The Challenge
Tata Power Ltd's thermal power generation facility required a significant upgrade to its existing valve actuation systems. The aging actuators were experiencing increased failure rates and maintenance costs, impacting overall plant availability. The upgrade needed to be executed in planned shutdown windows without extending outage durations.
The primary requirements were high-reliability actuators rated for elevated temperatures, seamless integration with the existing DCS infrastructure, and compliance with ISO safety standards.
Our Solution
Regal Controls' engineering team conducted a comprehensive site audit and designed a phased implementation strategy. We supplied pneumatic and electric actuators with digital positioners, custom-fabricated mounting hardware, and local control panels for critical isolation and control valves.
- Supplied pneumatic scotch yoke and rack-and-pinion actuators for various valve sizes.
- Integrated digital smart positioners with HART communication protocol.
- Fabricated local control panels with pneumatic logic for fail-safe operation.
- Provided on-site commissioning and calibration support during planned shutdowns.
The Results
The project was delivered on schedule within the planned outage window with zero safety incidents. The new actuator systems improved valve response times and eliminated the recurring failures that plagued the legacy equipment. Tata Power reported improved operational efficiency and reduced maintenance costs in the months following commissioning.
