CDI CD42-STS User Manual Download

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1801 North Juniper Avenue

Broken Arrow, Oklahoma 74012 U.S.A.

+1 (918) 258-6068 worldwide

www.pigging.com

[email protected]

CD42-STS

Subsea Diver/ROV Pig Location and Tracking System

USER GUIDE

24-HOUR EMERGENCY TELEPHONE NUMBER

+1(918)645-0477

Summary of Contents for CD42-STS

Page 1: ...Avenue Broken Arrow Oklahoma 74012 U S A 1 918 258 6068 worldwide www pigging com support pigging com CD42 STS Subsea Diver ROV Pig Location and Tracking System USER GUIDE 24 HOUR EMERGENCY TELEPHONE NUMBER 1 918 645 0477 ...

Page 2: ...ally hazardous It is necessary therefore to follow correct procedures in the use of this equipment to maintain a safe working environment No person should use this equipment unless fully aware of potential hazards of working with pressurized pipelines and trained in the procedures stated in this manual The purchaser of this equipment is responsible for the training and competence of operators and ...

Page 3: ... Physical Checkout 6 Power ON 7 Operational Checkout 8 OPERATION 11 Tracking 11 Locating 14 Pinpointing 15 CHANGING INSTALLING BATTERIES 18 OPTIONAL EQUIPMENT 24 ROV Handles 24 Close Proximity Antenna CPA 26 WARRANTY CARE MAINTENANCE 32 Warranty 32 Making a Warranty Claim 32 Care and Maintenance 33 Service and Repairs 33 SYSTEM SPECIFICATIONS 34 NOTES 35 ABOUT CDI 36 ...

Page 4: ...ary or stuck pig DEPLOYMENT The CD42 STS may be deployed below the ocean to depths of 8 0000 ft 2 439 m and is designed to be either carried by a diver or ROV It is rated for a maximum pressure of 3 650 psi 245 bar COMPONENTS The CD42 STS is constructed of stainless steel A control button adjusts antenna gain which is displayed on an array of 16 light emitting diodes LED The LEDS also indicate tra...

Page 5: ...nchers and receivers POWER The CD42 STS is powered by six 6 D cell alkaline batteries The batteries are located in the unit s stainless steel housing Changing these batteries requires disassembly of the housing see pg 18 The CD42 STS will operate for up to 60 hours 2 5 days on a change of batteries DETECTION METHODS The CD42 STS can track and locate any pig or inline inspection ILI tool equipped w...

Page 6: ... receiver is assembled at CDI and should be ready for operation upon receipt The batteries are installed and the unit is sealed and tested for functionality just prior to shipment Check for any damage to the CD42 STS receiver after removal from the shipping container Check the antenna for any bends dents or deformities ...

Page 7: ...the system to access the power switch You ll need a 1 5 8 in open end wrench or adjustable wrench to loosen plug Press the red pushbutton switch to toggle the system power ON OFF Inspect O ring and O ring groove before replacing plug see pg 21 for O Ring inspection and maintenance information Replace plug Tighten until snug do not over tighten ...

Page 8: ...a self check This is indicated by a rapid back and forth scrolling of the LED array The LEDs on each side will flash in succession from bottom to top and back down five times as shown here The CD42 STS is operational when the self check has completed but you may wish to adjust the signal gain before placing the unit into service See following pages ...

Page 9: ... is looking for electromagnetic pulses To verify that the unit is operating prior to deployment bump the antenna with your hand The displays LEDs will jump and confirm it is operating Gain Adjustment Press and hold the control button momentarily to redisplay the current gain setting To increase signal gain continue to hold the button down After approximately 3 seconds you will see the LEDs light i...

Page 10: ...n the CD42 STS is used in very close proximity to a transmitter such as at a pig launcher or receiver The gain setting is stored in non volatile memory It is retained when the receiver is powered down and even if batteries are removed When the unit is powered back up your gain setting will be displayed in the power ON sequence ZERO GAIN GAIN LEVEL 3 GAIN LEVEL 8 MAXIMUM GAIN ...

