ABQINDUSTRIAL WDV-18K WD Series DC Magnetizing Coils Instruction Manual

ABQINDUSTRIAL WDV-18K WD Series DC Magnetizing Coils

Product Information

Product Name: Western Instruments WD-Series DC Magnetizing Coils WDV 16 Coils

Description: The WDV-16 Coil is designed to operate from a 230 VAC (60 Hz) power source. It is capable of inducing a DC magnetic field in ferrous materials for testing purposes. The coil also has an optional AC feature that allows for a fixed level of AC field. The unit conducts electricity in a circular fashion, which induces a longitudinal magnetic field in a central conductor. The coil is robust and resistant to cracking and disbonding due to age or high/low temperatures. It is suitable for both dry and wet method media.

Key Features:

• Operates from 230 VAC (60 Hz) power source
• Induces DC magnetic field in ferrous materials
• Optional AC feature for fixed level of AC field
• Robust encapsulant resistant to cracking and disbonding
• Suitable for dry or wet method media

Product Usage Instructions

1. Ensure that the WDV-16 Coil is operated within the parameters set by the operational specifications provided in the user manual.
2. Connect the coil to a 230 VAC (60 Hz) power source.
3. Do not press the Energize Push Button when changing the Field Polarity or Field Selection Switch.
4. Monitor the DC Indicator (Red) and AC Indicator (Green) to determine the type of current being supplied.
5. Use the Field Selection Switch to switch between DC (up position) and AC (down position) modes.
6. Use the Field Polarity Switch to select positive (up position) or negative (down position) polarity.
7. Adjust the Current Intensity Control Knob to set the desired amperage output. The range is from 0 to 10,000 Ampere Turns.
8. Press the Energize Button to activate the coil and generate the magnetic field.
9. Ensure that the Internal Aluminum Wire Coil does not overheat, as this can reduce the overall Ampere Turn output. Monitor the temperature and take appropriate measures to prevent overheating.

Note: These operating instructions also apply to separate power supplies provided as retrofits to other manufacturers’ coil assemblies. Western Instruments makes no claims or warranties when used with other manufacturers’ coils.

Western Instruments WD-Series DC Magnetizing CoilsWDV 16 Coils Manual

Description

WDV-16 Coil is operated from 230 VAC (60 Hz) Power, which is inverted and induces a DC Magnetic Field in the ferrous material being tested. The Optional AC Feature, permits a fixed level for an AC field as well. As the unit conducts electricity in a circular fashion, it induces a Longitudinal Magnetic field in a Central Conductor. This device should be utilized within the parameters set by the operational specifications within this guide.

1. Coil Housing – The Coil Housing is cast from a durable Urethane Rubber, which protectsthe Aluminum Wire Core. This Robust encapsulant is resistant to cracking and disbondingdue to age or high/low temperatures, and is suitable for Dry or Wet Method media. Cast intothe top inside portion of the Coil Housing are 7 nonferrous Connecting Rods, which are usedto mount the Aluminum Control Panel Housing. These Connecting Rods are also used tomount optional ID Wear Bars, which protect the Urethane Encapsulant.
   The WDV-16 is also equipped with 3 Nonferrous Connecting Rods, located on the bottom of the inside portion of the Coil. These Connecting Rods can be used for ID Wear Bars or for rigidly mounting the coil for auxiliary uses, such as a Coil Car used on a Custom Testing Fixture or Western’s Mini-Bench.

2. Control Panel Housing – The Control Panel Housing is used to mount the Solid StateElectronic Controls of all WD-Series Coils. It is designed to protect the Control Componentsfrom damage due to the riggers of field or shop use. The reverse (or underside) of theControl panel acts as the mounting plate for all of the Control Components, while the topside is where all the operator controls are located. As indicated in promotional literature, theVariable Power Supply (WDV-Series) is equipped with adjustable amperage which isvariable from 0 to 10,000 Ampere Turns output.
   Variable Power Supply (WDV Coils)
   The Control Panel Housing used in the WDV Coils is slightly taller than that on the WDPCoils. The WDV panel is equipped with the following control components;

