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ADWEL WTD-501 Operating Manual

Wedge tightness detector
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Wedge Tightness Detector
Model WTD-501
Operating Manual
WTD MODEL 501
Version 2.4
Software Version 3.x
May, 2006.

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  • Page 1 Wedge Tightness Detector Model WTD-501 Operating Manual WTD MODEL 501 Version 2.4 Software Version 3.x May, 2006.
  • Page 2 Website: http://www.adwel.com © 2001 ADWEL International Limited, Canada Copyright of this document is owned by ADWEL International Limited except for information supplied by other parties. No reproduction in whole or in part is to be made without the written authorization of...

  • Page 3: Table Of Contents

    LIST OF CONTENTS 1. INTRODUCTION Description ......Requirements ......2.
  • Page 4 5. STEP-BY-STEP SOFTWARE USE Overview of Use ......26 5.1.1 Creating a Unit ....5.1.2 Opening a Unit .
  • Page 5 LIST OF FIGURES WTD 501 and Hand Held Probe ..... Front View Showing Allen Screws for Width and Angle Adjustment . . Probe Without Bars or Sidecars .
  • Page 6 Open Existing Unit Dialog Box ..... . Browse Dialog Box ......Generate New Calibration File Dialog Box .
  • Page 7 Default Folder ......Browse for Folder ......Power Selector and Power Switch in Power Entry Module .

  • Page 8: Introduction

    1. INTRODUCTION The Wedge Tightness Detector (WTD) was originally developed under contract to the Electric Power Research Institute (EPRI). The WTD is designed to measure stator slot wedge tightness in turbo-generators, hydro-generators, and motors. The main components of this instrument are a manual probe, calibration block, electronics case, software and computer.

  • Page 9: Requirements

    In addition to housing the system power supplies, the electronics case includes the electronics for receiving the accelerometer data and filtering data from selected parts of the frequency spectrum. REQUIREMENTS An IBM compatible computer (486DX2, 66MHz, 8MB RAM or better) running W95, W98, NT or W2000 and a minimum of 20 MB of hard disk drive space for program and data storage is required.

  • Page 10: Hand-Held Probe Adjustment

    HAND-HELD PROBE ANGLE AND HEIGHT ADJUSTMENT The sidecars on the probe assembly allow the probe to be used with generators/motors of almost all sizes. The sidecars slide in and out on and are supported by round rails that come in 75 mm (3”), 150 mm (6”) and 225 mm (9”) lengths. The sidecars can be raised or lowered by inserting the rails into one of the three holes at each end of the probe.

  • Page 11: Probe Without Bars Or Sidecars

    On the front and back of each sidecar, the bottom bolt allows the user to set the distance the sidecars are from each other, while the two top bolts allow the sidecar to be angled. Set the distance between the sidecars by sliding them along the rails until they line up with the slot teeth of the machine to be tested.

  • Page 12: Electronic Case Overview

    ELECTRONIC CASE OVERVIEW The Electronic Case houses the system power supplies, electronic circuit boards and interface wiring. The WTD Model 501 is designed to be a rugged instrument. However, the user should exercise care in handling the unit. Figure 4: WTD Electronics Case Back Panel The power supplies included are an unregulated +24V supply and a +15 and –15 VDC regulated supply.

  • Page 13: Computer Setup

    Figure 6: Electronics Case Front Panel COMPUTER SETUP Any IBM Compatible computer with RS-232 port running Windows 95, 98, or 2000, with an 80486-66 MHz or more recent processor, minimum 8 MB RAM, 20 MB of disk space available and a 3.5”- 1.44 MB floppy disk drive may be used with the Wedge Tightness Detector and related software.

  • Page 14: Communication Port Selection

    Figure 7: Communication Port Selection Figure 8: Communication Port Testing Figure 9: Communication Port Confirmation WTD SERIAL NUMBER...

  • Page 15: Calibration Block

    CALIBRATION BLOCK The calibration block is a steel block imitating stator iron with a wedge in the center. The wedge is not user adjustable. Placement of the hand held probe between the front edge and the marked line (see line 2 below for the loose setting, and the left side of the probe in front of “line 1”...

