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Turbine Controls Limited GAS TURBINE CONTROL SYSTEMS Pre-developed control systems for gas turbines Standardised control systems for gas turbines. Low cost and faster installation. GAS TURBINE CONTROL SYSTEMS

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Page 1: GAS TURBINE CONTROL SYSTEMS - tcluk.net · Gas turbine control systems Standard control systems developed for gas turbines +LZPNULK ... The TCL SMARTStart system for gas turbine DC

Turbine Controls Limited

GAS TURBINE CONTROL SYSTEMSPre-developed control systems for gas turbinesStandardised control systems for gas turbines.

Low cost and faster installation.

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Page 2: GAS TURBINE CONTROL SYSTEMS - tcluk.net · Gas turbine control systems Standard control systems developed for gas turbines +LZPNULK ... The TCL SMARTStart system for gas turbine DC

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Gas turbine control systemsStandard control systems developed for gas turbines

Designed to replace the existing control panel suite with all control and protection functions:

• PLC controller, simplex, duty/standby or TMR hardware configuration. Programmed with: - Fuel governor control - Start up sequence control - Alarm and trip protection - Temperature/pressure monitoring

• HMI hardwired and PC based• AVR for generating sets• Generator protection

• Compressor surge control

Systems designed to interface seamlessly with the retained plant enabling:

• Step change in reliability• Enhanced functionality• Vastly improved diagnostics• Improved maintainability

Our team of design engineers use the latest software and design techniques to produce an integrated system that will:

• Minimise the system cost• Reduce the outage time for installation• Produce a payback period based in months rather than years

System design

Any non-standard I/O can be included using spare modules and channels which have been pre-wired. This allows other plant devices to be included without costly system re-design.

Control and protection functions include:

• PLC controller programmed with the following functionality: - Fuel governor control - Start up sequence control - Alarm and trip protection - Temperature/pressure monitoring

• HMI hardwired and PC based• AVR for generating sets• Generator protection or compressor surge control,

depending upon drive application

The PLC program also includes the TCL phase matching synchronising software, which greatly reduces synchronising time and hence start-up costs.

The supply can include the TCL EGV gas fuel valve or Posiflow liquid fuel system. Alternatively the controls can interface with the existing fuel valves.

The pre-developed system provides a cost effective solution without the cost associated with a one-off design.

GE Frame 3 and 5

TCL have developed a standard control system for the GE Frame 3 and 5 engines. The system includes the necessary inputs and outputs to interface with any Frame 3 or 5 standard plant devices.

Duplex or triplex mode systems available for increased system integrity.

Ruston TA/TB/TD/Typhoon and TornadoTCL have developed a standard control system for the Ruston gas turbines in the range 1MW to 6MW. The system includes the necessary inputs and outputs to interface with standard plant devices.

In the case of the TA range all hydraulic control devices are removed and their functions programmed into the PLC. This greatly improves reliability and aids fault finding.

GE Frame 5 control panel

TA control panel

Turbine Controls Limited52, Kenilworth Drive T +44 (0)116 271 7248

Oadby, Leicester F +44 (0)116 271 7250

LE2 5LG UK [email protected]

Or visit us at www.tcluk.net

Page 3: GAS TURBINE CONTROL SYSTEMS - tcluk.net · Gas turbine control systems Standard control systems developed for gas turbines +LZPNULK ... The TCL SMARTStart system for gas turbine DC

Turbine Controls Limited

SMARTStart Gas Turbine Soft Start System

Digitally controlled gas turbine starter system to provide soft

start to DC powered starter motors

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SMARTStart Gas Turbine Starter

The TCL SMARTStart system for gas turbine DC starter motors is

designed to address the issue of aging starter systems which rely

on electro-mechanical timers and DC contactors.

Over time and continued operation these electrical devices

become unreliable causing:

• Increased start fails

• Reduced component life

• Increased down time as spares are difficult to source; particularly

those requiring 120V.dc operating voltages

Functions

The SMARTStart system includes an integrated micro-controller

to provide:

• Programmable current profile during start up

• System diagnostics, to detect starter motor faults

• Interface with the existing control system

• via hardwired inputs & outputs

• Serial communications interface, via Ethernet

System Design

In a traditional DC starter electro-mechanical contactors control

the motor speed by switching resistors in and out. This causes

high current peaks and mechanical stress during the start cycle.

The TCL SMARTStart system uses solid state components to

control the current through the starter motor and provide a more

progressive increase in the current). This soft start greatly reduces

the stresses on the starter motor, increasing life and reliability.

To provide an operator interface with the equipment a HMI is

mounted on the front panel, providing the following features:

• Monitoring of system parameters

• Adjustment of set-points, ramp rates, etc.