   • Power On/Off, controls the AC power to the Coil’s Control Components. This switch isprotected by two15 Amp Breakers located on the Power Cord Side Plate of the Coil,these will kick out if the current draw exceeds 30 Amps. The red indicator shows theoperator that the AC power is turned on.
   • Intensity Current Control Knob allows the operator to control and monitor the DCamperage to the coil. The Amp Meter may not be completely linear, with respect to theknob position while the unit is not activated, but will indicate the actual current when thecoil is energized. The Amperage, with respect to the knob position, is always indicated whenever the Main Power Switch is activated. The scale engraved on the control panel is not calibrated and is only used as a reference point for the operator.
   • Calibrated LCD Amp Meter is 3 digits, and also indicates if the applied field in positive (+)or negative (-). The Display only indicates DC Current and is off in AC Mode.
   • +/- Field Polarity Switch requires the operator to pause between positive an negativefields, as the existing field in the coil needs to collapse prior the opposite polarity beingapplied. The Field direction is switched from positive to negative to demagnetize a workpiece or to enhance a residual magnetic field.
   • Field Selection Switch allows the Operator to Select a DC (up) or AC (down) Field.
   • Push Button Energize switch is located adjacent to the Polarity Switch, and whiledepressed allows current to flow through the coil.
     Do not press the Energize Push Button when changing the Field Polarity or Field Selection Switch.
     Note: These Operating Instructions also apply to Separate Power Supplies provided as retrofits to other manufacturers Coil Assemblies. Western Instruments makes no claims or warranties when used with other manufactures Coils.

3. Duty Cycle – The Duty Cycle (maximum duration) for periodic operation is set
   to avoid overheating of the Internal Aluminum Wire Coil. Warm (or hot) Core Wires have anincreased resistance, and will reduce the overall Ampere Turn output of the Coil.
   WDV Models should not be activated, using the Field Activation Switch, for more than 2minutes at a time When in DC Mode. The activation time should be followed by an equal orlonger cool down (or off) cycle. This 50% duty cycle is set to protect the Core and ControlComponents from overheating. If the operator has any concern about the actual or planned operation of the Coil, Western Instruments or the Distributor should be consulted. No matter if the Coil is equipped the Thermo-Protection Switch or not, duty cycles must be observed. The Duty Cycle of the unit while in AC mode is 75%, which means the unit can be operated for extended periods of time without overheating the Core. This time should not exceed 5 minutes on, followed by a 2 ½ minute cool down cycle.

4. Field Characteristics; – WD-Series Coils are classified as DC units and are designed toinduce a Longitudinal Field in a Work Piece positioned though the Centerline of the Coil. ATransverse Field may be introduced, if the Work Piece is short enough, by placing itperpendicular and inside the Coil’s inside surface. WD-Series Coils are designed to complywith specifications requiring Residual or Active Fields. AC Option is designed to convert the Output Field from DC to AC. When configured tooperate in AC Mode, the output of the coil is a minimum of 4000-Ampere Turns, but is sizeand input voltage dependent. The AC Option is only available where coils have beenspecifically manufactured with is capability.
   Do not press the Energize Push Button when changing the Field Polarity or Field Selection Switch.

5. Operation; – The Coil is either placed on the Work Piece, such as a threaded end of a pipe,or if the Work Piece is small it can be held within the inside of the coil. If held and if it is shortenough to be rotated within the coil, a longitudinal or transverse field can be induced into theWork Piece. Application of particles, depending on the specification and skill of the operator,are applied during (Active Field) or after the field is set-up in the Work Piece (Residual Field).Active Field Inspection requires less skill by the operator in the application of the particles,while in Residual Field Inspection there is no particle migration and greater skill and care mustbe taken in media application. When to Coil is placed over the Work Piece and the Field Intensity is set by the operator withthe Current Control Knob, the Coil is Energized (a “Shot”) with the Push Button EnergizingSwitch. A positive or negative field is induced, followed by an Active or Residual FieldInspection. To demagnetize the Work Piece;

6. The operator places the coil back over the work piece, reduces the Current Control

7. Knob by approximately 20% from the magnetization current selected.

8. The field is activated, in the opposite direction from the magnetization shot, for a slightlyshorter duration of time.

9. The Current Control Knob is again reduced by approximately 20%, and the field isactivated, in the same direction as the magnetization shot, again for a slightly shorterduration.

10. Steps 1 through 3 are repeated until the final shot at 0 amps. The number of Demag shots may be decreased or increased depending on; the amount of field induced during magnetization; the size; and the magnetic permeability of the Work Piece.

Caution: The energy flowing through the internal Coil, in either AC or DC Modes, produces a great amount of stored energy, taking at least one second to dissipate after the power has been turned off.

Maintenance

After extended use, WD-Series Coils should be cleaned with a mild soapsolution. The unit should be visually inspected regularly for any damage that could causeharm to the operator, or the material being inspected. Special attention should be paid to the;control switches/boots; Current Control Knob; and the power cord (cable). Any potentialproblems to these assemblies must be reported to the distributor or Western Instruments forinstructions on corrective action.
Other than routine maintenance, the operator can expect a longer service life. Depending onthe Industry or in-house specification utilized, and the type of service (field or shop) the ampmeter assembly should be calibrated at regular intervals. Furthermore, during calibration thefield produced by the coil should be tested to ensure there is no reduction in the performanceof the unit.
The distributor or Western Instruments should be contacted for any specific instructions onmaintenance, due to the specific environment of operation. Repairs, that need to be carriedout on the product, should be performed by an authorized service depot or WesternInstruments.

