Enduro Ddl Caliper Tool User manual

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0002-40-38085 Rev 01 © Enduro Pipeline Services, Inc. All Rights Reserved.
P.O. Box 3489 · Tulsa, Oklahoma 74101-3489 · Office [phone]
Fax [phone] · www.enduropls.com
ENDURO
DdL™ Caliper Tool
User Manual
Using the ENDURO Tech-Less
DdL™ Caliper Inspection Tool
P.O. Box 3489 · Tulsa, Oklahoma 74101-3489 · Office [phone]
Toll Free 1-800-752-1628 · Fax [phone] · www.enduropls.com

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0002-40-38085 Rev 01 © Enduro Pipeline Services, Inc. All Rights Reserved.
Table of Contents
ENDURO DdL™ Caliper Procedures
Section Topic Page
A. DISCLAIMER 3
1. Survey Preparation 4-9
1.1. Pipeline Cleanliness 4
1.2. Loading into / Unloading from Pipeline 4
1.3. Medium to be used to propel DdL™ Caliper Tool 4
1.3.1. AIR 4-6
1.3.2. WATER 7-9
1.3.3. PRODUCT 9
1.4. Main Line Valve (MLV) Locations 9
2. DdL™ Caliper Tool Pre-Run 10-50
2.1. Unpacking Shipment 10
2.2. Laptop Computer 10-11
2.3. AGM2 Box 11
2.4. Powering Up the DdL™ Caliper Tool 12-13
2.5. Powering Up the AGM2 Box 14-17
2.6. Connecting Laptop Computer to the DdL™ Caliper Tool 18-26
2.7. Connecting Laptop Computer to the AGM2 Box 27-33
2.8. Final DdL™ Caliper Tool Check 34-37
2.9. Loading DdL™ Caliper Tool into Pipeline 38-50

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3. DdL™ Caliper Tool Post-Run 51-64
3.1. Removing DdL™ Caliper Tool from pipeline 51-58
3.2. Connecting Laptop Computer to the DdL™ Caliper Tool 59-64
4. Download Dialog Window 65-75
4.1. Downloading the DdL™ Caliper Tool 65-71
4.2. Powering Down the DdL™ Caliper Tool 72-75
5. Upload Dialog Window 76-82
5.1. Uploading the data to ENDURO Headquarters 76-82
6. Erasing Data from DdL™ Caliper Tool 83-86
6.1. Erase Challenge Dialog 66-86
7. Shipping DdL™ Caliper Tool back to ENDURO 87
7.1. Packing Shipment / Logistics 87
8. NewCommTC 64 Dialog User Interface Reference 88-106
8.1. Communication Dialog Windows 88-98
8.2. Download Dialog Windows 99-114
8.3. Upload Dialog Windows 115-123
9. Troubleshooting 124
9.1. Troubleshooting Laptop Computer 124
9.2. Troubleshooting DdL™ Caliper Tool 124

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0002-40-38085 Rev 01 © Enduro Pipeline Services, Inc. All Rights Reserved.
DISCLAIMER
* The following steps MUST be performed to help increase the odds for a successful survey. *
Failure to follow these steps could result in damage to the survey equipment and / or lead to an unsuccessful survey.
** From this point forward, Enduro Pipeline Services, Inc. will be referred to as ENDURO. **
*** Any company that has rented the DdL™ Caliper Tool will be referred to as CUSTOMER. ***
****It is not necessary to upload the data from the Laptop Computer to Enduro Headquarters after each download****
Data can be stored on the Laptop Computer and uploaded as a batch after all runs are complete, or at any time in-between
WARNING
The Laptop Computer and Support Devices are NOT explosion proof.
Move to a safe area before using any of the provided equipment and devices.
WARNING
DO NOT Erase Data from the DdL™ Caliper Tool unless instructed by ENDURO directly.

