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Summary of Contents for GPL 5000
- Page 1 2023 GPL 5000 Users’ Guide GPL Odorizers 12450 West Cedar Drive Lakewood CO 80228 303-927-7683 This is the users’ guide for the GPL 5000 www.GPLOdorizers.com Natural Gas Odorization System. Patented Preston Marcoux GPL Odorizers 12/11/2023...
- Page 2 Dear Valued Customer, Thank you for your purchase of the GPL 5000 Natural Gas Odorization System. This document, in its entirety, is the GPL 5000 User’s Guide. Understand that failing to adhere to these instructions may result in the void of warranty, destruction of property, injury, or even death.
- Page 3 GPL Odorizers. Limit of Liability GPL Odorizers, its employees, agents, and the authors and contributors of this document specifically disclaim all liabilities and warranties, express or implied (including warranties of merchantability and fitness for a particular purpose), for the accuracy, currency, completeness, and/or reliability of the...
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Page 4: Table Of Contents
GPL 5000 User Guide Contents Summary ..............................5 Login ................................5 Mechanical Principles of Operation ......................7 Bulk Tank ............................... 7 Inlet Filter .............................. 7 Odorant Ball Valve ..........................7 Odorant Pressure Regulator ......................... 8 Flow Meter ............................8 Flow Indicator ............................8 Manifold Block ............................ - Page 5 GPL 5000 User Guide Manual Gas ............................36 Solenoid Max Time Open ........................36 I/O Assignment ........................... 37 High Flow............................. 37 No Odorant ............................38 Gas Signal ............................39 Tank Level ............................39 Memory Battery ..........................40 Isolation............................... 40 Modbus Map ............................42 Web Pages...............................
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Page 6: Summary
Depending on site conditions, the odorization may occur through either the reduced flow or maximum flow pathways. Login To log in to the GPL 5000 PLC, the technician must use the below credentials. If multiple logins are required, contact the factory for assistance. User: Supervisor... - Page 7 GPL 5000 User Guide Figure 1: Mechanical components of the GPL 5000 P a g e GPL5000-UG-012424-Rev1...
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Page 8: Mechanical Principles Of Operation
A bulk tank is used in most odorization applications to supply odorant or fluid to the GPL 5000 unit. The bulk tank used with the GPL 5000 needs to have an MAOP of at least 30 PSIG greater than that of the MAOP of the injection point. -
Page 9: Odorant Pressure Regulator
GPL 5000 User Guide Odorant Pressure Regulator Operation: The odorant pressure regulator cuts the blanket pressure from the tank to the desired pressure before injection. Normal Operation: In normal operation, the odorant pressure regulator must be set 5-10 PSIG above the injection pressure. -
Page 10: Solenoid Valve
No annual maintenance is needed. Solenoid Valve Operation: There are two solenoid valves in the GPL 5000, and both control a flow path and act as a barrier to allow the GPL 5000 to move fluid to an injection point. Normal Operation: Depending on site parameters, the solenoid valves actuate to achieve the target injection rate. -
Page 11: Screens
GPL 5000 User Guide Screens The HMI/PLC controls all the operations of the GPL 5000. All inputs/outputs are connected to the PLC (Solenoid Actuation, Flow Meter Ticks, Flow Signal, etc.) The bright LCD and touchscreen allow the end user to control and configure all settings for the odorizer. The following screens outline all the variables found in the controller. -
Page 12: Main Menu
H. An easy way to determine if the GPL 5000 is batching is by looking at the two valve symbols underneath the “Injection Rate” and “Gas Rate” boxes. In Figure 2, a solid red background shows that neither solenoid has actuated and the unit is not batching. -
Page 13: Flow
GPL 5000 User Guide Figure 3: Main Menu Screen Flow Please note that the GPL 5000 does not meter the flow rate of the media needing odorization. The odorizer needs to have a flow signal to odorize the fluid. Refer to Figure 4. -
Page 14: Odor
GPL 5000 User Guide “noise” or not a true 4 mA when there is 0 flow. The Max Gas Rate sets the span (full-scale value) of the 4-20mA. The “Actual Gas Rate” displayed at the top is the live gas rate. Depending on the source, this may change. - Page 15 GPL 5000 User Guide Figure 5: Odor Screen lb/pulse out represents the amount of odorant injected before a digital output signal is sent from the odorizer HMI. The end user can change this value depending on the application by selecting the lb/pulse out and changing the value on the screen.
