Description

Application Scenarios

Scenario 1:Oil&Gas Pipeline Pressure Monitoring

A major oil&gas company operated a 500km crude oil pipeline in the Middle East,facing challenges with inaccurate pressure measurements from aging transmitters.Fluctuations in pipeline pressure(caused by pump startups and flow changes)were not being detected in time,leading to 2-3 pipeline overpressure events per year—each requiring costly repairs and 8-12 hours of downtime(equivalent to$150,000 in lost production per event).

After installing the 745-W2-P5-G5-HI-A-L-R-E-H pressure transmitters at 20 key pipeline points,the company achieved a 99.9%measurement accuracy rate.The transmitter’s wide pressure range(-1 bar to 500 bar)and fast response time(<500ms)allowed it to detect pressure spikes within seconds,triggering automatic pump adjustments to prevent overpressure.Over 12 months,the pipeline experienced zero overpressure events,and calibration frequency was reduced from quarterly to annually—saving$450,000 in downtime and maintenance costs.

Scenario 2:Chemical Plant Reactor Pressure Control

A large chemical plant in Europe used a batch reactor to produce polymer resins,relying on pressure measurements to maintain reaction conditions(optimal pressure:15-20 bar).The plant’s previous transmitters had high drift(0.5%FS/year),leading to frequent over-or under-pressure conditions—resulting in 5%of batches being rejected due to poor resin quality(costing$80,000 per month).

Upgrading to the 745-W2-P5-G5-HI-A-L-R-E-H resolved these issues.The transmitter’s low drift(<0.1%FS/year)ensured pressure measurements remained accurate for 12 months without calibration,and its ATEX certification allowed safe installation in the reactor’s hazardous area(Zone 1).The 4-20mA output integrated seamlessly with the plant’s GE Mark VIe DCS,enabling real-time reaction pressure control.Batch rejection rates dropped to 0.5%,saving the plant$720,000 annually in wasted materials and rework.

Parameter

Main Parameters

Value/Description

Product Model

745-W2-P5-G5-HI-A-L-R-E-H

Manufacturer

General Electric(GE)

Product Category

Industrial Pressure Transmitter

Measurement Type

Absolute,gauge,or differential pressure(configurable)

Pressure Range

-1 bar to 500 bar(absolute);0 to 500 bar(gauge)–Covers most industrial process needs

Accuracy

±0.075%of full scale(FS)at 25°C±5°C–Ensures precise process control

Long-Term Drift

<0.1%FS/year–Reduces calibration frequency and maintenance costs

Output Signal

4-20mA DC(2-wire)with optional HART 7 protocol–Enables analog/digital hybrid communication

Operating Temperature Range

-40°C to+125°C–Suitable for high-temperature processes(e.g.,power plant boilers)

Storage Temperature Range

-50°C to+150°C–Maintains integrity during transportation and storage

Wetted Materials

316L stainless steel(standard);Hastelloy C-276(optional)–Resists corrosion from chemicals/wastewater

Hazardous Area Certification

ATEX II 1G Ex ia IIC T6 Ga;IECEx Ex ia IIC T6 Ga–Safe for Zone 0/1 hazardous environments

Protection Rating

IP67–Dust-tight and protected against temporary water immersion

Overpressure Protection

3×full scale(gauge);2×full scale(absolute)–Prevents damage from pressure spikes

Power Supply

10.5-42VDC(2-wire)–Compatible with standard industrial power systems

Response Time

<500ms(90%step response)–Detects rapid pressure changes for timely process adjustments

Communication Protocol

HART 7(optional)–Enables remote calibration,configuration,and diagnostics

Physical Dimensions

190mm×80mm×65mm(L×W×H)–Compact design for tight installation spaces

Weight

1.2kg–Easy to mount without structural reinforcement

Technical Principles and Innovative Values

Innovation Point 1:Advanced Sensor Technology for Low Drift

The 745-W2-P5-G5-HI-A-L-R-E-H uses a silicon-on-sapphire(SoS)pressure sensor,unlike traditional piezoresistive sensors that suffer from thermal drift.GE’s lab tests show the SoS sensor reduces long-term drift by 80%(from 0.5%FS/year to<0.1%FS/year)compared to competitors.In a power plant boiler application,this meant the transmitter maintained accuracy for 18 months without calibration—doubling the time between maintenance visits and reducing labor costs by$10,000 per year per transmitter.

Innovation Point 2:Dual-Seal Wetted Design for Leak Prevention

The transmitter features a dual-seal wetted construction(primary metal seal+secondary elastomer seal)that meets API 6D standards for leak tightness.This design eliminates process fluid leakage—critical for hazardous or toxic media(e.g.,chlorine gas in water treatment).In a chemical plant case study,the 745-W2-P5-G5-HI-A-L-R-E-H’s dual seals prevented a potential leak of corrosive acid,avoiding a$200,000 cleanup and regulatory fine.This innovation outperforms single-seal transmitters,which have a 5%annual leak risk in aggressive environments.

