Upgrading obsolete control systems is a cost-effective way to improve the operation and reliability of a gas turbine. ICS provides a range of gas turbine controls specifically designed as a modern retrofit replacement for the Analog and Electro-Hydraulic control systems on all models of gas turbines. ICS gas turbine controls utilize our field proven TC3 digital control system for Turbine and integrated Turbine-Generator/Compressor control, protection and sequential functions.                                                                                                                                          

The TC3, and it’s predecessor TC2000PLUS have been applied on most models of gas turbines ranging from 2MW to 100+MW, industrial and Aero-derivative units.

The TC3 overcomes the limitations of Analog and Electro-Hydraulic governor and sequencing equipment, while also implementing gas turbine control philosophies and operational enhancements. The system provides high availability and reliability, while digital electronics provide exact and permanent calibration.

In addition to application specific TC3 configuration, most retrofit projects include a full installation engineering package, and may also include fuel system and instrumentation upgrades and driven equipment control upgrades. Each application is fully factory tested in the customer controller as a totally prefabricated and tested unit before shipment.

TC3 Gas Turbine Control Functions - TC3 Gas Turbine Control Application
The TC3 automates all aspects of the turbine control, protection, start-up, and shutdown sequences. It interfaces directly to existing instruments, or to new devices supplied by ICS as part of a fuel system or instrumentation upgrade;

The TC3 control software is built from a library of proven Functional Control Algorithm modules. This allows ICS to use standard governor code, ensure a high standard, proven software, and reduced commissioning time. Common Functional Control Algorithms for gas turbine controls include;

The TC3 is very flexible and it allows for a high degree of customization, as required to incorporate project specific unit or customer needs, and features not possible with black box controllers.

Integrated Compressor Controls
For compressor drive applications ICS offers a non-proprietary train solution with significant cost savings when compared to traditional ‘black-box’ approaches. Anti-surge control, compressor control, and process control functions are all tightly integrated with the turbine control in a single high-performance open-architecture controller.

Integrated Generator Controls
For generator drive turbines, ICS provides generator controls, AVR and static excitation systems, and generator protection modules as part of the same package. The application of modern digital devices provides exact control while serial communication to the turbine controller provides a common database with full status and trending of all systems on a common reporting database to deliver seamless control and protection in a clean upgrade package.

Control Upgrade Benefits

• Reduces costly shutdowns & avoids forced outages - Increased reliability/availability means less downtime. Comprehensive data logging and diagnostics of machinery variables for troubleshooting and analysis simplify preventative maintenance
• Improved performance - Auto start-up/synchronization, better speed/load control and AGC responsiveness, with additional control schemes for plant efficiency improvements
• Easier Maintenance - Features like auto testing of valve/trip systems facilitate maintenance
• Additional Protection - Automatic soft start-up and shutdown sequences reduce thermal and dynamic stresses on thermal stress on blades and combustion parts. Monitoring of turbine devices and new instrumentation adds protection
• Plant Control Integration – TC3 communication to DCS/RTU/IEC devices using industry standard protocols
• Optimizes output – By removing operation limitations due to control problems, the TC3 provides precise digital control of the turbine in all operating modes and can allow more efficient operation of the turbine/plant
• Reduced training and spare parts costs - The system is easy to use and requires minimal training to operate. Non-proprietary hardware spare parts and available from multiple sources.
• Eliminates Obsolete systems
• Comprehensive upgrade options – ICS provides a comprehensive range of retrofit upgrade package solutions for steam turbine valve actuators, excitation/AVR, generator protection systems, instrumentation and monitoring provides as part of an integrated upgrade package

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