The TC3 is the latest generation turbomachinery controller from ICS, designed for control of gas and steam turbine generator and mechanical drive. It is a digital control system with integrated governor and sequencing. Based on powerful PLC controllers, it provides the recognized advantages of open-architecture and non-proprietary hardware. At the heart of the TC3 is ICS’ proven library of modular turbomachinery control functions. The TC3 incorporates the advanced control design concepts developed by ICS and proven in over 200 turbine control applications.

The TC3 is available in Simplex and Redundant versions.

Design Features

Proven design – Control Algorithms and system design are field proven, incorporating current control philosophies and operational enhancements. The system is designed to be rugged, and provide high availability and reliability.

PLC based – PLCs are high volume production, powerful and rugged, ideally suited to turbine control. Open architecture, non proprietary hardware ensures low maintenance costs compared to black box controllers

Integrated control – The TC3 can integrate turbine and compressor/generator control and sequencing in a single controller, to deliver a highly integrated system and eliminate multiple box approach

Digital – Digital electronics provide exact and permanent calibration.

Hardware independent – ICS control design is available on Allen-Bradley and GE-Fanuc, as well as customer specified hardware. The TC3 can accommodate specific design standards, including CSA, SIL.

Flexibility – The TC3 applies to a range of turbines, allowing for a common fleet-wide solution, simplifying maintenance and reducing parts inventories.

Communications – Support of many industry communication protocols allows for high degree of integration of intelligent devices, and links to higher level plant control and information systems

Easy customization – Specific application needs – hardware and software - are easily configured from the core controller design

Ease of use – The system is designed for easy installation, with a minimum of downtime. Technician friendly hardware/software and features like auto testing of fuel and valve/trip systems facilitate maintenance.

ICS Quality Assurance - ISO9001 registered

TC3 Software
At the heart of the TC3 control software is ICS’ proven library of modular turbomachinery control functions for turbine and generator or compressor control, protection and sequencing. Each TC3 application is then customized to meet the project needs, allowing for incorporation of customer specific features not possible with black box controllers. All application engineering and controller software is controlled under ICS ISO9000 registered quality system requirements. Each application is fully factory tested in the customer controller as a totally prefabricated and tested unit before shipment.

Deterministic Computation of Logic and Control Loops always within a predefined period of time guarantees performance and response. IEC61131 Programming allows programming of discrete, process, mathematical, and sequential type applications all in the same processor using Ladder Logic (LD), Function Block Diagram (FBD), Structured Text (ST), and Sequential Function Chart (SFC). Programming languages can be mixed in the program routines to suit users need.
Symbolic data addressing allows assigning a name to a variable as opposed to a register similar to DCS programming.
Plant Control Integration – TC3 communication to DCS/RTU/IEC devices using industry standard protocols

TC3 Hardware
The TC3 uses programmable logic controller (PLC) open-architecture, non-proprietary hardware to ensure flexibility, easy maintenance and off-the-shelf spare parts. Over the last 10 years, PLC advances have made it the ideal platform for turbine control, with powerful processing capability, communication compatibility with other systems, and a large installed base and proven robustness. For the TC3, ICS offers common PLC controller platforms from leading suppliers, including Allen-Bradley and GE-Fanuc.

Hardware features:

Failsafe – hardware and overall system design is failsafe

Deterministic redundant I/O Bus operating at 10 Mbits/sec.

High Speed Isolated I/O – 4-20ma, +/- 10VDC, RTD, T/C, Pulse Input, Relay Output, Digital Input. 1-2 msec I/O updates for High Bandwidth Loops (-3dB > 35 rad/sec), valve position loop control, 10 msec update for turbine rotor speed control.

Communications – To Intelligent Devices, RTU’s, Excitation Controls, Generator Protection, Vibration Protection, DCS, using standard communication protocols (Modbus, DNP3) over RS232, RS485, and Ethernet Hardware Networks.

Software configured I/O modules - Allows for easy insertion of I/O modules where replacement of the module is necessary, don’t need to look up a hardware configuration document.

Pre-Emptive Multitasking controller allows you to split the application code so that individual programs (and their data) can be compartmentalized and tied to different priority tasks. This enables easy segregation of the application software and to operate them on different time (priority) levels.

Security Protection. Built-In Multiple User, Multiple Level Password system allows for full control, read only, or total lock-out of the source routine depending on the routine. This allows only those who need to modify or view code to do so.

Comprehensive diagnostics, module/channel failure, low and high limits, open/short circuit, monitoring of variables.

Redundancy - For critical applications, ICS offers the STC2000 in a redundant version, with dual CPU and Triple modular redundant (TMR) configurations

TC3 Operator Interfaces
The most common interface to the TC3 is a personal computer (PC) based HMI Workstation which allows the Operator to monitor and control the Turbine, view and diagnose alarms and collect and analyze operational data. The HMI high-resolution graphics displays comprehensive monitoring and control features and provides maintenance and troubleshooting facilities for the unit.HMI Screens are designed to present information in a user-friendly manner and offer Operator monitoring and control capabilities, which were not possible with the original control system. The HMI may be panel-mounted or remotely mounted.

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