Page 11: ...ged signal received by the CD42 STS receiver As the signal level increases or the transmitter gets closer the peak LED will light and shift to the right and as the signal diminishes the peak LED will shift to the left The LED indicators that are below the peak LED will pulse to indicate the pulses received by the transmitter Tracking a Moving Pig The CD42 STS system must be within a few meters of ...

Page 12: ...entation parallel to pipe NOTE When the CD42 STS receiver is used in conjunction with an ROV the thruster motors will create large magnetic fields that will interfere with the operation of the CD42 STS receiver It may be necessary to park the ROV periodically to create a quiet electromagnetic environment for this system This is an unavoidable side effect of all magnetic based pig location and trac...

Page 13: ...This is a two dimensional representation of a signal peak The peak LED will shift to the right to indicate the increasing average strength as transmitter pulse strength increases After the pig passage the operator moves quickly to the next predetermined spot to wait and monitor the signal for the approach of the pig SIGNAL PEAK COIL CENTERLINE ...

Page 14: ...uck the amount of pipeline in which it could be is at a minimum If the last confirmed tracking location is known all the operator has to do to locate a stuck pig is back track the pipeline until the receiver reads the signal To locate a stationary pig the diver or ROV operator moves along the pipeline with the antenna held parallel to the pipeline The peak signal indicator will shift right as the ...

Page 15: ... Back track again until the perceived maximum signal is received At this point the CD42 STS receiver is at its closest approach to the pig This point on the pipeline can be marked for cutting or other remedial actions See next section Pinpointing SIGNAL PEAK COIL CENTERLINE ...

Page 16: ...n a more precise method known as pinpointing can be used to further increase the location accuracy With the pinpointing method the antenna of the CD42 STS is rotated to be perpendicular to the pipeline rather than parallel Once rotated the operator looks for the minimum null signal rather than the maximum A 3 D representation of the signal null is shown here ...

Page 17: ...Location and Tracking System Page 17 of 36 This method relies upon the physics of the coupling between the magnetic transmitter inside the pipeline and the receiving antenna on the outside of the pipeline SIGNAL NULL COIL CENTERLINE ...

Page 18: ...crews 1 4 20 x 5 8 in and lock washers from the operator end of the housing Note the clocking orientation of the end cap to the antenna positioning WARNING Do not perform this procedure in a hazardous environment Ensure that you are in a safe and non explosive atmosphere prior to opening Always use caution when opening any device that has been in a high pressure environment such as a deep sea oper...

Page 19: ...CAUTION The end plate is heavier than it looks be careful not to damage the O ring or circuitry under the plate Do not bump or drop the end plate Avoid straining the ribbon cable or cable connections Carefully disconnect ribbon cable connector from circuit board on end plate ...

Page 20: ...o lower batteries are installed Positive side inward WARNING When installing batteries replace all batteries at the same time When replacing batteries use batteries from the same package or manufacturing batch whenever possible This device is designed for use with alkaline batteries Do not mix alkaline and lithium batteries Always observe correct polarity when installing batteries ...

Page 21: ...r anything else that might interfere with a proper seal A brittle and or deformed O ring may not properly seal If in doubt replace it Lubricate O ring with a light coating of high temperature grease such as Dow Corning MOLYKOTE 44 End plate O ring CDI Part No 700 50 2247 90 Carefully reattach cable connector to end plate circuit board Ensure both rows of pins are seated properly and that none are ...

Page 22: ... Page 22 of 36 Ensure plate is lined up properly before installing fasteners Note the clocking orientation of the end cap to the antenna positioning Reinsert the eight 8 socket head cap screws 1 4 20 x 5 8 and lock washers See tightening sequence on next page ...

