ITM Blog Posts

The Blog Post category contains blog posts associated with ITM’s testing services, LabVIEW programming, Test & Measurement Hardware, Boiler Monitoring Systems, and iTestSystem applications.

Another Successful Condition Monitoring System Installation

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Last week our team successfully and safely installed another Boiler Monitoring System (BMS).  This system, a Sootblower Fouling Detection (SFD) system, monitors structural and vibration sensors that quantify the boiler’s response to sootblower operations. The SFD system analyzes the boiler response data and outputs Key Performance Indicators (KPIs) such as fouling level, sootblower efficiency, and sootblower health to automated boiler cleaning systems.

This boiler uses over 50 sootblowers located at different elevations to clean soot build-up from boiler steam tubes.  Since the vibration measurement locations are relatively far apart, the SFD system requires a distributed monitoring system consisting of several junction  boxes that monitor and process data for groups of sensors.  One team of engineers mounted the vibration sensors to the sootblowers and confirmed communication back to a local junction box containing the National Instruments condition monitoring hardware.  The other team installed the junction box panels and terminated the sensor cables.

After all the sensor installations and terminations were completed, each sensor’s location and calibration were verified.  While the sensor verification was being completed, one engineer worked with the mill IT department and the controls engineer to establish remote connection to the system and confirm communication with the mill’s automated cleaning system.

After commissioning the system and returning to our home base, our engineers are now monitoring the system through a VPN connection and assisting boiler operators with optimizing their cleaning process.

For more information about our ryan.welker@iTestSystem.com or phone @ 1.844.837.8797 x702

industrial Monitoring Systems

FFFFFantastic ITM Team Building Weekend: Norris Lake, TN

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Floating Dock Norris Lake

Zach’s Ready to GO

RJ Shredding

RJ Wakeboarding

Ryan Catching Air

Todd Wakeboarding

Todd wih Blue Gill

Moonlight Fire

ITM held its an annual team building over the weekend of October 11th; fun, fish, food, fire, and firsts ensued.

I would like to thank ITM owner Tim Carlier and our host Ryan Welker for a fantastic weekend at Norris Lake, TN.  It was great to hang out and get to know our team outside of work.  Now let’s get to all those Fs.

Food, Fun & Firsts.  The weather was amazing on Friday (mid 70’s).  After everyone arrived and a lunch of grilled hamburgers, hotdogs, brats, and grilled sausages prepared by Ryan, we all went for a four (not three) hour boat tour of the lake.  On the tour, Ryan, Todd, RJ, and Zach all took turns wakeboarding.  It looked like some of the wipeouts hurt more than others.  Some of the boaders reported bruising and extreme soreness.  To alleviate their aching muscles, we pulled into a secluded cove and floated with life vests in the soothing 76 degree water.  While floating and storytelling, we learned a few things about each other, among them, that this was Zach’s first time boating and water skiing and that no one believes my stories.

More Food, Fishing & Fire. After returning to the dock and another Zach first, some of us tried our hand at fishing while Ryan again cooked for us.  Dinner was salad, grilled steak, baked beans and baked fresh blue gill.  After dinner, everyone (almost) headed down to the patio by the lake for drinks and relaxation around the fire ring.  I hear that it was a late night around the hot fire and that the team likes story telling.

More Fun, Fishing, Fire. Saturday, we woke to a brisk, breezy, and drizzly morning and Todd sleeping on the porch.  Ryan fixed us goetta, bacon, and eggs which were delicious.  While Ryan was cooking, I went trolling for fish in my fishing kayak equipped with a fish finder.  Apparently, fish like to stay as far away from my boat as possible.  The fish finder said they were at least fifty feet below my boat.  My excursion was abruptly cut short by a monsoon.  Luckily, I was only 50 ft from the dock, so I only had to empty one inch of water from my kayak.

As we waited for the fog to clear, some of the team decided to turn fishing into a competition.  Todd ended up winning the tournament because he caught a turtle and the rock that I caught didn’t count.  The teams fishing tally: 9 Blue Gills, 1 Channel Catfish, 1 Red Eared Slider (turtle), 1 pair of corroded $400 Ray Ban sunglasses, and a rock.

At three o’clock the dense fog that drifted in after the fishing tournament finally lifted and the remaining team went on a boat cruise to the big water of Norris Lake.  With the temperature in the upper 50’s this ride was a little different than the previous day.  It was the first time I wore flannel with my swim trunks.  RJ was the only one brave enough to wakeboard, because we convinced him that he would be warm while in the water.  From his face while he boarded and the goose bumps when he got back on the boat, I don’t think the warm water helped.

After the boat ride and another great dinner (slow cooked ribs) by chef Ryan, we all retired to the patio again for drinks, music, and more story telling.  The full moon, roaring fire, falling hickory nuts, and the iPhone 11 led to a picturesque evening.  RJ used all of the new features of the iPhone camera to make sure it was well documented.

I believe that our team building weekend was a huge success.  All of us got to work together in a completely different environment than usual and I believe that everyone can appreciate each others contribution to the team.

