Power Generation

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

Accelerometers for Rotating Machinery Vibration Measurements

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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. Ā 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 Type Typical Frequency Limit
Magnet 2,000 Hz
Adhesive 5,000 Hz
Stud 6,000 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.Ā  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 whatā€™s available.

Ā 
Manufacturer PCB Dytran BRƜEL & KJƆR Endevco Kistler
Model # 353B03 3055D1 4533-B 256HX -10 8702B500-M1
Sensitivity 10 mV/g 10 mV/g 9.8 mV/g 10 mV/g 10 mV/g
Frequency Range (Ā±5%) 1 to 7000 Hz (Ā±5%) 1 to 5000 Hz (Ā±10%) 0.2 ā€“ 12800 Hz (Ā±10%) 1 to 10000 Hz (Ā±5%) 1-10000 Hz
Temperature Range -65 to +250 Ā°F -67 to +250 Ā°F ā€“67 to +257 Ā°F -67ĖšF to +257ĖšF -67ĖšF to +257ĖšF
Height 0.88 in 0.64 in 0.54 in 0.55 in 0.67 in
Weight 0.38 oz 0.35 oz 0.3 oz 0.14 oz 0.32 oz
Housing Material Titanium Titanium Titanium Titanium Titanium
Electrical Connector 10-32 Coaxial (side) 10-32 Coaxial (side) 10ā€“32 Coaxial (side) 10ā€“32 Coaxial (top) 10ā€“32 Coaxial (side)
Mounting Thread 10-32 Female 10-32 Female 10-32 Female 10-32 Female 10-32 Female

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

Another Successful Condition Monitoring System Installation

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Last week our team successfully and safely installed another Boiler Monitoring System (BMS).Ā  This system, a Sootblower Fouling Detection (SFD) system, monitors structural and vibration sensors that quantify the boilerā€™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.Ā  Since the vibration measurement locations are relatively far apart, the SFD system requires a distributed monitoring system consisting of several junction Ā boxes that monitor and process data for groups of sensors.Ā  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.Ā  The other team installed the junction box panels and terminated the sensor cables.

After all the sensor installations and terminations were completed, each sensorā€™s location and calibration were verified.Ā  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 millā€™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

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.Ā  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. Ā 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.Ā  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 machineā€™s operating status. Collecting the machine status information is just as important as collecting the structural data.Ā  Many machines transmit these operating variables and operating stages over their network/bus.Ā  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,Ā  machine pressures from PI historian via the UFL connector (TCP), and vehicle speeds and pressure via CAN.Ā  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.Ā  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.Ā  Email: mark.yeager@itestsystem.com or Phone: 1.844.TestSys

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Recent News:Ā  Ohio University Asphalt Cracking Prediction System Project

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.

Ā  Gauge Epoxy Solder Wiring Coating Covering
Temperature Ā 
Liquid Exposure Ā  Ā  Ā 
Impact Forces Ā  Ā  Ā 

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 structureā€™s dynamic behavior using both experimental and Finite Element Analysis (FEA) technologies.Ā  OneĀ method usedĀ to identify a structure’s vibration modes is to perform a roving accelerometer or roving hammer impact test.Ā Ā In anĀ impact test,Ā engineers measure the response of a structureĀ from anĀ impulseĀ delivered byĀ 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 locationsĀ toĀ resolve the vibration motion.Ā  Not only do test engineers need to keep track of the locations, they also need to keep track of theĀ 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 aĀ 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 YeagerĀ orĀ Ryan Welker.

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Sootblower Fouling Detection (SFD) presented at BLRBAC Spring 2019

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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.Ā  SFD isĀ ITMā€™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 systemā€™s Key Performance Indicator (KPI) outputs for closed or open loop control, and the systemā€™s potential sootblower steam savings of 1-4% MCR.Ā  He also highlighted the safety and maintenance benefits that the system provides.

SFD Technical Presentation Handout Download

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,Ā  513.405.0181

Building a Modern User Interface in LabVIEW

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ļ»æWhen we develop LabVIEWā„¢ applications for our customers, a common request is for a simple, resizable and intuitive user interface (UI) for data visualization.Ā  In these cases, we use a tree control and a subpanel.Ā  This type of UI functions like a tab control that automatically resizes.Ā  The main benefit of using a subpanel is to make your code more modular.

Figure 1: Modern User Interface with a Tree and Sub Panel.

To illustrate the modularity that this type of UI creates, I made an example LabVIEWā„¢ project.Ā  The main VI shown above uses a tree control to switch between a VI containing a graph and a VI containing a table.Ā  I used our multi-queue event architecture for VI information communication messaging.Ā  The image below shows the main VIā€™s significant functions.

Figure 2: Main VI’s Block Diagram – Significant Functions

The main VIā€™s functions are listed below.

Functions

  1. Initialize queues and events and then generate initialize event.
  2. Initialize tree and add tree items.
  3. When a user selects an item in the tree, generate data and then send it to the subpanel VI.
  4. Receive SubPanel Ready event from a subpanel VI and then insert the VI into the subpanel.
  5. Destroy queues and unregister for events.

In this example the subpanel VIs are very simple.Ā  They populate an indicator (table or graph) and then generate a SubPanel Ready Event.Ā  The two (2) subpanel VIs and block diagrams are shown below.

Figure 3: SubPanel VIs: Graph.vi and Table.vi

Contact Information: For more information on this example or our LabVIEW development service contact:

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

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Boiler Monitoring Technologies at BLRBAC Spring 2019 Meeting

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Integrated Test & Measurement (ITM) is presenting its patented Sootblower Fouling Detection (SFD) technology at the Spring 2019 Black Liquor Recovery Boiler Advisory Committee (BLRBAC) meeting in Atlanta, GA on Wednesday, April 10, 2019.

ITMā€™s SFD system effectively offers the following benefits to boiler operations:

  • Optimizes sootblowing to reduce boiler fouling
  • Reduces sootblower steam consumption
  • Detects sootblower mechanical faults
  • Identifies dangerous conditions around packing leaks

Find out more about ITMā€™s Sootblower Fouling Detection (SFD) system and other Boiler Monitoring Solutions at https://itestsystem.com/solutions/industrial-monitoring-systems/

Conference details can be found at http://blrbac.org/meeting-registration

Have questions? Contact Tim Carlier @ Tim.Carlier@iTestSystem.com

Archiving CompactRIO Process Data to PI

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The tool we most commonly use for real-time embedded process monitoring and control applications is the NI CompactRIO.Ā  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.Ā  Most of the time, our customers also require usĀ  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.Ā  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.Ā  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

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ļ»æļ»æThe 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.Ā  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 shortenĀ 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. Ā Ā  Catastrophic thin-lipped burstsĀ  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. Ā SHOP assists operators in the management of boiler start-ups by enabling the detection of superheater tube clear events (TCEā€™s).

If youā€™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.