Page 23: ...ach screw in a rotating cross pattern shown below in 20 inch pound increments If using a powered driver avoid over tightening Continue until the cap screws reach 60 inch pounds torque After reaching the 60 inch pound level continue the torque pattern and torque to 70 inch pounds This is the final torque level 2 6 1 3 5 4 7 8 ...

Page 24: ... System Page 24 of 36 OPTIONAL EQUIPMENT ROV Handles These easily installed fishtail handles are designed for efficient ROV tooling CDI Part 943 50 0003 01 Installation Tool required 1 8 in Allen wrench 1 Remove flat socket head screws two on each side ...

Page 25: ...CD42 STS Subsea Diver ROV Pig Location and Tracking System Page 25 of 36 2 Remove stock handles 3 Insert ROV handles 4 Secure but do not over tighten ...

Page 26: ...only to nearby signals Where multiple pigs are in close proximity to one another the CPA is useful to distinguish an individual PIG without cross interference from adjacent pigs CDI Part 81 10 0075 00 Installation Tool required 3 16 in Allen wrench 1 Remove the six 6 socket head cap screws 1 4 20 x 5 8 and lock washers from the standard 26 4 in 670 5 mm antenna mounting ...

Page 27: ...CD42 STS Subsea Diver ROV Pig Location and Tracking System Page 27 of 36 2 CAREFULLY retrieve the antenna wiring from the unit until you find the connector ...

Page 28: ...cation and Tracking System Page 28 of 36 3 Disconnect standard antenna Inspect O ring and O ring groove before installing or replacing antenna unit See pg 21 for O Ring inspection and maintenance information CDI Part No 700 50 2222 90 ...

Page 29: ...stem Page 29 of 36 4 Connect the CPA and thread the excess wiring back into the unit 5 Line up CPA with unit as shown Note orientation of cutout to Power Switch cap if antenna is improperly installed it will be difficult to remove cap to power up the unit ...

Page 30: ...ea Diver ROV Pig Location and Tracking System Page 30 of 36 6 Reinsert the six 6 socket head cap screws 1 4 20 x 5 8 in and lock washers See tightening sequence on next page Tighten the cap screws by hand until snug ...

Page 31: ...ern shown below in 20 inch pound increments If using a powered driver avoid over tightening Continue until the cap screws reach 60 inch pounds torque After reach ing the 60 inch pound level continue the torque pattern and torque to 70 inch pounds This is the final torque level The CPA configuration is complete 4 2 5 3 6 1 2 6 1 3 5 4 ...

Page 32: ...entative sample thereof must be returned to CDI at the Purchaser s expense The equipment must be accompanied by the Purchaser s written order describing the defect s and authorizing CDI to invoice the Purchaser for any charges not covered by the warranty Upon receipt of the equipment and Purchase Order CDI will examine the equipment and make a determination of the nature and cause of the defect If...

Page 33: ...equipment should only be operated by qualified personnel who are familiar with any and all manuals and procedures for said equipment s operation Service and Repairs Cost for repairs not covered by the warranty or carried out after the warranty period has expired will be charged at the current hourly or set service rate plus the cost of materials upon approval by Purchaser Equipment for repair must...

Page 34: ...c Transmitters Standard CD42 Family Detection Speed 0 01 meter sec to 20 meter sec Visual Indicator 16 Super bright LED array indicates transmitter signal strength Power Source D Cell 6 Alkaline Batteries Battery Life 60 hours 2 5 days Controls Gain Adjustment via Non penetrating Pushbutton Dimensions 36 5 in 927 1 mm length x 6 in 152 4 mm diameter Operational Temperature Range 4 F to 140 F 20 C ...

Page 35: ...CD42 STS Subsea Diver ROV Pig Location and Tracking System Page 35 of 36 NOTES ...

Page 36: ...the United States for more than 32 years CDI currently employs 45 people in the areas of electronics and mechanical design software and firmware programming electronics manufacture machining and more All CDI products are designed and built completely in house utilizing an on premises machine shop boasting six fully automated CNC machines as well as full time electronics assembly personnel ...

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