Notes: other weekend notes that didn’t start with F.

Tim’s pellet gun is loud and probably scared off a few fishermen.

Deerfield lives up to its name.  I saw at least 100 deer over the weekend.

Golfing in the fog at Deerfield is fun for everyone, except for the deer I almost killed with an errant low fairway wood shot that skidded under its legs.  Ryan said it jumped and looked confused.

Everyone wanted to get fruit and veggies on the way home after eating all that meat.

iTestSystem Tip: Sensor Auto-zero Utility Update

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Our iTestSystem customers who routinely acquire data with high channel counts and data from full-bridge transducers recently requested that we update the sensor auto-zero utility to improve test setup efficiency.   In the latest version of iTestSystem, we updated the sensor auto-zero utility to include all channels that use the From Custom Scale option.  This update enables users to quickly adjust selected channel offsets with only a few mouse clicks.

One of our test engineers recently used this feature to test and calibrate a new load cell design for measuring loads in a manufacturing process.  He was able to quickly calibrate and zero the strain gauges along with a calibrated load cell and a pressure transducer prior to testing and before each directional test. The offset values are included in the calibration data files for traceability.

Contact Information: For more information about this update or iTestSystem contact:

Chase Petzinger – Integrated Test & Measurement (ITM), LLC. Email: chase.petzinger@itestsystem.com or Phone: 1.844.TestSys

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Machine Failures Caused by Intermittent Damaging Events

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Over the years we have been tasked with identifying the root cause of machine structural failures. In many cases, we can determine the failure mode through strain and vibration testing, order analysis, modal analysis, and operating deflection shape analysis.  What tests can you run when the damaging conditions are intermittent and not easily identified?

In these cases, we like to install a cellular networked temporary data acquisition (DAQ) system that can autonomously log vibration and strain data along with machine status data. We have deployed two types of DAQ systems to collect data remotely.  An interactive system that includes an industrial PC running our iTestSystem software and National Instruments (NI) Compact DAQ hardware and a headless system that utilizes NI Compact RIO hardware.  Our test engineers prefer using the interactive solution for troubleshooting because they can view real-time signal waveforms and collected data files, and then adjust the test parameters accordingly without having to reprogram the hardware.

Rugged Measurement System

Figure 1: Headless networked data acquisition system

When potentially damaging events are identified in the vibration and strain data collected by these systems, it is important to know the machine’s operating status. Collecting the machine status information is just as important as collecting the structural data.  Many machines transmit these operating variables and operating stages over their network/bus.  Recently we have recorded process data from Allen Bradley Control Logix PLCs via Ethernet/IP, mining machine data from a Siemens controller via proprietary TCP/IP protocol, boiler condition data from a DCS via Modbus TCP,  machine pressures from PI historian via the UFL connector (TCP), and vehicle speeds and pressure via CAN.  Fortunately, we were able to use and adapt LabVIEW communication protocol tools to build applications and addons that allow this network tag data to be collected along with structural data.

LabVIEW Modbus to Shared Variable Code

Figure 2: Modbus to Shared Variable Tool

After the data collection phase, our engineers perform statistical analysis on the sensor and status channels in all data files and aggregate the results into a database for searchability. To identify the root cause probabilities, you can process the channel statistics data using your favorite correlation algorithm or application.  The image below shows an example data set containing related sensor data that was processed using a LabVIEW correlation test tool.

LabVIEW Correlation VI

Figure 3: Correlation Test Example vi

Contact Information: For more information about our remote data acquisition service, our LabVIEW development service, or iTestSystem contact:

Mark Yeager – Integrated Test & Measurement (ITM), LLC.  Email: mark.yeager@itestsystem.com or Phone: 1.844.TestSys

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Recent News:  Ohio University Asphalt Cracking Prediction System Project

ITM adds NI-9253 Compatibility to iTestSystem

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This week we added another module to the iTestSystem compatibility list.  One of our iTestSystem users recently needed to collect data from thirty-two (32), 4 to 20 mA current sensors along with their vibration measurements.  National Instruments (NI) recently introduced a new C-Series current module, the NI-9253, that was a perfect fit for this application.

The NI-9253 module has eight (8) simultaneous sampled (50kHz max), +-20 mA, 24-bit input channels.  It has several diagnostic features to ensure your system is operating nominally at all times with open channel detection, power supply detection, and configurable thresholds. The NI-9253 has eight LEDs that indicate the status of each channel and the power supply so a user can easily determine the system’s status in the field.  The NI-9253 also features a number of programmable hardware filters (Butterworth and comb) to reduce signal noise.

iTestSystem Info

in iTestSystem monitoring applications or with custom cRIO RT and FPGA control applications contact Mark Yeager or Chase Petzinger.

Strain Gauge Installations for Field Testing

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shaft torque sensor

Image1: Shaft torque strain gauge installation example for field testing

Our engineers and technicians have epoxied, soldered and spot welded strain gauges for applications ranging from high temperature exhaust systems to miniature load cell measurements. Every application requires a unique understanding of the strain measurement requirements including installation environment.

