Retrofits & Upgrades
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Gas Turbines - Generator Drive
Gas turbines are regarded the core of many industries, especially in the power generation industry. As gas turbines age, their associated control systems become the main challenge to manage and maintain in a safe and cost-effective manner. Owners and operators of Gas Turbines face other issues, such as the spare parts obsolesce, lack of expertise of legacy systems and the cease of OEM support.
TCS provides a robust, state of the art, advanced and cost-effective control system for turbo-machinery applications, developed according to industry standards, as an alternative to many gas turbines’ makes and models to protect, monitor and control gas turbines used in various applications and industries, such as Power Generation, Oil & Gas, Chemicals & Petrochemicals, Steel factories, etc. we offer control systems that are developed on industry proven control hardware platform, which can be selected according to end user preference, ensuring seamless integration with the plant’s existing systems, which does not require any third-party products for interfacing.
TCS specializes in the Control upgrade of many OEM gas turbines, GE heavy duty (Frame 5, 6, 7, & 9) and industrial gas turbine (LM2500, LM5000, LM6000), Siemens SGT-series, Rolls Royce turbines, Solar turbines, Westinghouse, P&W and many others.
We offer complete turnkey solutions for new installations as well as for the retrofits and modernization of existing Gas turbine Control system customized for each specific customer’s technical requirements. Our offering also includes site surveys, equipment selection, detailed design and engineering, installation, commissioning & startup
TCS provides a robust, state of the art, advanced and cost-effective control system for turbo-machinery applications, developed according to industry standards, as an alternative to many gas turbines’ makes and models to protect, monitor and control gas turbines used in various applications and industries, such as Power Generation, Oil & Gas, Chemicals & Petrochemicals, Steel factories, etc. we offer control systems that are developed on industry proven control hardware platform, which can be selected according to end user preference, ensuring seamless integration with the plant’s existing systems, which does not require any third-party products for interfacing.
TCS specializes in the Control upgrade of many OEM gas turbines, GE heavy duty (Frame 5, 6, 7, & 9) and industrial gas turbine (LM2500, LM5000, LM6000), Siemens SGT-series, Rolls Royce turbines, Solar turbines, Westinghouse, P&W and many others.
We offer complete turnkey solutions for new installations as well as for the retrofits and modernization of existing Gas turbine Control system customized for each specific customer’s technical requirements. Our offering also includes site surveys, equipment selection, detailed design and engineering, installation, commissioning & startup
The main features TCS offered GT Controls upgrade:
- The system can be Simplex, Dual or TMR options with Hot Swap capability.
- Fuel Governor.
- Auto Synch & Power Monitor.
- Automatic start-up, auxiliaries sequencing.
- Combustion Control.
- Exhaust temperature Control.
- Alarm Management.
- Advanced Trending Capabilities.
- Generator Stator temperature monitor.
- Lube oil temperature monitor.
- Vibration monitor.
- Wheel-space monitor.
- Predictive Analytics (Optional).
Gas Turbines - Compressor Drive
TCS, through its experience over the years, developed the expertise and knowledge, to provide an advanced and sophisticated integrated Turbine & Compressor Train Control utilizing advanced algorithm and system hardware using the hardware platforms of renowned OEMs. We offer a fully integrated solution for turbo-compressor train application in the Oil & Gas industry.
Our integrated train control solution is an agile control regulating the rate at which the compressor’s operating point approaches the surge line, thus allowing for smooth transition to stable operation.
In addition, TCS, as a one-stop shop, has highly skilled personnel with the relevant experience in the electro-mechanical interface with the compressor.
Our integrated train control solution is an agile control regulating the rate at which the compressor’s operating point approaches the surge line, thus allowing for smooth transition to stable operation.
In addition, TCS, as a one-stop shop, has highly skilled personnel with the relevant experience in the electro-mechanical interface with the compressor.
The train control package includes:
- Control and sequencing
- Anti-Surge Control
- Capacity / Performance Control
- Process Control
- Suction Pressure Control
- Load Sharing
- Discharge Pressure Control
- De-Coupling of Speed/Load
- Precision EGT limiting (depending on the prime mover)
- Operation and performance monitoring
- Easy troubleshooting tool
- Trending and Historian
- Simulation tool
Control platforms TCS offers:
- Allen Bradley Controllogix5000®
- Siemens S7 400
- Woodward Micronet Plus®
- GE Speedtronic MK VIe®
Steam Turbines
TCS offers a steam turbine speed controller that is state-of-the-art and cost-effective solution to regulate the driver’s speed and power. It offers a fully automated speed control during normal and critical operating conditions and features critical speed avoidance to protect plant equipment from damage.
