Table of Contents
One Series Transmitter: Introduction
Hydroelectric power plants rely on continuous and reliable lubrication systems to protect turbines, pumps, and other rotating equipment. Any interruption in lubrication oil flow can lead to equipment damage, unexpected downtime, and costly repairs.
One major utility provider in Colombia operating several hydroelectric power generation facilities faced recurring challenges with conventional mechanical pressure switches installed on their lubrication oil systems.
To improve reliability, reduce maintenance requirements, and simplify pressure monitoring, the operator selected the ONE Series Transmitter from United Electric Controls.
The results included improved visibility, simplified maintenance procedures, reduced inventory requirements, and more than 80% savings in maintenance time.
The Challenge
The hydroelectric facility used multiple mechanical pressure switches to monitor lubrication oil pressure on critical turbine systems.
Over time, the maintenance team experienced several operational challenges.
1. Difficult Process Verification
The existing mechanical pressure switches did not include a local display.
As a result, technicians could not easily verify the actual process pressure or determine whether the switch was operating correctly.
To check pressure values, maintenance personnel had to access remote gauges located in difficult-to-reach areas throughout the facility.
This increased inspection time and complicated troubleshooting activities.
2. High Maintenance Requirements
The installed pressure switches required regular calibration and verification to ensure accurate switching performance.
Each switch demanded approximately one hour of maintenance time during every maintenance cycle.
With multiple switches installed throughout the facility and at least two maintenance cycles annually, maintenance costs continued to increase.
The plant needed a solution that could reduce maintenance workloads while improving system reliability.
The Solution
The utility provider replaced 24 competitive mechanical pressure switches with the ONE Series Transmitter (1XTXSW) across several applications within the facility.
For the lubrication oil system application, the transmitter was programmed to monitor oil pressure continuously.
If lubrication pressure falls below 2.2 bar, the device automatically activates the backup lubrication system to maintain oil flow through the turbine equipment.
This ensures uninterrupted lubrication and protects critical rotating assets from damage.
Why the ONE Series Transmitter Was Selected
The customer selected the ONE Series Transmitter for several important reasons.
1. Large Backlit Display Improves Visibility
One of the biggest limitations of the previous mechanical switches was the inability to display process values.
Operators often struggled to determine whether a switch was functioning properly.
The ONE Series Transmitter solved this problem with its large integrated backlit display.
The display allows operators and maintenance personnel to instantly view real-time pressure readings, even in low-light environments commonly found in industrial facilities.
This significantly improves troubleshooting and operational confidence.
2. Significant Reduction in Maintenance Time
Traditional mechanical pressure switches often require periodic recalibration because switching points can drift over time.
The ONE Series Transmitter simplifies this process by allowing technicians to program setpoints and deadbands directly at the device.
Instead of performing frequent mechanical adjustments, technicians can quickly verify the displayed pressure value against nearby gauges and make any required adjustments electronically.
As a result, the customer achieved more than 80% reduction in maintenance time compared to the previous system.
3. Flexible Programming Simplifies Operations
The programmable architecture of the ONE Series Transmitter enables users to configure operating parameters directly in the field.
Operators can easily adjust:
- Alarm setpoints
- Shutdown setpoints
- Deadband settings
- Process monitoring parameters
This flexibility reduces commissioning time and simplifies future system modifications.
4. Embedded Diagnostics Improve Reliability
The ONE Series Transmitter includes built-in diagnostic capabilities that continuously monitor device performance.
These diagnostics help maintenance personnel quickly identify potential issues before they affect plant operations.
The result is improved reliability and reduced unexpected downtime.
5. Dual Relay Outputs Reduce Hardware Requirements
The integrated dual relay design provides significant cost and inventory advantages.
Instead of purchasing multiple pressure switches for different control functions, the operator can use:
- One relay for alarm notification
- One relay for emergency shutdown functions
This reduces the total number of switches required and cuts spare parts inventory requirements by nearly half.
Final Conclusion
This successful installation demonstrates how the ONE Series Transmitter can modernize legacy pressure monitoring systems while significantly reducing maintenance requirements.
By replacing conventional mechanical pressure switches with a smart, programmable solution, the hydroelectric facility improved visibility, increased reliability, and reduced maintenance workloads by more than 80%.
For power generation facilities seeking a smarter approach to pressure monitoring and lubrication system protection, the ONE Series Transmitter offers an efficient and proven solution.
Contact SWME for ONE Series Transmitter Solutions
SWME supplies United Electric Controls’ ONE Series Transmitter for power generation, oil & gas, water treatment, chemical processing, and industrial automation applications.
Our technical team can assist with product selection, application engineering, and system integration to ensure the right solution for your process requirements.
Contact SWME today to discuss your pressure monitoring and safety instrumentation needs.
