Insights & Resources

Remote Monitoring of Solar Photovoltaic (PV) Plant

Scope:

The customer wanted to introduce a scalable, secure, customizable, and cost-effective remote monitoring solution, and also to develop a platform that can monitor, manage and forecast power generation to help meet supply commitments to Utilities.

Solution:

• Customized EAGLE Framework – Solution accelerator for local and remote monitoring
• Build Solar Photovoltaic (PV) specific computation engine
• Integrate 1 PLC and 2 Modbus gateways that collects data from field devices (~2000 IO points)
• Integrate systems specific to PV like weather stations, pyranometer, etc.
• Integrate third-party AC and DC side equipment like invertors and transformers.
• Implement automated as well as manual control features for periphery lightings and exhaust fans
• Implement remote monitoring of the plant from customer headquarters

Results:

• Highly modular, scalable and customizable platform for remote visualization and control
• Built-in capabilities like geospatial information, remote data acquisition, reporting and  highly customizable user interface
• Uses industry standard technologies like OPC UA for secure and reliable data transfer over the internet
• Supports a wide range of industrial protocols
• Offers powerful and intuitive user interface building capabilities with scripting support

Japanese OEM saves 6,000 Man-Months

Scope:

A Japanese multinational OEM formed a long-term partnership with QuEST to design and develop a customized distributed control system. The next-generation system runs on client-server architecture and integrates with database systems, mobile apps, and cloud apps.

Solution:

• Ideation, design, development, and testing
• Deployment support
• Product sustenance and enhancement
• Migration and porting
• Cloud and mobility enhancements

Results:

• OEM has deployed QuEST’s distributed control system for more than 100 thermal power plants across the globe
• OEM saved 6,000 months of engineering resource time, which generated significant savings

Leading wind turbine OEM saves $11 Mn with Managed Services

Scope:  

Identify opportunities to reduce component and development process costs for one of the world’s leading wind turbine OEMs. Evaluate processes for conceptual or detail design, design evaluation and verification, sourcing negotiations, and best-cost country selection.

Solution:

• Provided multi-faceted, cross-functional team, including wind turbine experts
• Recommended cost-savings across the product development lifecycle
• Ensured designs with cost saving measures, met performance requirements
• Identified redundancies to be eliminated in materials, processes, labor, inspection, packaging, and logistics
• Explored best-cost country manufacturers and suppliers to reduce costs

Results:

• $11 million savings in product development cost, realized through design changes and best-cost country sourcing
• Streamlined solution implementation, reducing drag on internal resources

Leading Power equipment manufacturer reduces unplanned expenditure by 25%

 Scope:

A leading Power manufacturer wanted to increase the availability of turbines through mechanisms that can avoid damage and hence reduce unplanned expenditure. They partnered with QuEST to develop a tool that can also make the data spread across multiple silos, help in rapid data mining, and give a consolidated view to monitor performances.

Approach:

• Review of performance and alarm data from different power plants
• Develop algorithm to monitor performance parameters
• Implement fuzzy and statistical methodologies combined with data mining techniques to predict failure
• Display the output in various user-friendly formats

Result:
Technical

• Reduced labour-intensive data mining effort by integrating data from multiple databases
• Low-cost/rapid software development process
• Packaging tool for easy-to-use application

Business

• Timely and accurate assessment of gas turbine component health during operation avoids damage
• Increased availability by 30%
• Reduced unplanned expenditure by 25%

US OEM cuts BTU Costs by 50% with Propane Fuel System Design

Scope:

US-based OEM partnered with QuEST to develop a fuel system to support burning liquefied propane and heavy gas fuel during start-up, runtime and shut-down.

Approach:

• QuEST designed the gas system based on flow parameters and component selection with fuel variants.
• Key components include heat-tracing and blanketing systems to maintain fuel temperature and a compressor discharge pressure (CDP) bleed-piping system.
• QuEST also developed field modification instructions and a mechanical design package that includes CAD models, engineering drawings, material data, interface details, and vendor part specifications.
• To ensure system performance, QuEST conducted pipe stress analysis and computational fluid dynamics (CFD) flow analysis and confirmed that the system adheres to Power industry regulations.

Results:

• 50% reduction in cost per BTU
• Avoids overspend shutdowns
• Accommodates unit design variations and allows for retrofitting

US Museum reduces Gas and Electricity Consumption by 15%

Scope:

Reduce energy use for a major US museum by implementing an energy efficient temperature and humidity control solution integrated with the museum’s HVAC system.

Approach:

Optimized energy consumption by leveraging an IoT network to access 1.3TB of historical data. Applied Machine Learning algorithms to predict optimal set points for dehumidification, reheating and re-humidification.

Results:

• 15% reduction in electricity and gas consumption
• Savings from lower usage of natural gas was $70,000 per year
• Savings from lower consumption of electricity was $280,000 per year

End-to-End Aftermarket Capabilities

QuEST offers a wide range of fully managed aftermarket services supported by a dedicated CoE for each customer. Our unique combination of local-global resources provides the expertise Power companies need to execute aftermarket services efficiently, and to keep power systems operating at optimum capacity.