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1. Survey Preparation:
1.1. Pipeline Cleanliness:
1.1.1. The CUSTOMER must verify that the pipeline is clear of any dirt and debris, excessive amounts of water, and any other foreign objects
that could cause damage or issues to / with the DdL™ Caliper Tool.
1.1.1.1. Contact ENDURO for further information and details regarding required cleanliness for the DdL™ Caliper Tool.
1.2. Loading into / Unloading from Pipeline (Types of Traps):
1.2.1. Verify with ENDURO what type of Traps will be utilized to Launch and Receive the DdL™ Caliper Tool.
1.2.1.1. These traps can be permanent, rented, or even temporary types of traps.
1.2.1.2. There must be an adequate number of inlets on each type of trap to allow proper Medium flow into and out of the pipeline.
1.3. Medium to be used to propel the DdL™ Caliper Tool:
1.3.1. Running the Tool with AIR
1.3.1.1. Single Stage Air Compressor(s) is / are recommended.
1.3.1.2. ENDURO will recommend the amount of CFM required to propel the DdL™ Caliper Tool at a sufficient rate per the
pipeline specifications provided to ENDURO.
1.3.1.2.1. These requirements will change depending on pipe diameter and line section length.
1.3.1.2.2. CUSTOMER will need to inform ENDURO if the CFM requirements are unable to be met.
1.3.1.2.2.1. CUSTOMER will inform ENDURO what CFM is available so that calculation adjustments can
be made to verify that the CFM total will be enough to propel the DdL™ Caliper Tool properly.
1.3.1.2.2.2. CUSTOMER will inform ENDURO what size CFM Air Compressor(s) are available and how
many of each size.
1.3.1.2.3. CUSTOMER will have the Air Compressor(s) configured to maximize the volume of air being produced by the
Air Compressor(s).
1.3.1.2.3.1. Some Air Compressors can be set to a Low or High output.

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1.3.1.2.3.2. Unless otherwise specified by ENDURO, ENDURO recommends that the Air Compressor(s) be
set to the Low output setting to maximize the air volume being produced by the Air
Compressor(s).
1.3.1.3. ENDURO will recommend the amount of pressure (PSI) required to be placed on the pipeline in relation to the
recommended amount of CFM required to propel the DdL™ Caliper Tool.
1.3.1.3.1. These requirements will change depending on pipe diameter and line section length.
1.3.1.3.2. Once ENDURO has been informed of the total amount of CFM that is available, adjustments may be made to
the required pressure on the pipeline.
1.3.1.3.3. This pressure MUST already be on the pipeline prior to the DdL™ Caliper Tool being launched.
1.3.1.3.4. This pressure will be maintained at the receive location once the DdL™ Caliper Tool has been launched into
the pipeline.
1.3.1.4. The discharge outlet(s) should be 3 inches or larger and each Air Compressor should have an individual entry point into
the pipeline.
1.3.1.4.1. Inform ENDURO of the size of hoses to be used to connect the Air Compressors to the pipeline.
1.3.1.4.2. Do NOT attach the hoses to any Tees unless approved by ENDURO.
1.3.1.4.3. Do NOT attach the hoses to a Manifold unless approved by ENDURO.
1.3.1.5. If Check Valves are to be used for Launching the DdL™ Caliper Tool, guide bars should be welded onto the inside bottom
of the bowl of the Check Valve, so the tool does not drop into the bowl.
1.3.1.6. ENDURO recommends that no restrictions be present between the Air Compressors and pipeline.
1.3.1.6.1. NOTICE:The Valves connecting the Air Compressors to the pipeline need to be fully opened once the
DdL™ Caliper Tool has been launched.
1.3.1.6.2. Verify that there are no Dryers connected between the Air Compressors and the pipeline.
1.3.1.6.2.1. This will help rule out the possibility of an air volume restriction that may hinder the DdL™
Caliper Tool from running at a steady rate / speed.
1.3.1.7. CUSTOMER must have pressure gauges at the launch and receive locations prior to the DdL™ Caliper Tool being
launched.