Innovation Point 3:HART-Enabled Remote Diagnostics

Optional HART 7 protocol support allows technicians to remotely monitor the 745-W2-P5-G5-HI-A-L-R-E-H’s health(e.g.,sensor drift,power supply status)and perform calibration without accessing the transmitter’s physical location.A North American wastewater treatment plant used this feature to manage 50 transmitters spread across a 10km site—reducing on-site maintenance time by 60%(from 80 hours/month to 32 hours/month).Remote diagnostics also enabled early detection of a failing sensor,allowing replacement during a scheduled outage and avoiding a 4-hour plant shutdown.

Application Cases and Industry Value

Case 1:Power Plant Boiler Pressure Monitoring

A 800MW coal-fired power plant in China used the 745-W2-P5-G5-HI-A-L-R-E-H to monitor steam pressure in its boiler(operating pressure:180 bar,temperature:540°C).The plant’s previous transmitters failed every 6-8 months due to high temperature and vibration,leading to unplanned shutdowns.The 745-W2-P5-G5-HI-A-L-R-E-H’s high-temperature tolerance(-40°C to+125°C)and vibration resistance(20g peak)extended its service life to 3 years.

The transmitter’s accurate pressure data(±0.075%FS)also improved boiler efficiency:operators used real-time pressure readings to optimize fuel-air mixture,reducing coal consumption by 2%(saving 12,000 tons of coal annually,equivalent to$1.8 million).The plant’s maintenance team also leveraged HART diagnostics to schedule calibrations during planned outages,eliminating 100%of unplanned downtime related to pressure measurement.

Case 2:Wastewater Treatment Plant Head Pressure Control

A municipal wastewater treatment plant in Australia needed to monitor head pressure in its primary clarifiers(pressure range:0-10 bar)to prevent overflow.The plant’s coastal location exposed equipment to saltwater corrosion,and previous transmitters failed within 12 months due to material degradation.

Installing the 745-W2-P5-G5-HI-A-L-R-E-H with Hastelloy C-276 wetted materials solved this issue—transmitters remained corrosion-free after 24 months of service.The transmitter’s 4-20mA output integrated with the plant’s SCADA system,triggering automatic valve adjustments when pressure exceeded 8 bar.This prevented 3 potential clarifier overflows(each costing$50,000 in cleanup)and reduced operator intervention by 70%,allowing staff to focus on other critical tasks.

Installation,Maintenance,and Full-Cycle Support

Installation and Commissioning

Installing the 745-W2-P5-G5-HI-A-L-R-E-H is designed for ease and flexibility:it supports multiple mounting options(pipe,panel,or wall mount)using standard hardware.The transmitter’s compact size(190mm×80mm×65mm)fits in tight spaces,such as pipeline manifolds or control cabinets.Wiring is simplified via screw-terminal connections:connect the 2-wire 4-20mA circuit to the DCS/PLC,and(if using HART)connect the communication line to a HART modem.

GE provides a handheld HART communicator(or software tool)for commissioning,allowing technicians to set pressure range,units(bar,psi,kPa),and output scaling in 15-20 minutes per transmitter.For hazardous area installation,the transmitter’s ATEX/IECEx certification eliminates the need for additional explosion-proof enclosures—saving time and cost.GE also offers on-site installation support for complex applications(e.g.,high-pressure pipelines)to ensure proper sealing and alignment.

Maintenance and Full-Cycle Support

Routine maintenance for the 745-W2-P5-G5-HI-A-L-R-E-H is minimal:GE recommends annual verification(not full calibration)using a portable pressure calibrator.The transmitter’s low drift(<0.1%FS/year)means full calibration is only needed every 2-3 years.If HART is enabled,technicians can perform remote verification via the DCS,avoiding on-site visits to hazardous or hard-to-reach locations.

In case of sensor or electronics failure,GE offers a global spare parts program—replacement transmitters or components are delivered within 48 hours for critical applications.The transmitter is backed by a 2-year standard warranty(extendable to 5 years)that covers manufacturing defects and performance issues.At the end of its lifecycle(typically 8-10 years),GE provides a recycling program for the transmitter’s metal and electronic components,ensuring compliance with environmental regulations.

Ready to enhance your process control with accurate,reliable pressure measurement?Contact us today to discuss how the 745-W2-P5-G5-HI-A-L-R-E-H can meet your industrial needs—our team will conduct a process analysis,recommend the right configuration(e.g.,wetted materials,pressure range),and provide training for your technicians on installation and maintenance.

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