Energy

The Energy category contains Case studies and blogs related to ITM’s energy engineering services.

Prevent Costly Mistakes on Industrial Monitoring Hardware Updates

Are you contemplating updates to your industrial monitoring hardware? Perhaps a COVID slowdown has given your team time to finally upgrade to that latest and greatest National Instruments controller.  

Before you make that leap, there’s one extremely important factor to consider, and that is the software running your equipment. If your code isn’t ready, there is far more to consider than a simple hardware swap, and your crew could be headed toward a serious loss in productivity and efficiency.  

The reality is that production engineers are routinely staring at industrial monitoring equipment that is nearing or reaching end-of-life, and they need to act to prevent unforeseen failures. The team at Integrated Test & Measurement can help with hardware upgrades, but we can also dive into your software to be sure your code is up to date and any customizations that have been made over the years are updated to assure your complex equipment is communicating the way it was designed to and all signals continue to report properly.  

Why is this holistic hardware/software approach recommended when it comes to upgrades? Consider the situation where a client upgrades a control module on a test cell only to find out that the new equipment is no longer compatible with the old software. It is akin to adding a new printer to your desktop computer without upgrading the drivers. Only in this instance, the fix is far more complex than a quick download. The result is that piece of equipment may now need to come offline for an extended time, and if you don’t have an in-house spare, your industrial monitoring is about to take a hit.  

ITM has seen an uptick in requests for assistance from clients who are running either outdated hardware, software or both. In some instances, partners may no longer have access to the person who customized their software. But that is no problem for ITM. Our LabVIEW experts are adept at not only understanding these complex software changes but they can clean up your code to simplify future upgrades, too. In other words, if your programming resources are no longer available, look to ITM for support with code enhancements, development and updates. 

One common migration for ITM’s industrial monitoring clients, for example, is moving from an older NI CompactRIO to a newer more suped up CompactRIO. A common mistake in this and other instances is underestimating the time it may take to update custom software, so rather than trying to do the work in house, let ITM speed up your process.  

Our experts can travel to your site, evaluate both your equipment and your software running it to develop and implement an upgrade plan that works for your team. Whether that means a slower measured approach or a quick turnaround on a tight deadline, ITM will develop a custom solution that meets your needs. 

Paper Mill Thermocouple Monitoring

One solution for monitoring steam tube temperature/s located inside its utility boiler to make sure start-up conditions were met.

Silo Load Monitoring

Plant operators need to continuously measure bulk material levels/weight in their silos and hoppers to ensure their processes are running safely, efficiently, and without bottlenecks. Measuring these levels allows operators to automate vessel filling, verify material consumption, and prevent overfilling.

What we offer

ITM provides its customers with a variety of structural load monitoring systems. Using strain gauge based transducer technology, ITM can design and implement a real-time system to continually monitor load responses of the supporting members on an array of structures.

Strain gauge based measurements are more accurate and typically less expensive than load cell retrofitting. The addition of a monitoring system can also reduce the risks associated with manual measurements including contamination of product and, more importantly, injury to a worker.  

How do you measure bulk material levels/weights in silos and hoppers?

The two ways to measure bulk material quantity in silos/hoppers are level indicators (laser, ultrasonic, radar) and weight measurements (load cells, strain gauges).  Weight measurements are more accurate, safer to install, and can be installed during operation.  Of the types of weight measurements, ITM prefers to implement strain gauge-based solutions since they do not require structural modification of the vessel.

An ITM silo monitoring system typically consists of weatherproofed strain gauges for each silo leg and a NI CompactRIO embedded controller to acquire data, process signals, and output results. Systems are scalable to accommodate all the silos at the plant.

The graph above shows a typical trend of real silo data during unloading.  Weight levels are sent directly to factory DCS systems and historians via common communication protocols like Ethernet/ip and Modbus, or they can be viewed on the system’s webpage or a local/remote workstations and panels.

What are the challenges when measuring bulk material levels/weights?

Most bulk material storage is outside, so temperature and other environmental factors must be accounted for not only in the durability of the equipment, but in the sensor design and data processing. Changes in temperature, wind, and humidity can result in changes to the load path in silo legs. Load changes are account for by instrumenting all or most of the silo legs and selecting the appropriate strain gauge bridge design which results in continuously accurate weight measurements.

While other systems require calibrating the system with known loads (point calibration), ITM calibrates the system using a shunt voltage across the strain gauge bridge. This process automatically calibrates the system and eliminates the requirement of having pre-known material weight added to the vessel.

For more information about silo monitoring, contact Ryan Matthews @ 1.844.837.8797 x706.  To see how ITM’s structural load monitoring systems work watch this video below.

Structural Validation & Testing of Generator Sets

A case study describing a reliable system for testing generator vibration levels after production in order to verify proper unit design and assembly.

Clinker Detection System

A proprietary monitoring technology developed by Integrated Test & Measurement is introducing a brand new approach to address “fouling” in coal-fired power plants as well as the pulp and paper industry.