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1.3.1.7.1. ENDURO does not provide pressure gauges with the Standard Support Equipment that is sent with the DdL™
Caliper Tool.
1.3.1.7.2. These gauges MUST remain on the pipeline through the duration of the survey.
1.3.1.7.3. The gauges MUST be either:
1.3.1.7.3.1. Digital-type readout (preferred)
1.3.1.7.3.2. Analog-type readout not to exceed 100 psi.
1.3.1.7.3.2.1. ENDURO may recommend a larger Analog-type gauge only if the pressure on
the pipeline may exceed 100 psi.
1.3.1.7.3.2.2. NEVER use an Analog-type gauge that is 300 psi or greater.
1.3.1.8. CUSTOMER will have assigned personnel at the launch and receive locations to monitor any changes during the entire
time the survey is in progress.
1.3.1.8.1. Any changes that are monitored during the survey MUST be documented by the CUSTOMER and relayed to
ENDURO. Some examples are listed below:
1.3.1.8.1.1. Air Compressor(s) stopped working
1.3.1.8.1.2. Pressure being released at the receive location has stopped for a long period of time.
1.3.1.8.1.3. Large amount of debris and / or water was brought in by the DdL™ Caliper Tool at the Receive.
1.3.1.8.1.4. Pressure has equalized at both Launch and Receive locations for a long period of time.
1.3.1.9. CUSTOMER will regulate / maintain the pressure on the pipeline at the receive location once the DdL™ Caliper Tool has
been launched.
1.3.1.9.1. CUSTOMER will have assigned personnel to handle this task throughout the duration of the survey.
1.3.1.9.1.1. The pressures on the pipeline will be monitored constantly, making only small adjustments when
needed, to regulate / maintain the required psi.
1.3.1.10. Contact ENDURO for further information and details regarding this method of propelling the DdL™ Caliper Tool.

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1.3.2. Running the Tool with WATER
1.3.2.1. ENDURO recommends that Fresh Water be used when running the DdL™ Caliper Tool in a water environment.
1.3.2.2. ENDURO recommends that the CUSTOMER have a minimum of 25% over the amount of water that is required for line
fill to accommodate the possibility of Water bypassing around the DdL™ Caliper Tool during the survey.
1.3.2.2.1. This will help ensure that the CUSTOMER will have enough Water to complete the survey without having
long periods of potential stoppages due to insufficient Water amounts on-site.
1.3.2.2.2. CUSTOMER must verify that the pipeline is clear of any issues that may cause the DdL™ Caliper Tool to not
transition through the pipeline properly (refer to section 1.1. for further details).
1.3.2.2.2.1. Any potential areas that may stop the DdL™ Caliper Tool may result in excessive amounts of
Water usage, possibly causing the CUSTOMER to run out of Water before the survey is
completed.
1.3.2.3. ENDURO will recommend the minimum flow rate pump required to propel the DdL™ Caliper Tool at a sufficient rate per
the pipeline specifications provided to ENDURO.
1.3.2.3.1. ENDURO will specify the minimum psi capability of the pump(s) that will be required.
1.3.2.3.2. A Flow Meter MUST be installed between the pump and pipeline to help determine that the proper flow rate is
maintained during the survey.
1.3.2.4. CUSTOMER will inform ENDURO in advance of how the tool will be ran if WATER will be used:
1.3.2.4.1. Water pushing Air
1.3.2.4.2. Water pushing Water
1.3.2.5. ENDURO recommends all connections to the pipeline be hard pipe for safety reasons.
1.3.2.6. If Check Valves are to be used for launching the DdL™ Caliper Tool, guide bars should be welded onto the inside bottom
of the bowl of the Check Valve, so the tool does not drop into the bowl.
1.3.2.7. CUSTOMER must have pressure gauges at the Launch and Receive locations prior to the DdL™ Caliper Tool being
launched.
1.3.2.7.1. ENDURO does not provide pressure gauges with the Standard Support Equipment that is sent with the DdL™
Caliper Tool.
1.3.2.7.2. These gauges MUST remain on the pipeline throughout the duration of the survey.