• Graphical indication of motor current

• Real time trending of motor current

• Status of digital and analogue signals

• Alarm indication

• Viewing of PID loop

The SMARTStart system provides a reliable and cost effective

solution for gas turbine DC starter systems, increasing starter

motor life and improving system reliability.

Pulse Width Modulated Start Cycle

Installation

The SMARTStart system is assembled in a cubicle sized

1,200x800 and is designed to occupy a smaller footprint than

the existing starter controls. The cubicle includes termination

points for all field cables and can be installed in a floor or wall

mounted position.

Digital Inputs & Outputs

Pre-programmed

Digital Inputs Digital Outputs

Start Remote Enable

Stop Remote Charge By Pass

Start Permissive Ready

Start Local Ignition Permissive

Stop Local Fire Permissive

Remote Selected Tripped

Local Selected

Emergency Stop

Reset

16 inputs & outputs for user configuration

Quality Control

TCL have the following quality control accreditations

• ISO 9001:2008

• ISO 14001:2004

• BS OHSAS 18001:2007

• CSA Z299.2-85 Quality control developed for CANDU

nuclear plant

The system software is produced using rigorous quality control

procedures developed during TCL’s experience with developing

software for nuclear power plants.

Specification

Operating temperature -20oC to 70oC

Storage temperature -40oC to 85oC

Heat dissipation 3.1kW max

Weight 7.7kg

Shock operating 30g

Shock not operating 50g

Turbine Controls Limited

52, Kenilworth Drive T +44 (0)116 271 7248 Oadby, Leicester F +44 (0)116 271 7250 LE2 5LG UK [email protected]

Or visit us at www.tcluk.net

Page 5: GAS TURBINE CONTROL SYSTEMS - tcluk.net · Gas turbine control systems Standard control systems developed for gas turbines +LZPNULK ... The TCL SMARTStart system for gas turbine DC

Turbine Controls Limited

Electrical Panel ManufactureDesign, manufacture, test and installation of electrical control panels

High quality electrical control panel manufacture

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Testing is carried out against the design specifications and will typically include:• Hardware wiring tests• Specific component tests• System functional tests• Software functional tests (if applicable).

More specialised tests have been carried out to clients specific requirements, such as:• Environmental test, e.g. temperature, humidity• EMC and RF testing.

Site Installation and Commissioning

TCL have an experienced team of site technicians and engineers who are available to install and commission the completed control panels. This includes LV, MV and HV control panels.

After Sales

TCL have a dedicated customer support department to provide an after sales support of all installed system. This team is available to carry out:• Telephone support• 24/7 Call out and fault finding• Planned maintenance routines.

Quality Control

TCL have the following quality control accreditations:• ISO 9001:2008, Quality management• ISO 14001:2004, Environmental management• BS CHAS 18001:2007, Health and safety management.

Electrical Panel ManufactureDesign, manufacture, test and installation of electrical control panels

Turbine Controls Limited South Africa

36 Ross Street T +27 18 294 4882 Potchefstroom F +27 86 670 8683

2520 South Africa [email protected]

Or visit us at www.tclsa.co.za

Turbine Controls Limited

52, Kenilworth Drive T +44 (0)116 271 7248 Oadby, Leicester F +44 (0)116 271 7250 LE2 5LG UK [email protected]

Or visit us at www.tcluk.net

Building on over 29 years’ of control system design and manufacturing experience TCL now offer the design and manufacture of bespoke panels for numerous control system applications to customer specifications. We offer a flexible service to suit customer requirements and can include one or more of the following services:• Control panel design by our team of experienced engineers• Sourcing of panel equipment or integration of client

supplied equipment• Manufacture of the panels to a TCL or client design in

our workshop• Testing of the panels in our fully equipped workshop.

The service builds on the design experience of our engineering team in the design of control equipment for many varied applications including hazardous and non-hazardous environments. Typical applications include:• Process control and monitoring• Fire & gas protection

• LV & MV switchgear.

Design

The design is carried out by experienced electrical engineers. We are flexible in our approach allowing the client to determine the level of design input required from TCL. So the scope of the design can vary from a system layout based on the customer’s specification to a full design from scratch, including a site survey. The deliverables could therefore include:• A site survey at the customers facility• Production of a design specification• General arrangement drawings• Panel cut-out dimensional drawings• Parts lists (BOM).

Drawings are usually produced in AutoCAD format but other formats are available on request.

Manufacture and Test

Systems are manufactured at the TCL works by our skilled technicians. All work is controlled by procedures within our ISO 9001 quality control manual.Components can be supplied by TCL or ‘free issued’ by the client. TCL have a comprehensive supplier network which enables us to procure components at very competitive prices.

Control panel manufacture in our workshops

Single bay process control panel front and rear