PPL Power Stations Deploy Emerson Smart Wireless for Real‑Time Equipment Monitoring

Emerson Process Management’s Smart Wireless technology has proven "extremely cost‑effective and reliable" for PPL Generation, delivering continuous performance data from critical boiler feed pumps at Montour power station in Washingtonville, Pa., and from feedwater and air heaters at Brunner Island Unit 1 in York Haven, Pa.

"The additional information provided by the wireless instruments allows us to more effectively monitor the mechanical and thermal performance of these valuable assets," said Joe Murach, supervisor of equipment reliability.

Until now, key temperature and pressure measurements were unavailable for the software that analyzes thermal performance and sets preventive maintenance schedules. The high cost of installing wiring had been a major barrier. Wireless was the only viable solution to capture the needed data, Murach explained.

After an on‑site demonstration proved its ability to transmit reliably through the plant’s dense infrastructure, Emerson’s Smart Wireless was selected. Rosemount wireless transmitters now monitor suction pressure and differential pressure across the feedwater pumps’ suction screen, providing essential insight into their overall condition.

A mesh‑based Smart Wireless network at Brunner Island monitors feedwater heater and air preheating systems, with more than 25 transmitters strategically placed around the unit. These data points feed directly into the plant’s history and reliability monitoring software.

"The Emerson technology handles the power plant environment flawlessly," Murach added. "Transmitters communicate with the gateway across multiple floors and through walls. By eliminating the need for drilling through concrete, installing conduit, and pulling cables, we’ve achieved an easy, cost‑effective, and highly reliable wireless solution.

Each device in the network acts as a router, forwarding messages until they reach the Smart Wireless Gateway. When obstacles arise—temporary scaffolding, new equipment, or a parked construction trailer—the mesh automatically reroutes data, ensuring redundant paths and superior reliability compared to direct, line‑of‑sight links. This self‑organizing system optimizes data reliability while minimizing power consumption and setup effort.

Murach emphasized the operational benefits: "We can now monitor our feedwater pumps and thermal efficiency in real time, allowing us to optimize boiler performance and detect issues early. This proactive approach lets maintenance teams intervene at the optimal moment, preventing unexpected failures.

For more information, visit www.emersonprocess.com/smartwireless.

About PPL
PPL Corporation, headquartered in Allentown, Pa., controls more than 11,000 MW of generating capacity in the United States, sells energy in key U.S. markets, and delivers electricity to over 4 million customers in Pennsylvania and the United Kingdom.

About Emerson Process Management
Emerson Process Management, an Emerson business, leads in automation for the chemical, oil & gas, refining, pulp & paper, power, water & wastewater, mining, metals, food & beverage, pharmaceutical, and other industries. With brands such as PlantWeb, Fisher, Rosemount, Micro Motion, Daniel, DeltaV, Ovation, and AMS Suite, Emerson combines advanced technology with industry‑specific engineering, consulting, project management, and maintenance services.