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1.3.2.7.3. The gauges MUST be either:
1.3.2.7.3.1. Digital-type readout (preferred)
1.3.2.7.3.2. Analog-type readout.
1.3.2.7.3.2.1. Select an Analog-type gauge that is adequate in psi readings per the ENDURO
recommendations when running with Water.
1.3.2.8. When running with Water pushing Air, the CUSTOMER will NOT be required to maintain any pressure on the line in
front of the DdL™ Caliper Tool.
1.3.2.8.1. CUSTOMER will have assigned personnel at the launch and receive locations to monitor any changes during
the entire time that the survey is in progress.
1.3.2.8.2. Any changes that are monitored during the survey MUST be documented by the CUSTOMER and relayed to
ENDURO. Some Examples are listed below:
1.3.2.8.2.1. Pump stopped working
1.3.2.8.2.2. Water ran out
1.3.2.8.3. Contact ENDURO for further information and details regarding this method of propelling the DdL™ Caliper
Tool.
1.3.2.9. When running with Water pushing Water, the CUSTOMER will maintain a minimum of 20 psi over what the static
pressure is on the pipeline at the receive location before the DdL™ Caliper Tool has been launched.
1.3.2.9.1. This may require that all outlets be closed on the receiver until the minimum of 20 psi over static pressure has
been reached.
1.3.2.9.1.1. Once the minimum pressure has been reached, regulating and maintaining this pressure will
commence.
1.3.2.9.2. CUSTOMER will have assigned personnel to handle this task during the entire time that the survey is in
progress.
1.3.2.9.2.1. The pressures on the pipeline will be monitored constantly, making only small adjustments when
needed, to maintain the required psi.
1.3.2.9.3. CUSTOMER will also have assigned personnel at the launch location to monitor any changes during the entire
time that the survey is in progress.

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1.3.2.9.4. Any changes that are monitored during the survey MUST be documented by the CUSTOMER and relayed to
ENDURO. Some Examples are listed below:
1.3.2.9.4.1. Pump stopped working
1.3.2.9.4.2. Water ran out
1.3.2.9.5. Contact ENDURO for further information and details regarding this method of propelling the DdL™ Caliper
Tool.
1.3.3. Running the Tool with PRODUCT
1.3.3.1. Verify with ENDURO the type of on-stream environment that will be used to propel the DdL™ Caliper Tool.
1.3.3.2. Verify with ENDURO the flow rate that will be available to propel the DdL™ Caliper Tool.
1.3.3.2.1. ENDURO may request a lower flow rate due to speed calculations per pipeline specifications provided.
1.3.3.3. Verify with ENDURO the Operating Pressure that will be present on the pipeline during the survey.
1.3.3.4. Verify with ENDURO if any injection points are present on the pipeline.
1.3.3.4.1. These injection points may affect the tool velocity.
1.3.3.4.2. ENDURO may request that these injection points be isolated during the survey to help control tool velocity.
1.3.3.5. Contact ENDURO for further information and details regarding this method of propelling the DdL™ Caliper Tool.
1.4. Main Line Valve (MLV) Locations
1.4.1. Verify that all MLV Locations are set up for the DdL™ Caliper Tool to transition through properly.
1.4.1.1. Verify MLV is fully opened
1.4.1.2. Verify that any Bypass lines present are closed.
1.4.1.3. If Check Valves are present
1.4.1.3.1. Verify that the Check Valve is going in the same direction that the tool is to be ran.
1.4.1.3.2. Verify that the Check Valve has been locked into a Fully Opened position.

