Power Generation

The Power Generation category contains case studies and blogs related to ITM’s power generation machinery engineering and testing services.

Archiving CompactRIO Process Data to PI

The tool we most commonly use for real-time embedded process monitoring and control applications is the NI CompactRIO.  These controllers allow us to embed algorithms that acquire and analyze high speed process sensor data and then output derived key performance indicators (KPIs) to other control systems.  Most of the time, our customers also require us  to send the KPIs to a real-time data infrastructure like OSIsoft’s PI System so plant managers and engineers can use the data to find energy savings, monitor asset health, or optimize processes.

For our latest CompactRIO systems we have developed APIs that allow us to send or receive data directly to/from PI.  We utilize the PI Asset Framework and the UFL Connector to automatically generate PI tags from the device and update the process tag values either on value change or on a time basis.

These tools greatly simplify our CompactRIO to PI System communication process by eliminating intermediary data servers and automatically generating PI tags based on a CompactRIO system’s configuration.  If you are interested in using these APIs for PI or developing a CompactRIO system contact Mark Yeager or Chase Petzinger.

ITM’s Patented Technologies Prevent Boiler Tube Leaks

The US patent office has recently awarded patents to ITM for (2) two of the underlying boiler safety and process optimization technologies embedded within our CDS and SHOP systems.  These systems monitor boiler conditions and alert operators when boiler tube damaging events/conditions occur.

Clinker Detection System (CDS)US Patent 10060688B2

The Clinker Detection System (CDS) measures the relative weight, location, and frequency of clinkers that impact a boiler floor. This technology enables operators to shorten boiler outages, identify fouling problems, optimize soot blower operations and identify damaging impact events.

Superheater OverHeat Protection (SHOP)US Patent 9541282B2

The Superheater OverHeat Protection (SHOP) system helps mitigate the risk of superheater tube failure due to short-term overheat during boiler start-ups.    Catastrophic thin-lipped bursts  can occur in superheater steam generation tubes when steam flow is insufficient, when deposits restrict flow, or when tubes are blocked by water due to a rapid firing rate during boiler start-up.  SHOP assists operators in the management of boiler start-ups by enabling the detection of superheater tube clear events (TCE’s).

If you’re interested in learning more about these systems and other boiler/process monitoring solutions, feel free to contact Ryan Welker by e-mail at ryan.welker@itestsystem.com or phone at (844) 837-8797.

Putting a HALT to Hazardous Hopper Maintenance – Power Magazine

Check out my article “Putting a HALT to Hazardous Hopper Maintenance” in the May 2018 edition of Power Magazine.  This article describes a system for detecting dangerous plugging conditions inside ash hoppers.  Ash hoppers are used in the power industry to collect hot ash from utility boilers. – Mark Yeager

Follow the link below for the on-line version.

https://www.powermag.com/putting-a-halt-to-hazardous-hopper-maintenance

For more information about a Halt System or our other Boiler Monitoring Systems contact Ryan Welker @ (844) 837-8797 x702

 

Increase the IQ of Your Intelligent Sootblowing in Power Magazine

Check out the article “Increase the IQ of Your Intelligent Sootblowing” by my colleague Mark Yeager in the December edition of Power Magazine.  In this article, Mark describes ITM’s Sootblower Fouling Detection (SFD) technology which allows for targeted sootblowing, by pinpointing exactly when and where sootblowing is required in chemical recovery and coal-fired power boilers.

https://www.powermag.com/increase-the-iq-of-your-intelligent-sootblowing

Superheater Overheat Protection (SHOP) @ BLRBAC Spring 2017

BLRBAC 2017 DetailsITM’s president Tim Carlier (tim.carlier@iTestSystem.com) is presenting its Superheater Overheat Protection (SHOP) technology at the Spring 2017 Black Liquor Recovery Boiler Advisory Committee (BLRBAC) Meeting  in Atlanta, GA on April 12th.  SHOP helps boiler operators avoid short term overheat failures of recovery boiler superheater tubes.

ITM will also introduce new boiler and plant optimization technologies/systems that their partners have used to streamline processes.