Wiring

W-Series 230 Volt Models, are designated by a “K” placed after the Serial Number and theModel number (e.g. WC-6K), are shipped without an AC Power Plug as there is nointernational standardization. When installing an AC Power Plug onto the AWG 18-3 PowerCord, the following is the identity of the 3 Color Coded Conductors;

• Green – Ground
• White – Neutral
• Black – Live

Care must be taken to insure the proper installation of an AC Power Plug, and if there is any question, contact your distributor or Western Instruments. If an AC Plug in not installed before use, any warranty is void.
Calibration
WD-Series Coils should have their Amperage Meter Calibrated annually or after control repairs have been made (power cords and plugs are not considered “Controls”). However, the customer’s Quality Manual or a Reference Specification may require more frequent Calibrations. North American customers can have calibrations made at an Authorized Service Centre. International customers may not have a Service Centre located in their region, so a qualified company must be found. A company that repairs Industrial Electrical Controls should have the necessary expertise to perform a calibration. If Western Instruments is provided appropriate documentation, the Calibration Procedure can be provided to such a company.

Warranty

Western Instruments warrants all WD-Series Coils against defects in materials and workmanship for a period of 1 year from receipt by the end user. Consumable items are warranted against defects in materials and workmanship for 30 days form receipt by the end user. If Western Instruments receives notice of such defects during the warranty period, Western Instruments will either, at its option, repair, replace, or condemn products that prove to be defective.
Any warranty is void if the unit has been modified in any way, mistreated, or if it has been repaired by an unauthorized agency. The end user agrees that any equipment’s disposition, when returned for warranty work, is at the full discretion of Western Instruments as to whether a claim is under warranty or due to misuse. Western Instruments warranty shall overlook normal wear, however does not include operation outside the environmental specification of the product. Any warranty work is FOB western Instruments, and any returned units shall include a written description, by the end user, of the fault.
Western Instruments makes no other warranty, either expressed or implied, with respect to this product. Western Instruments specifically disclaims any liability arising form the use of this equipment. For the correct use of Western Instruments W-Series Coils refer to the Operating Instructions, furthermore we recommend instructional training to CGSB or ASNT qualifications. Western Instruments highly recommends the end user exercises all possible safety precautions, including the use of protective equipment, while operating this or other industrial equipment.

Specifications

• Model: WDV-16
• Voltage: 230 VAC 60 Hz
• Current: DC – 17 Amps AC – 20 Amps
• Capacity: DC – 0 to 16,000 Amp Turns (Minimum) AC – 4,000 Amp Turns (Fixed)
• Size: 16” (406mm) Inside Diameter.
• Weight: 107 Pounds (49kg)

Western Instruments WD-Series DC Magnetizing Coils – WD Coils Ref

This write-up hopes to aid the reader to understand the rationale behind Multi-Turn, Low Amperage Coils. WD-Series Coils have become an Industry Standard for the inspection of Threaded Connections used on Drill Pipe, and other Oil Well Drilling Tools.

The science of Drilling Oil and Gas Wells has advanced tremendously over the last 30 years, to where the Drill Stem does not rotate, but the Drill Bit is driven by a ‘Mud Motor” fashioned after a Progressive Cavity Pump. This technology has allowed Drillers to Steer the Drill Stem, to where a well might only have a vertical drop of 200 meters, but continues horizontally for over 1000 meters. When this type of Horizontal Well is being drilled, the crew is given accurate telemetry by Monitoring While Drilling (MWD) Instrumentation. This Instrumentation requires the area around the Drill Bit to be free of Magnetism, as the MWD Instrumentation uses the Earth’s Magnetic Field as a reference. WD-Series Coils are renowned for their portability and effectiveness in the Demagnetization of Bottom Hole Assemblies (BHA’s).

Magnetic Particle Inspection Coils are available in two forms;

1. Traditional High Amperage Mobile Power Packs (3-6000 Amps), with afew (3 to 5) wraps of heavy 4/0 cable.
2. Multi-Turn, Low Amperage Coils with between 1000 and 2000 Turns ofsmall gauge wire, supplied from a Low Amperage Power Supply.