We also provide upgrades for steam turbine speed control that still uses mechanical or legacy electronic control systems to make it compatible with a wide range of control platforms.
Our custom-engineered control system retrofit package delivers a full complement of digital controls needed to modernize a turbine governor. It is an open system that is fully configurable to any industrial steam turbine and is integrated to the train control system.
Our offered steam turbine control system enables fully automated system, which offers a safe operation and startup/shutdown speed control with critical speed avoidance. It has the capability to protect the steam turbine against over-speed occurrences and automatic startups and shutdowns sequences.
Our retrofit solutions are also designed for obsolete hydro-mechanical and electro-mechanical steam turbine systems. TCS has the capability to design and develop state of art condensing and extraction steam turbine controller with variable steam extraction.
It is designed to provide control of the steam turbine extraction pressure set-point, while executing higher priority tasks of limiting process parameters, such as turbine rotor speed, steam pressure at various points, power, steam flow, and control valves positioning.
The extraction controller interacts with the steam turbine speed or process controller through signal exchanges. All our offered solutions are IEC-61131-compliant PLC platform.
We also provide upgrades for steam turbine speed control that still uses mechanical or legacy electronic control systems to make it compatible with a wide range of control platforms.
Our custom-engineered control system retrofit package delivers a full complement of digital controls needed to modernize a turbine governor. It is an open system that is fully configurable to any industrial steam turbine and is integrated to the train control system.
Our offered steam turbine control system enables fully automated system, which offers a safe operation and startup/shutdown speed control with critical speed avoidance. It has the capability to protect the steam turbine against over-speed occurrences and automatic startups and shutdowns sequences.
Our retrofit solutions are also designed for obsolete hydro-mechanical and electro-mechanical steam turbine systems. TCS has the capability to design and develop state of art condensing and extraction steam turbine controller with variable steam extraction.
It is designed to provide control of the steam turbine extraction pressure set-point, while executing higher priority tasks of limiting process parameters, such as turbine rotor speed, steam pressure at various points, power, steam flow, and control valves positioning.
The extraction controller interacts with the steam turbine speed or process controller through signal exchanges. All our offered solutions are IEC-61131-compliant PLC platform.
Our expertise are in the following steam turbine makes:
- General Electric
- Siemens
- Mitsubishi
- Toshiba
- Hitachi
- Fuji Electric
- Ebara
- Dresser Rand
- Mitsui
Control platforms TCS offers:
- Allen Bradley Controllogix5000®
- Siemens S7 400
- Woodward Micronet Plus®
- GE Speedtronic MK VIe®
Hydro Turbines
TCS offers a fully integrated upgrade solutions for the hydroelectric power plants. Utilizing various OEM hardware platforms, our solutions encompass all the benefits of modern digital technology. Our system application engineers have extensive experience in hydro turbines, having delivered upgrades for hydroelectric generation plants ranging from 1 MW to more than 100MW in generation capacity.
Our engineering team develops a customized hydroelectric turbine control solution that is ideal for all applications. All engineering, project management, system integration, testing and commissioning tasks are completed with high degree of professionalism. This integrated approach to both the design and packaging ensures consistent design philosophy, documentation, and quality throughout the project stages.
Our hydroelectric retrofits and upgrades ensure improved system control with proven components for greater reliability, as well as the advantages of a fully supported parts supply.
Our engineering team develops a customized hydroelectric turbine control solution that is ideal for all applications. All engineering, project management, system integration, testing and commissioning tasks are completed with high degree of professionalism. This integrated approach to both the design and packaging ensures consistent design philosophy, documentation, and quality throughout the project stages.
Our hydroelectric retrofits and upgrades ensure improved system control with proven components for greater reliability, as well as the advantages of a fully supported parts supply.
Types of Hydroelectric Turbines we are experienced with:
- Francis
- Kaplan
- Bulb
- Pelton
- Pump storage
Control platforms TCS offers:
- Allen Bradley Controllogix5000®
- Siemens S7 400
- Woodward Micronet Plus®
- GE Speedtronic MK VIe®
Synchronous Generators
Our Generator control and protection solutions are customized to suit the customers’ specific requirements. The offered solutions are designed for a wide range of generator applications in the power generation and O&G industries. In a typical upgrade solution, the GCP panel contains generator active power, reactive power, metering, automatic voltage regulators, generator protection and synchronizing relays.
