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OneWireless Enabled Performance Guarantee Test

Tata Power's power generation equipment OEMs (M/s BHEL) is required to provide all of the instrumentation and measurement devices for conducting performance guarantee and performance evaluation tests. M/s BHEL faced a number of specific challenges in conducting PG tests: employing high-accuracy digital communications for instrumentation, shortening setup and dismantling time, reducing hardware required, making portable instrument setup, avoiding temporary cabling work and the material waste costs

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  • SUPPLIER
  • Honeywell
    Honeywell invents and manufactures technologies to address some of the world’s toughest challenges initiated by revolutionary macrotrends in science, technology and society. They improves business performance for customers with automation and control solutions, equipment and services that enhance safety, reliability and efficiency. Year founded: 1906 Revenue: $40.3 billion (2014) NYSE: HON
  • INDUSTRIES
  • Energy
  • FUNCTIONS
  • Maintenance
  • CUSTOMER
  • Tata Power is India's second largest private power producer and is part of the Tata Group with more than 4,100 employees. The core business of the company is to generate, transmit and distribute electricity.

  • CONNECTIVITY PROTOCOLS
  • Modbus
    Other frequency
  • SOLUTION
  • Honeywell XYR 6000 wireless temperature, pressure and flow transmitters were installed at various process points to measure key process parameters. Multinodes were installed at vantage points within the power generation unit, and all data was made available for real-time visualization, trending/historization reports and data export to Microsoft Excel. The Experion platform was used for data logging, analysis and reporting to support the PG test procedure. Hardware Components - Honeywell XYR 6000 transmitter - MultiNode - WSG Software Components - Honeywell Experion platform

  • DATA COLLECTED
  • Fluid Flow Rates, Pressure, Process Parameters, Setup Time, Temperature
  • SOLUTION TYPE
  • SOLUTION MATURITY
  • Mature (technology has been on the market for > 5 years)
  • OPERATIONAL IMPACT
  • Impact #1
    [Efficiency Improvement - Maintenance]
    Real-time status reports enable maintenance personnel to remotely diagnose the status of a device which reduced CAPEX and OPEX required for conducting PG tests.
    Impact #2
    [Data Management - Data Accuracy]
    High-accuracy measurements from instruments with a digital communications capability by the solution.
    Impact #3
    [Efficiency Improvement - Time To Market]
    Programming time, production time, and installation time are shortened which reduced indirect costs.
  • QUANTITATIVE BENEFIT
  • Benefit #1

    Wireless technology would help save a total of $4.7M.

    Benefit #2

    The entire OneWireless infrastructure was installed and commissioned in just 2 days.

    Benefit #3

    Indirect cost caused by the end-customer can be reduced by 50% due to reduction in cycle time and increase in test efficiency.

  • USE CASES
  • Process Control & Optimization (PCO)
    Process Control and Optimization (PCO) is the discipline of adjusting a process to maintain or optimize a specified set of parameters without violating process constraints.The PCO market is being driven by rising demand for energy efficient production processes, safety and security concerns, and the development of IoT systems that can reliably predict process deviations.Fundamentally, there are three parameters that can be adjusted to affect optimal performance:- Equipment optimizationThe first step is to verify that the existing equipment is being used to its fullest advantage by examining operating data to identify equipment bottlenecks.- Operating proceduresOperating procedures may vary widely from person-to-person or from shift-to-shift. Automation of the plant can help significantly. But automation will be of no help if the operators take control and run the plant in manual.- Control optimizationIn a typical processing plant, such as a chemical plant or oil refinery, there are hundreds or even thousands of control loops. Each control loop is responsible for controlling one part of the process, such as maintaining a temperature, level, or flow. If the control loop is not properly designed and tuned, the process runs below its optimum. The process will be more expensive to operate, and equipment will wear out prematurely. For each control loop to run optimally, identification of sensor, valve, and tuning problems is important. It has been well documented that over 35% of control loops typically have problems. The process of continuously monitoring and optimizing the entire plant is sometimes called performance supervision.
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