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2. DdL™ Caliper Tool Pre-Run:
2.1. Unpacking Shipment:
2.1.1. Standard Support Equipment will be shipped with the DdL™ Caliper Tool.
2.1.1.1. The CUSTOMER will be required to use this provided equipment so that no unnecessary damage occurs to the DdL™
Caliper Tool when loading and unloading from the pipeline.
2.1.2. CUSTOMER must visually inspect the DdL™ Caliper Tool, to look for any apparent damage caused by shipment.
2.1.2.1. Contact ENDURO for any questionable areas that the CUSTOMER is unsure of regarding the tool condition.
2.1.2.2. ENDURO may request pictures of any areas of concern.
2.1.3. CUSTOMER will be provided a packing list of all equipment shipped with the DdL™ Caliper Tool.
2.1.3.1. CUSTOMER will need to verify that all equipment is present and accounted for, prior to proceeding.
2.1.3.2. CUSTOMER must keep this packing list for when it comes time to ship equipment back to ENDURO.
2.1.3.2.1. This will help the CUSTOMER verify that all equipment to be returned is present and accounted for.
2.2. Laptop Computer
2.2.1. ENDURO provides a Laptop Computer as part of the Standard Support Equipment shipped with the DdL™ Caliper Tool.
2.2.1.1. The Laptop Computer will be inside a protective Pelican Case.
2.2.1.1.1. Keep the Laptop Computer in the Pelican Case when not in use.
2.2.1.2. Packing list for Laptop Computer Pelican Case:
2.2.1.2.1. Laptop Computer
2.2.1.2.2. Laptop Computer Charging Cable
2.2.1.2.3. Communication Cable A – to connect Laptop Computer to DdL™ Caliper Tool.
2.2.1.2.3.1. USB TYPE A to USB MICRO B
2.2.1.2.4. Communication Cable B – to connect Laptop Computer to AGM2 Box.
2.2.1.2.4.1. USB TYPE A to USB TYPE B
2.2.1.2.5. External Hard Drive (E.H.D.)
2.2.1.2.6. Ethernet Cable

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2.2.2. Keep the Laptop Computer out of the elements as much as possible.
2.2.2.1. Premature Failure to the Laptop Computer could occur if left out in the Extreme Heat, Extreme Cold, Rain and/or Snow.
2.2.3. The Laptop Computer will be shipped from ENDURO fully charged, but the battery life will deplete over time.
2.2.3.1. CUSTOMER will verify that the Laptop Computer has been plugged into an AC outlet to allow the battery to reach a full
charge prior to beginning the survey.
2.2.3.2. Contact ENDURO for any IT issues regarding the Laptop Computer that was provided.
2.2.4. Locate the different computer ports that are on either side of the Laptop Computer.
2.2.4.1. 3 – USB ports
2.2.4.1.1. One USB port will be used to communicate with the DdL™ Caliper Tool.
2.2.4.1.2. One USB port will be used to connect an External Hard Drive that ENDURO has provided.
2.2.4.1.3. One USB port will be used to connect the AGM2 Box.
2.2.4.2. 1 – Ethernet Port
2.2.4.2.1. For ability to connect an Ethernet Cable from the Laptop Computer to an Internet provided source.
2.2.4.3. 1 – Power Cable Port
2.2.4.3.1. Connect Laptop Computer to AC power via Charging Cable.
2.3. AGM2 Box
2.3.1. ENDURO provides an AGM2 Box as part of the Standard Support Equipment shipped with the DdL™ Caliper Tool.
2.3.1.1. The AGM2 Box will be inside a protective Pelican Case.
2.3.1.2. Located inside the AGM2 Box will be a communication port and a power button.
2.3.1.2.1. Refer to “Powering Up the AGM2 Box” for further details.
2.3.2. The main purpose of the AGM2 Box is to synchronize the DdL™ Caliper Tool with GPS Time.
2.3.2.1. This time sync must be done after the DdL™ Caliper Tool has been powered ON.
2.3.2.1.1. IF the DdL™ Caliper Tool has been powered down, an AGM2 sync MUST be done again when the tool is
powered back on.