At TCS, we offer a complete package for the Gen Excitation & Protection Systems & associated control auxiliaries. Specializing in the upgrade of older Gen Controls systems, TCS can design, supply, install and commission such systems in a cost-effective and efficient manner.
TCS, being a service provider for major Generators’ OEMs, we also provide installation and commissioning Services as part of our offered service packages.
In addition to Excitation Systems, we also specialize in Synchronizing Systems for generator schemes.
At TCS, we offer a complete package for the Gen Excitation & Protection Systems & associated control auxiliaries. Specializing in the upgrade of older Gen Controls systems, TCS can design, supply, install and commission such systems in a cost-effective and efficient manner.
TCS, being a service provider for major Generators’ OEMs, we also provide installation and commissioning Services as part of our offered service packages.
In addition to Excitation Systems, we also specialize in Synchronizing Systems for generator schemes.
We have expertise on the following OEMs’ systems:
ABB
Unitrol 1010, Unitrol 1020, Unitrol 6080
Protection: REG650, REG670, REG670-C30
Protection: REG650, REG670, REG670-C30
ALSTOM
DX21 C10/120 MC15 HC15
SIEMENS
RG3-T4 RG3-S7
Brush
Prismic A30, Prismic A12, MAS100, MCS100
Basler
DECS 125-15, DECS 100, DECS 200, DECS 250, DECS 300 and DECS 400
Gas Compressors
The reliability and efficiency of centrifugal compressor are directly affected by the interaction between the surge controller, inlet guide vanes, anti-surge valves, recycle pipelines and intercoolers. An improperly designed surge control strategy can lead to compressors being susceptible to multiple surge events, which can cause catastrophic damage to the compressor train and potential serious injury to personnel. The Anti-surge controller is one of the most critical components of compressor control applications that prevents a compressor from surging by continuously monitoring and the distance between the compressor’s operating point and its surge limit line. The controller modulates a recycle or blow-off valve to prevent the compressor’s operating point from reaching the surge limit while maintaining other process variables within safe or acceptable limits.
TCS offers a Compressor sequencing and anti-surge PLC-based control systems packaged using a variety of PLCs of major industrial suppliers depending on the customer’s need/preference.
Our PLC based Compressor Control system is fully tested by our engineers during and after the conceptual design phase. Our PLC based solutions’ logic diagrams and programming software are industry standard designed with local I/O and remote processors, and other arrangements depending on the customer’s requirements. Control system enclosures and wiring are available to meet all IEC applications, Class 2 / Zone 2 and non-hazardous installations. TCS offered Compressor Controls are fully redundant PLC solutions available with hot swap and online backup capabilities.
TCS offers a Compressor sequencing and anti-surge PLC-based control systems packaged using a variety of PLCs of major industrial suppliers depending on the customer’s need/preference.
Our PLC based Compressor Control system is fully tested by our engineers during and after the conceptual design phase. Our PLC based solutions’ logic diagrams and programming software are industry standard designed with local I/O and remote processors, and other arrangements depending on the customer’s requirements. Control system enclosures and wiring are available to meet all IEC applications, Class 2 / Zone 2 and non-hazardous installations. TCS offered Compressor Controls are fully redundant PLC solutions available with hot swap and online backup capabilities.
Gensets
TCS offers specialized controls and turnkey projects for the diesel and gas engines for all applications from simple backup applications, manually start-stop command, to advanced genset paralleling applications in island and parallel to utility operation. Capabilities include integration of PV and BSS (battery storage system), engine and generator protection, CAN engine interface, and programmable logic features with redundancy options in CAN and Hardware. We offer state-of-the-art digital control systems to upgrade your engines to the cutting edge in technology.
Types of Engines we are experienced with:
- Diesel Engines
- Gas Engines
- Dual Fuel Engines
Centrifugal Pumps
The Centrifugal Pump control system architecture is based on a modular layout. It includes the Multivariable control logic block for the process parameters control strategy, the equipment protection system block for continuous and fully automated pump protection, a diagnostic block capable of detecting the main pump subsystem malfunction, and finally the pump model block which allows to predict the pump behaviour in running conditions.
The operator can easily set the desired operating mode from the four main operating modes:
- Discharge Pressure Control
- Suction Pressure Control
- Flow Control
- Speed Control
TCS develops, designs and packages centrifugal pumps control systems for a wide range of pumping applications, using decades of practical experience.