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Page 16: Ccpm Graph
The CCPM graph is a useful troubleshooting screen. It shows the volumetric flow rate over time in of the GPL 5000 when the first solenoid is open (228B in Figure 1) and when both are open (228B and 228A in Figure 1). This screen shows when the unit is batching, as well as the current state of the unit. It shows if both flow paths are being utilized, which may indicate it is time to adjust the pressure on the regulator. - Page 17 GPL 5000 User Guide Figure 7: Alarm Screen Below is a walkthrough of each parameter: Alarm Test: Normal state is “Not Testing.” Switching this to “Testing” generates a “test alarm” digital output. This is typically used during startup to ensure that “Gas Control” detects an alarm signal from the odorizer.
- Page 18 The generated alarm is soft and does not shut the unit down. Tank Signal Alarm: GPL recommends that the odorizer has feedback from the tank to communicate the remaining odorant level. This is important as the flow meter (described in the mechanical principles of operation) meters both liquid and gas.
- Page 19 GPL 5000 User Guide Max CCPM: The maximum CCPM is a register that acts in tangent with the “No Odorant Alarm.” If the odorant tank is empty, gas moves through the odorizer instead of a liquid and flows at a much faster volumetric rate.
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Page 20: Alarm History
GPL 5000 User Guide Alarm History The alarm history shown in Figure 8 can be helpful when troubleshooting alarms and odorizer performance. Figure 8: Alarm History Screen Quick Inject Use the quick inject screen only in pickling or known injection situations. This injection is not based upon any injection rate data—it is a set volumetric amount. -
Page 21: I/O
GPL 5000 User Guide Figure 9: Quick Inject Screen The I/O screen shown in Figure 10 is a great troubleshooting page. The screen displays the current state of each input and output and which I/O point they are assigned to. -
Page 22: Soft I/O
Solenoid 2 Cycles show running counts of the number of times each solenoid has opened and closed. Keeping track of these values is essential, as GPL recommends replacing the solenoid valves after 1,000,000 cycles. Once a solenoid is replaced in the field, pressing the... -
Page 23: Usage
GPL 5000 User Guide Filter Age displays the month and year of the last filter maintenance. GPL recommends checking the filter yearly to ensure no debris is present. After cleaning/inspecting the filter, the date resets by pushing the Reset button to the right of the value. - Page 24 GPL 5000 User Guide Figure 13: Usage Screen If the application does not have an analog tank signal communicated to the PLC, the end user can manually enter the odorant level of the tank on the usage screen: 1. Push the “Tank Volume” and manually enter the known volume of odorant in the tank.
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Page 25: Monthly Usage
GPL 5000 User Guide Monthly Usage The monthly usage screen displays the amount of odorant injected, the volume of unodorized fluid (Figure 14), and the alarms triggered monthly. Figure 14: Monthly Usage Screen Select Month button permits scrolling through the months of a year. When selecting a month, the In Figure 14, the gas volume displays in ����������������... -
Page 26: Startup
GPL 5000 User Guide Startup Follow the procedure below to start up the GPL 5000. For additional assistance, please call the Service hotline at 303-437-3536. Figure 15 25 | P a g e GPL5000-UG-012424-Rev1... - Page 27 5. If the user’s model of the GPL 5000 has a manual override knob on the solenoids, ensure the solenoid override knobs (228B and 228A in Figure 15) are closed. (The arrow on the knobs should point to the C position.)
- Page 28 Figure 16: Injection Panel after the odorant supply has been opened. 4. Following the supply tubing to the mechanical cabinet of the GPL 5000, there is a valve located at the exterior of the box (252 in Figure 17). Open this valve slowly and check for leaks before continuing to step 5.
- Page 29 GPL 5000 User Guide Figure 17 Shows the odorant supply ball valve and pressure regulator. 6. Double-check that the ball valve at the injection point is closed before continuing. Open the electrical cabinet and log into the PLC using the username/password provided. (Refer to...
- Page 30 GPL 5000 User Guide Figure 18: Usage Screen 7. Open the ball valve at the injection point. Inspect for leaks. If none are present, continue to 8. 8. Access the alarms page of the PLC by pressing Menu Alarms. Acknowledge all active alarms by hitting the “RED ACK”...
- Page 31 GPL 5000 User Guide Figure 19 30 | P a g e GPL5000-UG-012424-Rev1...
