrupter in permanent transformer rectifier unit or set-up temporary impressed

current system for signal injection. Normal switching cycle a seconds ON, b seconds
OFF. Positive feeder cable connection to groundbed and negative feeder cable
connection to structure should be confirmed at commencement. See Figure 4.

Figure 4 - Interrupter Set Up to Inject Signal

2.1.3

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.

PCS-2000 Operators Manual

Page 7

2.1.5

Strap on meter, connect cables and drip tubing to probes. See Figures 5, 6 & 7.

Figure 5 - Equipment Set Up

Figure 6 - Confirming Operation of Equipment

PCS-2000 Operators Manual

Page 8

Figure 7 - Drip System Connections

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.

PCS-2000 Operators Manual

Page 9

2.2.3

When approaching a coating defect a noticeable swing will be observed on the

voltmeter at the same rate as the interrupter switching cycle. The amplitude of this
swing will increase as the defect is approached and decrease when walking past.
Needle swing is directional with probes held in a similar orientation parallel to the
pipeline. Needle swing to right indicates right probe closer to defect and vice versa.
See Note No. 2 under Figure 2.

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

Select a suitable volts scale in order to note amplitude of swings.

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.

PCS-2000 Operators Manual

Page 10

Figure 8 - Locating Defect Centre

2.3.3

Mark defect location by pegging (or alternative) and note location.

PCS-2000 Operators Manual

Page 11

Figure 9 - Voltage Gradients Resulting from Different Types of Defects

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.

PCS-2000 Operators Manual

Page 12

Figure 10 - Taking of Lateral Readings OL/RE

3.0

RECORDING AND INTERPRETATION OF RESULTS

Signal Strength.
ON and OFF potentials should be measured at all test points, risers, valves and other
pipeline appurtenances. The numerical potential difference is the signal strength.
e.g. ON potential
=
OFF potential
Signal strength

-1.45 volts
=
-0.95 volts
=
1.45 - 0.95 volts
=
0.5V or 500mV

As the surveyor approaches a coating defect, a pulsing signal is detected by the

voltmeter. See Figure 11.

PCS-2000 Operators Manual

Page 13

Figure 11 - Voltage Gradients around Defects

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

PCS-2000 Operators Manual

Page 14

Estimated signal strength at defect

=
200mV +
1500
(300 - 200) mV
500 + 1500
=
200mV + 75mV
=
275mV
A straight line attenuation effect is assumed between test locations to calculate the
signal strength at intermediate defect locations.
Having detected the epi-centre, a series of lateral readings are taken moving away to
remote earth. Lateral readings near the defect will yield maximum voltage differences
where gradients are at a maximum. Whereas readings at remote earth will indicate zero
to 1mV deflections. The summation of these readings is commonly referred to as the
over-the-line to remote earth voltage. The expression "percentage IR" has been adopted
to give an indication of defect size. For instance, if a series of lateral millivolt readings
to remote earth are 25, 15, 6, 4, 3, 1, 1, 0 and the attenuated signal at the location based
on adjacent test point readings is 275mV.
Over-the-line to remote earth voltage

Percentage IR

=
=

25 + 15 + 6 + 4 + 3 + 1 + 1mV
55mV

Overline to remote earth voltage x 100%

Signal strength

55 x 100%
275

20%

Theoretically, this percentage IR is used to predict the reduction in protection

levels ignoring polarisation effect. For example if adjacent test points have 'on'
potentials of -1000mV and it is assumed that the native state potential was: -550mV.
Potential at defect =
=
=
=

- Potential -(%IR/100 x potential shift)

- 1000 - (20/100 x (1000 - 550))
- 1000 - 90
- 910mV

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.

PCS-2000 Operators Manual

Page 15

3.1

Coating Repair Criteria and Cathodic Protection System Review

Reduction in protection will generally be proportional to the amount of poor coating.
Thus, any significant coating defects should be repaired. It is good practice to maintain
OFF potentials in the range of -0.85V to -1.15V. Over-protection for some coatings
can be disastrous as a result of hydrogen evolution and formation of alkali.
As a general rule, average to poorly coated pipelines should have coating defects
greater than 15% IR repaired. On well coated pipelines defects greater than 5% IR
should be repaired. As a guidance, 5% IR typically indicates 1.5 in2/10cm2 of bare
steel. This varies with resistivity at defect and depth of pipeline.
The cathodic protection system must be adjusted such that all the line is maintained in
a protected range without over-protection.

4.0

CARE AND MAINTENANCE

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.

PCS-2000 Operators Manual

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

Static spike must be used at all times.

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

Electrical connector sockets to be kept free from dirt.

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

Sharp side blows to the shaft must be avoided.

4.3.7

Water should be emptied from electrodes when equipment is not in use.

4.3.8

Avoid stretching or tugging cables.

4.3.9

Backpack bottles should be emptied of water and double capped after use.

4.3.10

Only fill bottles with clean water to avoid blockage of tubing.

4.3.11

Sponge tips must be kept moist at all times to avoid hardening up. Retain in sealed
bag.

* See Note No. 2 under Figure 2.

PCS-2000 Operators Manual

Page 17

WARNING:

Only qualified and experienced personnel should undertake connections to

AC and DC circuits. Exposed live cables are hazardous.

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

Low Signal Strength

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.

Test at different location.

Large defect at test location.

Test at different location.

Short to foreign structure.

Locate short and isolate.

Low Battery Indication

Batteries require recharging.

Put on charge.

Major Loss of Signal

Existence of large defects.

Increase current output or

relocate groundbed.

Short to foreign structure

Locate and isolate.

Change meter range.
Use water drip system.
Increase water drip rate of

Testing over high resistance

ground

If over bitumen place

Unable to Centre Defect

Test point resistivity

connected to pipeline.

Test at different location.

Long defect such as scratch

or split.

Trace voltage gradients by

placing one probe overline and
other laterally spaced to obtain
equi-voltage gradients.
See Figure 8 in Section 2.3.2.

PCS-2000 Operators Manual

Page 18

PROBLEM

Unable to Obtain any

Readings

Erratic Deflections of
Meter.

6.0

POSSIBLE REASON

ACTION

Several defects closely

spaced in a line.

As above.

Poor connections between

meter and probes.

Check cabling and connections.

Signal to line removed.

Check signal injection location

and interrupter.

Low Battery.

Charge.

Low level of water.

Replenish.

Improper contact due to

humidity at contact points.

Ensure all contact points and

connections are perfectly dry
and free from moisture.

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.

PCS-2000 Operators Manual

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.

PCS-2000 Operators Manual

Page 20

8.0

OPTIONAL SPARES, EQUIPMENT AND SERVICES

The following are available as optional items:
1. Cables
2. Replacement tips
3. Synchronous interrupters
4. Results plotting program

9.0

PATENT PROTECTION
Worldwide patent protection under the International Patent Co-operation Treaty has been
registered.

PCS-2000 (AUST) PTY LTD

PCS-2000 Operators Manual

Page 21