Upgrading obsolete control systems is a cost effective way to improve the operation and reliability of a steam turbine. ICS provides a range of turbine controllers specifically designed as a modern retrofit replacement for the Electro-Hydraulic and Hydro-Mechanical control systems on most models of steam turbine in the 2MW – 200MW range. ICS steam turbine controls utilize the field proven TC3 digital control system for Turbine-Generator control, protection and sequential functions.

The TC3 overcomes the limitations of Electro-Hydraulic and Hydro-Mechanical governor and sequencing equipment, while also implementing current 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 actuator and instrumentation upgrades and generator control upgrades. Each application is fully factory tested in the customer controller as a totally prefabricated and tested unit before shipment.

Utility Steam Turbine Applications
Applications for utility Steam Turbines are applied for control of straight condensing, reheat and non-reheat steam turbines up to 300MW. These upgrades may include integrated generator controls, generator protection and excitation/AVR upgrades, utilizing the latest commonly available industry-standard digital equipment.

Industrial Steam Turbine Applications
Applications for Industrial Steam Turbines cover all straight condensing, non-condensing, and automatic extraction steam turbines. Specific design features are incorporated to address control issues often unique to process plants including paper mills, oil refineries, chemical plants, and other industrial applications, generator and mechanical drive.

For many extraction steam turbines faced with operation limitations due to control problems, a control upgrade provides reliable, flexible and safe control of the turbine in all operating modes and can allow more efficient operation of the turbine.

TC3 Steam Turbine Control Functions
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 valve actuator or instrumentation upgrade;

• Governing - Steam Valve Control
• Sequencing
• Protection
• Monitoring
• HMI operator interface / data historian
• Vibration Monitoring
• Control interface to generator / mechanical drive
• Remote Monitoring and Communications

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 Steam Turbine control include;

• Inlet Pressure Controller
• Inlet Pressure Limiter
• Single & Multiple Extraction Pressure Control
• Extraction Pressure Control
• Exhaust Pressure Control
• Inlet / Extraction Valve Ratio Control
• Turbine Speed Control
• Generator load control
• Generator load limit
• Hotwell Level Control
• Generator Stator Temperature Limiter

The TC3 is very flexible, allowing 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 machinery 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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