  • Page 16: Operations Overview

    OPERATIONS OVERVIEW WEDGE TIGHTNESS DETECTOR SETUP To setup the WTD: 1. Ensure that the voltage selector indicates the correct voltage setting. If not, insert flat screwdriver in the slot at the top of the power entry module, and open plastic cover.

  • Page 17: Probe Placement On Wedges

    PROBE PLACEMENT ON WEDGES Place the probe on the first wedge, with the sensor shoe (the one closer to the connector end of the probe) on the selected test point. The white stripes that extend along the side of the hand held probe and sidecars let the user know where the center of the sensors are.

  • Page 18: Calibration References

    CALIBRATION REFERENCES To perform wedge tightness testing, the WTD needs examples of a tight wedge and a loose wedge in order to set the appropriate data analysis and processing parameters. These calibration references are stored in a calibration file and may be created in one of three ways: Generated, Calculated, or Extracted.

  • Page 19: Values For Colour Defaults

    Sub-directory Units is used to store Station/Unit data. System settings are stored in \ADWEL\SYSTEM, and \ADWEL\TEST is used for temporary file during the test. Using command Import and Export in Unit Menu, user can import or export one or all unit configuration files.

  • Page 20: Software Overview

    SOFTWARE OVERVIEW Figure 13: WTD Software Main Window The following sections will provide a more detailed overview of the WTD Model 501 software components (menus, icons, and bars) and detailed instructions on using the software. Select the underlined letter to execute the command. FILE MENU Open Test File: opens an existing test file.

  • Page 21: Unit Menu

    Figure 14: File Menu Print: sends file to a printer. This command is active only in single file display. Exit: closes the program. Also, a list of 8 most recently used test results will be displayed. UNIT MENU New: creates a new unit. Open: opens an existing unit.

  • Page 22: Reference Menu

    Figure 19: Help Menu Contents: contents of the instructional text introduced in an indexed format. ADWEL on the Web: use this to send e-mail message or visit Adwel Home page About WTD Model 501: credits banner screen with information about the version, author...

  • Page 23: Action Menu (Test Mode)

    ACTION MENU (TEST MODE) Figure 20: Action Menu (Test Mode) Import Data: imports existing test data into ongoing test. Test: starts testing operation. Delete: deletes user specified number of measurements-test points. Repeat: repeats user specified number of measurements-test points. Go To: skips to specified position (slot/wedge number). View: presents test data for quick viewing during the test, before a measurement file is created.

  • Page 24: Icons

    ICONS Icon Description Open Test File Compare results Convert Test File New Unit Open Unit Edit Unit Delete Unit Start Test Generate Reference Calculate Reference Extract Reference...
  • Page 25 Test Statistics Header File Contents RTI Colors COM Port Default Folder Delete measurement(s) Repeat measurement(s) Go To specified point View tested data Table 1: Icons NOTE: All commands that are available by clicking on icons are also available from the drop-down menus.

  • Page 26: Step-By-Step Software Use

    Step-by-Step Software Use The following sections will explain, step-by-step, how to initialize, configure, set-up, test, view data, and all other software-driven functions of the WTD Model 501. OVERVIEW OF USE After setting up the hardware, and placing the hand-held probe for testing, the user is ready to begin using the software.

  • Page 27: Slot And Wedge Description Tab

    Once the station and unit are created, the name will be saved in the station directory under the ADWEL\Units directory, with a cfg extension. The next tab is titled Slot and Wedge Description. In this tab you may fill in information for: number of slots in the machine;...

  • Page 28: Nameplate Tab

    manufacturer (drop down list, or type in); voltage (type in); current (type in); frequency (type in); rotation rpm (type in); temperature (with drop down list for degrees in K, C, or F); pressure (with drop down list for units in atm, bar, mmHg, or kPa); power (drop down list for HP, MW, or kW) rating and factor (type in for both);...

  • Page 29: Opening A Unit

    5.1.2 OPENING A UNIT To open a previously created unit, click on the Open Unit icon or select Open from the Unit menu. Figure 25: Open Existing Unit Dialog Box Either type in the name of the Station and Unit, or browse for the information. Double click on the station name, and click on the unit name.

  • Page 30: Generating Calibration Reference

    5.1.3 GENERATING A CALIBRATION REFERENCE To generate a new calibration file, after setting up the hand-held probe for testing, click on Generate Reference icon, or select Generate from the Reference menu. The calibration file name can be entered now or after tapping the references for loose and tight.

