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Instrumentation and Controls
- Instruments
- Control system parts
- Repair and calibration
- Field services
- Obsolescence
UNEW Industries supplies, repairs and calibrates the instruments and control-system hardware of turbines, compressors and process plants — from the wheel-space thermocouple on a gas turbine to the transmitters, analyzers and control valves across the plant, and the controller cards behind them. Every make, every generation, including the ones no longer made.
Instrumentation is where a plant loses the most time for the least money: a tripped unit waiting for one card, one probe or one servo valve. We hold the record of what is installed, we hold the spare, and we put it in.
What We Do
| Line | Scope |
|---|---|
| Instrument supply | Turbine and compressor package instruments, process field instruments, on-line analyzers, control valves and positioners — new, and refurbished where the original is no longer made |
| Control system parts | Cards, I/O modules, terminal boards, power supplies and HMI hardware for turbine control, vibration monitoring, DCS, PLC and safety systems — new, refurbished and functionally tested |
| Repair and calibration | Card and instrument repair on functional test benches; calibration with certificates traceable to national standards; exchange program for critical items |
| Field services | Loop checks, calibration and commissioning at outages; control system health audits; fault resolution and tuning; migration and upgrade support |
| Obsolescence and reverse engineering | Form-fit-function replacements for discontinued sensors, probes and cards, engineered from a sample |
Turbine and Compressor Package Instrumentation
The instruments inside the turbine and compressor package are the hardest for a plant to source and the first to stop the unit. We supply them for gas turbines, steam turbines, generators and compressor trains of every make.
| Measurement | Instruments |
|---|---|
| Temperature | Wheel-space, exhaust and combustion thermocouples; bearing metal and drain RTDs; compressor discharge and inlet thermocouples; thermowells and extension cables |
| Position | LVDTs on fuel gas, fuel oil and IGV actuators; limit switches; valve position feedback |
| Speed | Magnetic and passive speed pickups; toothed wheels; overspeed sensors |
| Flame and ignition | UV and IR flame detectors; spark plugs and igniters; ignition transformers and leads |
| Vibration | Proximity probes, extension cables and proximitors; accelerometers and seismic velocity sensors; keyphasor probes |
| Pressure | Pressure and differential-pressure transmitters and switches on fuel, lube oil, seal oil, hydraulic, cooling air and inlet filter systems |
| Actuation | Servo valves; hydraulic and pneumatic actuators; solenoid valves; fuel and IGV control valve components |
| Protection | Gas and hazardous-atmosphere detectors; fire detection in the enclosure; trip and reset solenoids |
Process Instrumentation
Plant-wide field instruments for refineries, petrochemical and fertilizer plants, gas processing and power generation.
| Category | Instruments |
|---|---|
| Pressure | Gauge, absolute and differential pressure transmitters; remote seal and diaphragm seal systems; pressure gauges and switches |
| Temperature | Thermocouples, RTDs, thermowells, temperature transmitters, multipoint assemblies for reactors and furnaces |
| Flow | Coriolis, electromagnetic, vortex, ultrasonic and differential-pressure flowmeters; orifice plates and flow elements |
| Level | Guided-wave and non-contact radar, displacer, magnetic level gauges, ultrasonic and hydrostatic level |
| Control valves | Control valves, actuators, positioners, I/P converters and solenoid valves — supply and repair |
| Wireless and networks | WirelessHART and ISA100 instruments and gateways; HART, Foundation Fieldbus and Profibus devices |
Instruments are supplied to replace or interchange with Emerson / Rosemount, Yokogawa, Honeywell, ABB, Endress+Hauser, Siemens, Fisher, Masoneilan, Samson and all other makes.
On-Line Analyzers
| Application | Analyzers |
|---|---|
| Steam and water | Silica, sodium, pH, conductivity and dissolved oxygen analyzers for boiler feed water, condensate and steam sampling panels |
| Process gas | Oxygen, moisture, H₂S, CO and CO₂ analyzers; gas chromatographs; sample conditioning systems |
| Emissions | Continuous emissions monitoring — NOx, SO₂, CO, O₂ and opacity |
| Combustion and fuel | Fuel gas calorimeters and Wobbe index analyzers; flue gas oxygen |
Analyzers are supplied complete with sample panels, and serviced on site: sensor and electrode replacement, reagent and calibration gas supply, sample system cleaning and calibration.
Control and Protection Systems
| System | Hardware supplied |
|---|---|
| Turbine control | GE Speedtronic Mark IV, Mark V, Mark VI and Mark VIe; Siemens TXP and SPPA-T3000; Woodward MicroNet, 505 and Atlas; ABB — controller cards, I/O packs, terminal boards, power supplies, HMI and network hardware |
| Vibration and condition monitoring | Bently Nevada 3300 and 3500 monitors, racks, power supplies and relay modules; Metrix and other monitoring systems |
| DCS and PLC | Honeywell, Yokogawa, ABB, Emerson, Siemens and Allen-Bradley controllers, I/O modules, communication and power modules |
| Safety and fire and gas | Safety instrumented system logic solvers and I/O; fire and gas panels and field devices |
| Generator and electrical | Excitation, protection relay and synchronizing hardware in support of the turbine outage |
As part of our control system services we record every card in the unit — part number, revision, serial number and firmware — so the correct spare is identified before it is needed. Cards are supplied new, or refurbished and functionally tested with burn-in, and critical cards are held on an exchange program.
Repair and Calibration
| Service | Scope |
|---|---|
| Card repair | Component-level repair of controller, I/O, power supply and communication cards; functional test on a bench with burn-in; firmware verification |
| Instrument repair | Transmitters, positioners, flame detectors, proximitors, servo valves and actuators repaired and tested |
| Calibration | Pressure, temperature, flow, level, vibration and speed instruments calibrated against reference standards, with certificates traceable to national standards |
| Servo valve service | Cleaning, filter and seal replacement, null adjustment and flow test of turbine servo valves |
| Exchange program | Refurbished, tested cards and instruments from UNEW inventory delivered against the return of the failed item |
Field Services
| Service | Scope |
|---|---|
| Outage instrumentation | Removal, calibration, reinstallation and loop check of package instruments at combustion, hot gas path and major inspections |
| Control system health audit | Hardware record, I/O, software and configuration, HMI and network, alarms and protection, spares — with a written report and a stocking plan |
| Fault resolution and tuning | Control faults, spurious trips, instrumentation faults; combustion and load control tuning |
| Commissioning | Loop checks, functional tests and trip tests on new installations, upgrades and relocated units |
| Migration and upgrade support | Engineering and site support for control system migrations, including the instrument and I/O changes that come with them |
Obsolescence and Reverse Engineering
Every control system reaches the point where the maker no longer supports it, and every turbine has sensors that are no longer listed. We keep those units running.
| Step | Scope |
|---|---|
| Installed-base review | Record of every instrument and card in the unit against the maker's current support status; identification of the items at risk |
| Sourcing | New-old-stock, refurbished and tested units for discontinued parts, from UNEW inventory and our network |
| Reverse engineering | Form-fit-function replacements for discontinued sensors, probes, cables, connectors and simple cards, engineered from a sample — dimensions, materials, electrical characteristics and calibration curve — and manufactured under a UNEW part number |
| Stocking plan | A spares set held for the unit, sized to the risk, under a service agreement |
From the first order onward the part is manufactured to UNEW data, and repeat orders and repairs are made to the same data. The plant is no longer dependent on the maker's support life for its own operating life.