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Page 32: Alarms & Responses
GPL 5000 User Guide Alarms & Responses Injection Rate Alarms – These alarms are triggered when the odorizer is not meeting injection rates correctly. HiHi and Hi HiHi – The injection rate is unacceptably high. This is a shutdown alarm, and the odorizer shuts off after all autoclears are used. -
Page 33: Lolo And Lo
C. If it’s pointing toward the O, use a flat-head screwdriver to correct this. 8. If the problem does not resolve, call the GPL Service hotline (303-437-3536) LoLo and Lo Lo – Warning alarm that the injection rate is lower than expected for the last batch. - Page 34 GPL 5000 User Guide another LoLo or autoclear, please continue to step 6. 6. Once the operator has restarted the unit, the best troubleshooting aids for the LoLo are the “Volume Until Batch” variable and the two solenoid valve indicators on the home screen. A...
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Page 35: Solenoid Valves
A steady or flashing red LED indicates a problem with the transmitter. 9. If the problem does not resolve, call the GPL Service hotline (303-437-3536) Solenoid Valves Solenoid 1 Override – The low-flow solenoid valve is in electrical override (open position) Solenoid 2 Override –... -
Page 36: Filter
The alarm clears once the date is reset. 5. Return to the PLC home screen and turn “SYSTEM” back “ON.” 6. If the problem does not resolve, call the GPL Service hotline (303-437-3536) Filter Filter Maintenance – Check and flush the filter of any debris yearly, as it is important to protect the downstream components and ensure the odorant has a clear path to the injection point. -
Page 37: Manual Gas
GPL 5000 User Guide 5. If the problem does not resolve, call the GPL Service hotline (303-437-3536) Manual Gas The Manual Gas alarm is a soft alarm showing when the unit operates in manual gas mode. It is important as it is not tracking live gas/fluid values. -
Page 38: I/O Assignment
MTO alarm is resolved. This number should steadily increase when the unit is injecting odorant. 6. If the problem does not resolve, call the GPL Service hotline (303-437-3536) I/O Assignment The I/O Assignment is a critical alarm that shuts down the unit. This alarm triggers if multiple outputs/inputs are sharing the same points. -
Page 39: No Odorant
A steady or flashing red LED indicates a problem with the transmitter. 6. If the problem does not resolve, call the GPL Service hotline (303-437-3536) 38 | P a g e... -
Page 40: Gas Signal
5. If the problem does not resolve, call the GPL Service hotline (303-437-3536) Tank Level The tank level alarm indicates that the odorant tank is low. It is a soft alarm and does not shut down the unit. -
Page 41: Memory Battery
7. When the controller boots up, you must load all the previous parameters onto the PLC. Refer to the pictures taken in Step 1. 8. If the problem does not resolve, call the GPL Service hotline (303-437-3536) Isolation The isolation alarm is a critical alarm that shuts the unit down. The isolation alarm occurs when the flow meter registers additional ticks when a batch is not occurring. - Page 42 If the low-flow actuator is the failed solenoid valve, the metering valve can help control the seal. 6. If the problem does not resolve, call the GPL Service hotline (303-437-3536) 41 | P a g e...
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Page 43: Modbus Map
GPL 5000 User Guide Modbus Map Protocol: Modbus RTU, Port MJ2, 9600 Baud, 8N1 COIL BLOCKS 6101 Shutdown; 6102 HiHi Alarm; 6103 Hi Alarm; 6104 Lo Alarm; 6105 LoLo Alarm; 6106 Man Gas Alarm; 6107 Solenoid 1 Override; 6108 Solenoid 1 Maintenance Alarm;... - Page 44 GPL 5000 User Guide Figure 20: Simply Modbus display of the Modbus Registers. Displaying 43600 - 43605 Figure 21: PLC display of Registers 43 | P a g e GPL5000-UG-012424-Rev1...
- Page 45 GPL 5000 User Guide Figure 22: Simply Modbus display of the Modbus Coil Blocks Figure 23: PLC Display of Coil Blocks 44 | P a g e GPL5000-UG-012424-Rev1...
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Page 46: Web Pages
GPL 5000 User Guide Web Pages Web pages are currently being developed for the GPL 5000. Please contact GPL Odorizers for more information regarding them and accessing the HMI data via cellular. 45 | P a g e GPL5000-UG-012424-Rev1...
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