  • Page 31: Test Set-Up

    5.1.4 TEST SET-UP Select Test from the Unit menu or click on the Start Test icon. A dialog box will appear that asks if you would like to select Random or Sequential testing. Select Random if you wish to return to the computer after each slot or wedge is tested; select Sequential if you prefer to test the whole machine, or only one part, wedge after wedge in a predefined order.
  • Page 32 To create first group click on Create. Highlight Group 1 after it appears in the list to the left of the Create button. Enter the Description (up to 20 characters). Enter the slot and wedge numbers to be tested (e.g. 1-3 or 14-15). Select whether the WTD will follow Wedges or Slots in the Test How field.

  • Page 33: Random Test

    5.1.6 RANDOM TEST If the user chooses to do Random Testing, he or she is required to return to the keyboard after completing a complete slot or one or more wedges in a single slot in order to select the next slot for testing.

  • Page 34: Repeat, Delete, Go To And View Commands

    5.1.8 REPEAT, DELETE, GO TO AND VIEW COMMANDS · Repeat command enables operator to repeat a specified number of wedges/test points · Delete command enables operator to disregard (leave without any data) a specified number of wedges/test points · Go To command enables operator to “jump” to any predefined test point and continue the test.

  • Page 35: Quick Test View

    NOTE: Latest test data will be NO DATA if you decide to skip some wedges in Repeat sequence, using command Go To. Quick viewing data while testing is in progress is executed by clicking on the View button or selecting View from the Action Menu. All wedges tested during that part of the test will be displayed in chronological order (see Figure 34).

  • Page 36: Importing And Finishing The Test

    5.1.9 IMPORTING AND FINISHING THE TEST At any time during the test, Import feature can be used. This feature is designed to allow partial re-testing of a machine after the test was terminated and a measurement file created. It is recommended to import test data at the very beginning of the re-test (before any point is tested) since imported data will overwrite all existing data.

  • Page 37: Viewing Test Results

    Use first choice for break during the test. This will take you out of the Test Window. The computer and WTD 501 instrument can be turned off without loss of data or settings. To resume, start the WTD program and click the Test button, or select Test from the Unit menu in the Main Window.

  • Page 38: Header File Contents

    Figure 39: Header File Contents The wedge tightness map is displayed in color, with different colors representing different categories of wedge tightness. The user can change the number of categories and the color for each category during the map display-click on the RTI colors icon to do this. White data field represents No Data measuring point.

  • Page 39: Comparing Test Results

    Figure 40: Test Statistics Window Two test results are installed together with WTD 501 software in the SAMPLES folder. 5.2.1 COMPARING TEST RESULTS Click the Display Two Results, or select Compare Results from the File Menu to compare results from two tests. Tests can be compared in two ways: with one test file viewed using two different calibration files, or with two test files compared using one calibration file.

  • Page 40: Two File Comparison

    Figure 42: Two file Comparison One calibration file used to compare two test files is also useful. It permits the user to have a standard to measure against for two separate tests. These might be tests that were done on the same unit at different times to measure wear and tear, or to measure the difference before and after rewedging, or tests done on the same model of a unit done on separate units to measure consistency of performance.

  • Page 41: Exporting Test File To Text Format

    Type in a meaningful name, Save the file in Text Files file format, In the \ADWEL\Data directory, or another directory of the user’s choice, Open the file in Microsoft Excel or Access, Lotus 1-2-3 or Approach, or another spreadsheet or database of the user’s choosing.

  • Page 42: Creating Calibration References

    CREATING CALIBRATION REFERENCES Calibration references can be created in three ways: -Generate -Calculate -Extract Click on Reference drop down menu or appropriate icon to start this procedure. To generate calibration file, select tight and loose wedge and perform operations described in chapter 5.1.3 GENERATING A CALIBRATION REFERENCE.

  • Page 43: Extract Loose Reference

    Figure 45: Extract Loose Reference Figure 46: Extract Tight Reference In addition to this procedure, calibration references can be extracted during single or two file display. Position the cursor on file display area and click on RIGHT mouse button. Click on Extract Reference and the following drop-down menu will appear: Figure 47: Extract References in File Display...