Our services include: Modifications and Upgrades, Outage and Repair Tool Engineering, Product Fleet Data Management, Repair Engineering, Nonconformance Engineering, Technical Publication Services, Spares and Service Part Management, Remote Monitoring and Diagnostics

Accelerated and Cost-effective Execution of Control System Engineering for New and Retrofit Projects

QuEST provides a range of control systems engineering services that span hardware engineering, software engineering, testing, and commissioning support to help OEMs, Utility companies, and EPCs to design and deploy new control systems and retrofit existing systems. Our services help Power companies to complete projects cost-effectively and provide global support in the Power market to meet the increasing demand for traditional and renewable forms of energy.

Our services include: System Configuration and I/O Engineering, Control Logic Implementation, HMI and SCADA Configuration, System Testing and Commissioning

Accelerated and Cost-Effective Digital Grid Transformations

QuEST’s digital grid solutions accelerate the deployment of new smart grids and enable Power companies to quickly modernize existing grids with minimum downtime, comply with industry standards, and also defend against cyber attacks.

Our services include: Remote Monitoring, IT-OT Systems Integration, Distributed Energy Resource Management System (DERMS), Demand Response Programs and Automated Smart Meter Infrastructure

Automate and Optimize Power Network Generation, Transmission, Distribution and Consumption

QuEST’s digital transformation solutions enhance the real-time capabilities of a wide range of Power company processes:

• Asset planning and performance management
• Operations and field support
• Energy aggregation, management and storage integration platforms
• Supply and demand platforms
• Network controls
• Connected and interoperable devices
• Digital customer models
• Smart sensors for homes, cars, cities, and wearables.

Our services include:  Artificial Intelligence, Enterprise Applications, Internet of Things (IoT), Virtual Reality/Augmented Reality, Robotics R&D and Security.

Actionable Insights to drive Digital Transformation of Power-system Engineering Processes

For OEMs and Utilities that need to optimize power generation, transmission, distribution, and consumption, QuEST provides the expertise to mine and analyze data from disparate systems. We leverage technology to cleanse and process data, and then produce data models to analyze the data and generate predictive analytic reports. With this information, Power companies can effectively analyze operational data in real-time to improve process efficiencies as well as system reliability and availability.

Our services include: Prognostics and Diagnostics, Energy Management and Power Utilization, Transmission and Distribution (System Reliability and Consumption Analytics) and Data Analytics for Actionable Insights

Modernize Engineering Processes to Accelerate System Delivery and Repairs While Lowering Production Costs

QuEST’s Manufacturing Engineering solutions feature quick turnaround times and detailed processes based on approved Power industry standards. We have built clear documentation on how to apply process improvements, so power companies can improve margins by optimizing manufacturing costs and enhancing product quality.

Our services include: Parts Production Engineering, Supply Chain Management, Aftermarket Support, Manufacturing Process and Inspection Optimization, and Technology Transformation.

Monitor and Control Development Lifecycles to Avoid Budget Overruns and Achieve Cost Targets

Leveraging our expertise in the leading product cost management application platforms, QuEST provides solutions for power generation, transmission, and distribution systems using a proactive approach that helps avoid cost overruns.

Our services include: Should-cost Analysis, Yield Optimization, Value Engineering, Product Teardown Analysis, Lean Manufacturing, and Target Costing

The Expertise to Support Unique OEM Workflows and Drive Products to Market Faster

QuEST provides mechanical design and simulation to support a wide range of power generation systems: gas turbines, steam turbines, generators, internal turbines, skids, enclosures and structures, as well as renewable energy systems for onshore and offshore wind power generation.

Our services include: New Product Development, Sustenance Engineering, Product Fulfilment, Product Cost-Out, Configuration and Engineering Change Management, and Piping Engineering Support

Drive New Product Development and Sustain Existing Systems

QuEST offers a wide range of software and electronic engineering services that help to drive new system design and development, and to enhance and sustain the lifecycle of existing systems. For every solution we deliver, we apply an extensive verification and validation process to ensure best performance.

Our software engineering services include: New Product Initiatives, Legacy Product Enhancement and Sustenance, Testing and Test Automation, Continuous Integration and DevOps.

Our electronics engineering services include: New Product Initiatives, Legacy Product Re-engineering and Obsolescence Management, Validation and Verification, and Certification Support Services

Software Engineering

• Since 2004, 500+ Man-years
• Development & Sustenance of NMS, DMS suites
• Real-time data (PMU) based situation awareness
• Next generation product development

Mechanical Engineering

• Transformers, Switchgears, Protection Relays, Power Electronics, Drives and Motors
• DAQ (RTU,BCU)

Embedded Systems

DAQ, IEDs, Protocols

Software Engineering

• Since 2007, 300+ man-years
• SAS development & sustenance
• Testing, Test automation and release management
• IEC61850 Expertise
• Engineering Tools & Frameworks
• Cyber Security

Embedded Systems

IEDs, Protocols

Remote Monitoring

DER integration & VPP

Collaborative DR

Embedded Systems

Smart meter design, firmware and protocols

Mechanical Engineering Services

• Since 1997, 1000+ Man-years
• Thermal/Fossil (GT, ST, Boiler, GN, BoP)
• Renewables (Wind, Solar, Hydro)
• Distributed Power – Aero derivative products

Software Engineering

• Since 1995, 500+ Man-years
• Monitoring & Control Solutions (DCS, SCADA) and Remote Monitoring

Embedded Systems

• RTUs, IO Cards, Protocols

System Engineering

• I&C detailed engg, control loops, wiring, components, control panel layouts
• System integration and testing, FAT, SAT