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2.4. Powering Up the DdL™ Caliper Tool
2.4.1. Locate the Power Plug at the Rear of the DdL™ Caliper Tool (refer to 2.4.1. Table).
2.4.1. Table

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2.4.1.1. Remove the protective covers from the Male and Female ends of the Power Plug.
2.4.1.1.1. Please keep these protective covers with the Standard Support Equipment; they will be utilized periodically
throughout this entire process.
2.4.1.1.2. Male Plug – Single Blue Line
2.4.1.1.3. Female Plug – Single Blue Line & Single Red Line
2.4.1.2. Insert the Male and Female ends together, aligning the alignment tabs with their corresponding slots.
2.4.1.3. Twist the Male Plug clockwise until it stops (refer to 2.4.1.3. Table).
2.4.1.3.1. A properly seated connection will cover the Single Red Line on the Female Plug.
2.4.1.3. Table
2.4.2. Once connected, the tool is powered up.
2.4.2.1. When the DdL™ Caliper Tool is not in use, keep the tool powered down by verifying that the Male and Female Plugs are
disconnected, and the protective covers are installed on both Plugs.

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2.5. Powering Up the AGM2 Box
2.5.1. Position the AGM2 Box so that it will be within cables length to connect to the Laptop Computer.
2.5.1.1. There must not be any obstacles blocking the AGM2 Box from establishing a Satellite connection.
2.5.1.1.1. For best Satellite connection, it is recommended to be outside, away from any large structures.
2.5.2. Locate the Power Button on the AGM2 Box once the lid is opened. (refer to 2.5.2. Table)
2.5.2.1. Press Power Button to turn on AGM2 Box.
2.5.2.2. A light within the Power Button will illuminate, showing that the AGM2 Box has been turned on.
2.5.2. Table

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2.5.3. After the AGM2 Box has been turned on, it will begin searching for Satellites.
2.5.3.1. There will be a series of lights that will begin to blink on the AGM2 Box (refer to 2.5.3.1. Table).
2.5.3.2. GPS SEARCH light will remain ON during the Satellite search.
2.5.3.1. Table

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2.5.4. Once the AGM2 Box has established a Satellite connection, the following lights will be on solid (refer to 2.5.4. Table):
2.5.4.1. GPS FOUND
2.5.4. Table

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2.5.5. IF the AGM2 Box is bumped or moved any time during this process, the remaining lights will become active (refer to 2.5.5. Table).
2.5.5.1. MAGNETIC ACTIVITY
2.5.5.2. PIG PASSED
2.5.5.3. If this happens, no action will be required.
2.5.5. Table
2.5.6. After the AGM2 Box has established a Satellite connection, proceed to the next step.
2.5.6.1. If the AGM2 Box is unable to establish a Satellite connection, power the box down and proceed back to “Powering Up
the AGM2 Box” to begin the process over again.
2.5.6.1.1. If the problem persists, Contact ENDURO Operations for further assistance.

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2.6. Connecting Laptop Computer to the DdL™ Caliper Tool
2.6.1. Power the Laptop Computer ON and allow it to fully boot up.
2.6.1.1. Press the “ctrl” key on the keyboard
2.6.1.2. A password must be typed in to unlock Laptop Computer
2.6.1.2.1. Password = 4461934
2.6.1.3. Contact ENDURO for any IT issues regarding the Laptop Computer that was provided.
2.6.2. Locate the Communication Cable A and plug the USB TYPE A end into the Laptop Computer USB Port labeled TOOL.
(refer to 2.6.2. Table)
2.6.2. Table

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2.6.3. Locate the Communication Port at the rear of the DdL™ Caliper Tool. (refer to 2.6.3. Table)
2.6.3. Table