Sootblower Fouling Detection System

Proprietary Technology from ITM provides boiler operators with insight into boiler and sootblowing efficiency.

Process Optimization with Embedded Monitoring Systems

Finding efficiency improvements and uncovering hidden unsafe conditions in a process can prevent injury and save your company millions.

Analyzing Vibration to Evaluate Sootblower Performance

ITM stake holders, we have recently received good news from the US Patent Office. They have recently allowed claims relating to the use of vibration measuring devices to evaluate the operation of a sootblower (US20190041201A1). This allowance strengthens the protection of the sootblower health and fouling detection features of ITM’s Sootblower Fouling Detection (SFD) Technology.

Additional Claims: “A method of evaluating an operation of a sootblower in a boiler system, the method comprising: operating a sootblower having a rotating lance tube; measuring a vibration in the boiler system caused by the operation of the sootblower, wherein the vibration is measured with a vibration measuring device; and analyzing the measured vibration to evaluate the operation of the sootblower.”

US Patent #: US20190041201A1

For more information about ITM’s SFD Technology or other Boiler Monitoring Systems, contact Ryan Welker @ (844) 837-8797 x702

Related Links

 

Accelerometers for Rotating Machinery Vibration Measurements

Choosing an accelerometer for rotating machinery vibration measurements can be a daunting task since there are so many options available. This blog outlines the characteristics you should consider when choosing a piezoelectric single axis accelerometer for general purpose vibration measurements and presents some accelerometers to consider.

Characteristics of a General Purpose Accelerometer

When measuring vibration on rotating equipment such as motors, pumps, and generators, the most common measurement location(s) are on the shaft bearing housing(s) at the shaft centerline. At this location, typical vibration levels perpendicular to the shaft are < 100 g and the frequency range of interest is < 5000 Hz.  A general purpose single axis piezoelectric accelerometer with either a 10 mV/g or 100 mV/g sensitivity fits this criteria.

Other characteristics to consider are size, mounting options, cable connections, grounding, and cost. Several mounting options are available. They include magnetic bases, adhesive bases and stud mounts. The mounting option you choose affects the frequency range of your accelerometer measurements. The table below shows typical frequency limits for accelerometer mounting methods.

Mount TypeTypical Frequency Limit
Magnet2,000 Hz
Adhesive5,000 Hz
Stud6,000 Hz

5 General Purpose Accelerometers

The table below shows some examples of stud mounted general purpose piezoelectric accelerometers. These accelerometers all have a female 10-32 coaxial / microdot connector.  It is important to note that this is not a complete list of accelerometers and there are many options available from each manufacturer. I would encourage you to go to the websites linked in the table and see what’s available.

 
ManufacturerPCBDytranBRÜEL & KJÆREndevcoKistler
Model #353B033055D14533-B256HX -108702B500-M1
Sensitivity10 mV/g10 mV/g9.8 mV/g10 mV/g10 mV/g
Frequency Range(±5%) 1 to 7000 Hz(±5%) 1 to 5000 Hz(±10%) 0.2 – 12800 Hz(±10%) 1 to 10000 Hz(±5%) 1-10000 Hz
Temperature Range-65 to +250 °F-67 to +250 °F–67 to +257 °F-67˚F to +257˚F-67˚F to +257˚F
Height0.88 in0.64 in0.54 in0.55 in0.67 in
Weight0.38 oz0.35 oz0.3 oz0.14 oz0.32 oz
Housing MaterialTitaniumTitaniumTitaniumTitaniumTitanium
Electrical Connector10-32 Coaxial (side)10-32 Coaxial (side)10–32 Coaxial (side)10–32 Coaxial (top)10–32 Coaxial (side)
Mounting Thread10-32 Female10-32 Female10-32 Female10-32 Female10-32 Female

For more information about collecting vibration data, accelerometers, iTestSystem, or test equipment rental, contact Mark Yeager @ (844) 837-8797 x701.

Sootblower Fouling Detection (SFD) presented at BLRBAC Spring 2019

We would like to thank the Black Liquor Recovery Boiler Advisory Committee (BLRBAC) for allowing us to present our patented Sootblower Fouling Detection (SFD) technology at the Spring 2019 meeting in Atlanta, GA.  SFD is ITM’s patented technology for measuring fouling/slagging along the path of an active sootblower in recovery and utility boilers.

During this presentation, Tim Carlier described the original SFD concept, the system’s Key Performance Indicator (KPI) outputs for closed or open loop control, and the system’s potential sootblower steam savings of 1-4% MCR.  He also highlighted the safety and maintenance benefits that the system provides.

For more information about the SFD technology or to schedule an online presentation or site visit to audit your specific application, contact Tim Carlier or Ryan Welker.

Contact Info:

Tim Carlier, President, tim.carlier@itestsystem.com, 513.608.4811

Ryan Welker, Business Development Manager, ryan.welker@itestsystem.com,  513.405.0181