If the strain gauge installation is to survive in the field you must plan for the conditions it will undergo. Three important variables that you should account for are temperature range, liquid exposure, and potential impact forces. These variables determine the type of strain gauge, epoxy, solder, wiring, coating, and impact/wear protection to use in the application. The table below shows which variables affect your installation choices.

  Gauge Epoxy Solder Wiring Coating Covering
Temperature  
Liquid Exposure      
Impact Forces      

Table1: Strain gauge installation variables

For more information about ITM’s strain gauging services contact Ryan Welker at email: ryan.welker@itestsystem.com or phone: 1.844.837.8797 x702

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Roving Accelerometer Impact Tests with iTestSystem

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3D Animator: Bike Frame Twist Vibration Mode at 26.2 Hz

In order to prevent or troubleshoot structural vibration problems, it is important to characterize a structure’s dynamic behavior using both experimental and Finite Element Analysis (FEA) technologies.  One method used to identify a structure’s vibration modes is to perform a roving accelerometer or roving hammer impact test.  In an impact test, engineers measure the response of a structure from an impulse delivered by a calibrated hammer using tri-axial accelerometers.

FRF View: Bike Frame Point 9 Coherence & Magnitude

Managing impact tests on large structures can be tedious and cost prohibitive, since they require collecting accelerometer responses at hundreds of locations to resolve the vibration motion.  Not only do test engineers need to keep track of the locations, they also need to keep track of the orientation that an accelerometer is positioned.

Our test engineers have found that the most efficient and cost effective solution for collecting impact data is to use a National Instruments (NI) cDAQ chassis with either NI-9234, NI-9232, NI-9231 or NI-9230 IEPE modules along with a calibrated impulse hammer and between 3 – 9 tri-axial accelerometers. To collect, manage, and visualize the modal data, our LabVIEW software engineers developed the Impact Test DAQ, FRF Viewer, and 3D Animator applications for our iTestSystem software platform. These applications incorporate tools that our test engineers need to manage and validate the quality of their modal data while in the field.

For more information about impact tests, modal analysis, our iTestSystem Impact Test applications, or to schedule a modal test contact Mark Yeager or Ryan Welker.

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FieldDAQ Sound & Vibration Module compatibility added to iTestSystem

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The FieldDAQ™ FD-11634 sound and vibration input module from National Instruments (NI) can now be used with the latest version of iTestSystem for your data collection needs.  The FD-11634 is similar to the NI-9234, NI-9232, NI-9231, and NI-9230 cDAQ dynamic input modules and can be used with IEPE type sensors such as accelerometers and microphones.  Like the other FieldDAQ™ modules, this module is IP65/IP67 dust and water resistant with an operating temperature range of  -40 °C to 85 °C.  Our test engineers would use these modules for collecting vibration data on mining and construction equipment, vibration data on rotating machinery within manufacturing facilities and test cells, and acoustic data for measuring equipment noise emissions.  No matter your need, data logging with this equipment is sure to impress.

The FieldDAQ™ FD-11634 module has 8 simultaneous sampled, ±1V or ±10 V, 24-bit differential input channels with AC/DC coupling. It has a maximum sample rate of 102.4kS/s and features built in anti-aliasing filters that automatically adjust to the sampling rate.

For advice about using the FieldDAQ™ FD-11634 sound and vibration modules in iTestSystem monitoring applications or with custom cRIO RT and FPGA control applications contact Mark Yeager or Chase Petzinger.

Click Here to view a video showing one of our test engineer collecting data from a submerged FieldDAQ™ module with iTestSystem.

Click Here for more information about iTestSystem.

ITM @ VIATC 2019: Vibration Institute Annual Training Conference

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VIATC 2019 Logo

Come see us at the VIATC 2019 Exhibit Hall in Booth 33!

Ryan Welker and Mark Yeager (CAT III Vibration Analysts) will be there to answer questions about our iTestSystem engineering measurement platform, our on-site testing services, LabVIEW consulting, and strain gauging services.

When: July 24 & 25th

Where: The VIATC 2019 conference and exhibit hall will take place at the Lexington Center, connected by a joint lobby to the Hyatt Regency Lexington.

Lexington Center
430 West Vine Street
Lexington, KY 40507

ITM Provides Global Solutions

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ITM provides software development, structural and mechanical testing services, industrial monitoring, strain gauging, and data analysis solutions to clients on five continents.  ITM is located in Milford, OH, but our software and hardware packages are used throughout the world.  For the past 18 years ITM has traveled to where our specialized services are needed.  Whether it is performing tests at 16,500 ft in the Andes Mountains or on oil rigs in the Gulf Coast, installing strain gauges at extreme temperatures, or monitoring systems in the US or on the other side of the world, ITM understands the challenges of working in tough environments and will ensure your projects are successful whether home or abroad.

If you need tests performed or monitoring systems developed anywhere in the world, contact Ryan Welker (ryan.welker@itestsystem.com or 1.844.837.8797 x702).