  • Page 44: Calibration Reference Warning

    Select Tight or Loose and small hammer will replace your cursor. Position this hammer on selected wedge and click on LEFT mouse button. After this, click on right mouse button again and repeat this process for another condition and save the calibration file. If selected references are not acceptable the following warning will appear: Figure 48: Calibration references warning Extracted references will be saved in calibration files with extension .ecl.

  • Page 45: Printing

    PRINTING Using Page Setup from File drop-down menu, page layout, margins and Header content can be defined, see following Figure. Figure 49: Page Setup When the desired wedge tightness map is displayed on the computer screen, choose Print from the File drop-down menu or click on Print icon. Figure 50: Print Setup Different choices are available on the Print Setup screen.

  • Page 46: Default Data Folder Selection

    5.6 DEFAULT DATA FOLDER To change default directory, click on drop-down menu Options and select Default Folder. New dialog box, will appear, see Figure 51. Figure 51: Default Folder Type in new default folder or click on three-dot square to browse. Using following dialog box select the folder.

  • Page 47: Maintenance

    NOTE: There are NO user-repairable parts on the WTD probe, the electronics case, or the software. If you are unable to troubleshoot and fix an inoperable unit by employing the tips provided on this page, please contact ADWEL. If the impact hammer should become clogged with dirt it can be flushed with a light penetrating oil compound like WD-40.

  • Page 48: Specifications

    SPECIFICATIONS Power Supply 230/115 V User selectable at 50/60 Fuse Rating 1A, 250V, M Slot width 26-225mm Probe adjustment or 1”-8” Slot depth 0-20mm adjustment (<10mm wide) 0mm-60mm (>25mm wide) Minimum wedge 60 mm length Dimensions Width - 25mm (or 1”) Height - 160mm (or 6¼”) Length - 145mm...
  • Page 49 Installation II – Light Category Industrial Environme Operating – 40 ntal Temperature – 104 Conditions Storage – 50 Temperature – 122 Relative Humidity 5% - 90% non-condensing Table 2: Equipment Specifications MARK OF COMPLIANCE:...

  • Page 50: Kit Contents

    KIT CONTENTS • Manual Probe with 75mm, 150mm and 225mm bars • Electronics Case • Data Processing and Analysis Software • Calibration Block • Connection Cables (power, probe, computer) • 3mm Allen Key • Operations Manual • Fiberglass Carrying Case...

  • Page 51: Appendix 1

    APPENDIX 1...
  • Page 52 In this Appendix, four different test set-up samples and WTD 501 connection diagram are attached. Test set up samples are based on a turbo generator with 36 slots and 20 wedges in slot and should help understanding of various “How to Test” options. Samples 1 and 2 demonstrate two options in Random Test Mode.
  • Page 53 SAMPLE 1 RANDOM TEST EXCITER TURBINE wedge number slot 1 10 11 12 13 14 15 16 17 18 19 20 10 11 12 13 14 15 16 17 18 19 20 LOCATION OF FIRST WEDGE EXCITER END TEST DIRECTION FORWARD SLOT NUMBER 32 (WHOLE SLOT)
  • Page 54 SAMPLE 2 RANDOM TEST EXCITER TURBINE wedge number slot 1 10 11 12 13 14 15 16 17 18 19 20 20 19 18 17 16 15 14 13 12 11 10 LOCATION OF FIRST WEDGE EXCITER END TEST DIRECTION BACKWARD SLOT NUMBER 32 (WHOLE SLOT)
  • Page 55 SAMPLE 3 SEQUENTIAL TEST EXCITER TURBINE wedge number slot 1 10 11 12 13 14 15 16 17 18 19 20 10 11 12 13 14 15 16 17 18 19 20 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 LOCATION OF FIRST WEDGE EXCITER END FOLLOWING...
  • Page 56 SAMPLE 4 SEQUENTIAL TEST EXCITER TURBINE wedge number slot 1 10 11 12 13 14 15 16 17 18 19 20 10 46 11 47 12 48 13 49 14 50 15 51 16 52 17 53 18 54 19 55 20 56 21 57 22 58...
  • Page 57 WTD Model 501 CONNECTION DIAGRAM WTD 501 COMPUTER POWER CABLE PROBE PART No: 501/C3 PROBE COMPUTER PART No: 501/C1...

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