The accepted Rule of Thumb for coils to inspect these BHA’s is 1,200 Ampere Turns for every inch of Diameter, thus for an average 6 5/8” OD Threaded Connection, the operator requires almost 8000 Ampere Turns of a DC Field. This DC field permits both the Male Threads (Pin End) and Female Threads (Box End) to be full inspected. AC Fields, induced by a Coil, will not provide enough field to inspect Box Ends.

If a High Amperage Mobile Power Pack is used, it would have to be very close to the Workpiece, with perhaps 40 feet of 4-0 Cable (to achieve a 5 Turn Coil). The Amperage, with average losses, would be in the order of 3000 Amps. These Mobile Power Packs, have a high capital cost, and very high Switch Gear installation costs. For economical use, the Power Pack (not looking very mobile at this point) should be run from a 3 Phase supply of at least 440-480 Volts.

Most high performance testing is done with a DC field, but Power Packs become more expensive if they are Full Wave. Multi-Turn, Low Amperage Coils produce virtual DC (from full wave rectified voltage), as the Inductance of the 1000+ turn Coil results in a virtual Full Wave DC output.

It is recognized, in all industries where Demagnetization (Demag) is performed, that a Reversing and Decaying DC Field provides the best demagnetization. High Intensity AC will provide Demag on smaller parts, however on Heavy Workpieces, with a very strong residual field, an Alternating Current just simply doesn’t work.

WD-Series Coils have quickly gained their popularity in the market, because they excel at Demaging, not to mention the relatively light weight and the convenience of the Integral Power Supply. With most specialized MPI testing, virtually all parts require a Controlled Field, and that normally means +/-3 Gauss after testing. This demagnetization is achieved manually, with the standard controls, by Reversing and Reducing the DC field between shots. In some cases WDV-Coils are used to introduce a specialized Magnetic Field, where both ends of a 11.3m (37’) length of Casing have the same polarity, which produces a very heavy node, of the opposite polarity, in the middle.

Multi-Turn, Low Amperage Coils can have the field Reversed with the use of a Toggle Switch, and Reducing the Field is simply done by turning a knob. With new Coil Controls, the Output Amperage is constantly displayed, and is an unusual feature on a Mobile Power Pack. To reverse the Field on a Mobile Power Pack, both Eitherend Connectors on the 4/0 cable must be removed from their receptacles, and their positions reversed when they are plugged back in. Like a Multi-Turn, Low Amperage Coil, reversing the Amperage is done by turning a knob. In the end, a Multi-Turn, Low Amperage Coil, can perform a Demag Operation in approximately one-fifth the time of a Power Pack with a 5 Turn Coil.

Multi-Turn, Low Amperage Coils, developed by Walter Gunkle in the mid 1950’s, are typically supplied from a Separate Power Supply that has an output of about 12 Amperes at 115Volts DC. These early Coils, which are still being manufactured in the same way, use an Aluminum Bobbin for the Coil form with a Separate Power Supply and remain virtually unchanged after more than 50 years. Unfortunately, little development work was done with this type of Coil until Western Instruments introduced its first WDV-10 in early 2000.

MPI Equipment is not certified by Specification Issuing Organizations (ASTM, ASME, API, etc,), but must comply with the requirements as set out in their documents. The use of a Coil is referred to as Indirect Magnetization as the magnetic field in induced into the workpiece. Multi-Turn, Low Amperage Coils are also typically employed for Localized Area inspection, as described in ASTM E709, and more specifically are defined as Air Core Coils. Reference Specifications tend to use complex (and confusing) formulas for the calculation of the Ampere Turns required to magnetize a workpiece. These formula are typically negated in favor of using the faster, more direct method of Artificial Discontinuities contained in devices such as a Pie Gauge or Slotted Shims (Castrol Strips or QQI’s), which are also approved for Verifying Systems Performance.

Western’s latest Development in this area is a Coil with the added feature of performing Automatic Reversing DC Demagnetization or Automatic Ring-Down®. With the simple press of a button, the Coil starts a series of Shots, with a reverse polarity and reduced amperage. The shots are repeated until the magnetic field is removed from even the heaviest workpiece.

Western currently produces 8, 10, 14, 16, 18, and 25” ID Coils. The jump from 18 to 25″ ID, is extensive, where the two larger sizes are primarily designed to Demagnetize Pipeline Pipe prior to Welding. We regularly entertain the production of different ID sizes where the customer requires two units. This is why we produce 16, 18, and 25” Models, that were initially delivered within 8 weeks.

Distributed by: ABQ Industrial LP USA
Tel: +1 281-516-9292 / 888-275-5772 eFax: +1 866-234-0451
Web: https://www.abqindustrial.net
E-mail: info@abqindustrial.net

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