Conference details can be found at http://www.blrbac.org/

Find out more about ITM’s Boiler Monitoring Solutions https://itestsystem.com/industrial-monitoring/

ITM Strain Gauging Services

Garrison Dam

Quantifying stress, strain and force within a structure using real world strain gauge measurements is commonly used to verify FEA models and estimate a component’s fatigue life.  Our engineers and technicians have planned and implemented challenging strain gauge installations for our customers around the globe.  Information from these strain gauge installations has allowed our customers to validate their designs and improve their product’s reliability.

For more information about these applications and our strain gauging services, contact Ryan Welker via email ryan.welker@itestsystem.com or phone: (844) 837-8797 x702

Save steam costs with new ITM technology – SFD

With steam costs reaching an estimated $5,600 a day — or roughly $2 million a year — for sootblowing operations in a single boiler, imagine the savings plant operators could achieve by optimizing sootblowing.

Sootblower Fouling Detection (SFD) is a new ITM technology for identifying when and where to clean boiler steam tubes.  Learn more about SFD by watching this video.

Fouling Detection with ITM’s Clinker Detection System (CDS)

Wasting sootblower steam because you don’t know where your boiler is fouling? We can help.  Watch this video to learn more about ITM’s Clinker Detection System (CDS).

Clinker Detection System Reduces Boiler Fouling and Boosts Efficiency

shop clinker detection system

Boiler monitoring technology replaces maintenance guess-work with data-driven accuracy.

SEPTEMBER 13, 2016; MILFORD, OH; USA – Integrated Test & Measurement (ITM), a leading provider of structural test and measurement engineering software and services, introduces its Clinker Detection System. Clinkers, some of which reach the size of a small car, are incombustible residue that forms inside black liquor recovery and coal-fired utility boilers. This build-up (fouling) has a significant impact on the efficient operation of the boiler system.

The ITM Clinker Detection System:
• Determines where boiler fouling has occurred
• Optimizes soot blower operation
• Identifies damaging clinker impacts on the bed/floor
• Shortens the duration of chill & blow events

The ITM Clinker Detection System identifies fouling problems and determines the effectiveness of boiler cleaning tools and processes such as sootblowers, sonic horns, pulse detonation cleaning events, and thermal shedding during chill and blow cleaning events. The solution involves mapping and instrumenting the boiler floor with industrial sensors that measure the size and frequency of clinker deposits as they become dislodged impacting the floor. At the same time the system identifies which sootblower caused the clinker to fall. Together this information pinpoints the clinker’s area of origin directing where clean-out should be concentrated.

ITM Founder & President, Tim Carlier, comments:
“Without hard data to pinpoint areas of build-up maintenance is flying blind as to when and where to run sootblowers. The ITM Clinker Detection System in essence provides visibility into the boiler. And because up to 6% of the steam generated by a boiler is used for sootblowers, any decrease, by even a small percentage, will generate significant savings when factored out over the course of a year. In addition to saving money, optimizing sootblowing also carries with it a positive environmental effect as plants don’t have to burn as much fossil fuel to generate electricity since steam is being consumed more efficiently.”

About ITM
Headquartered in Milford, OH (USA), Integrated Test & Measurement, LLC (ITM) focuses on three vertical spaces: Industrial Monitoring, Testing Services, and Configuration-based Test Software, iTestSystem. Founded in 2001, ITM helps companies reduce costs and improve efficiencies in product development, manufacturing, and production activities. Today, ITM provides software development, structural and mechanical testing services, industrial monitoring, strain gauging, and data analysis solutions to clients on six continents.

For more information on ITM, iTestSystem and ITM’s other products and services contact Ryan Welker via email: ryan.welker@itestsystem.com or phone: (844) 837-8797 x702

https://itestsystem.com/cds-clinker-detection-system/

Clinker Detection System (CDS)

Do you need to reduce your operating cost and carbon footprint on your recovery or coal fired boiler? If so, we can help. With over 15 years of experience in the development and installation of boiler fouling detection systems, ITM is excited to introduce our latest technology that is targeted at clinker impact detection, The Clinker Detection System (CDS). Click here to learn more or visit the CDS product page at https://itestsystem.com/cds-clinker-detection-system/.

cds-brochure