G AS T UR BINE CONTROL SYSTEMS

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

Turbine Controls Limited

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Gas turbine control systems

Standard control systems developed for gas turbines

Designed to replace the existing control panel suite with all control GE Frame 3 and 5
and protection functions:
TCL have developed a standard control system for the GE Frame
• PLC controller, simplex, duty/standby or TMR hardware 3 and 5 engines. The system includes the necessary inputs and
configuration. Programmed with: outputs to interface with any Frame 3 or 5 standard plant devices.
- Fuel governor control Duplex or triplex mode systems available for increased
- Start up sequence control system integrity.
- 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 GE Frame 5 control panel
• Improved maintainability Ruston TA/TB/TD/Typhoon and Tornado
Our team of design engineers use the latest software and design TCL have developed a standard control system for the Ruston
techniques to produce an integrated system that will: gas turbines in the range 1MW to 6MW. The system includes the
• Minimise the system cost necessary inputs and outputs to interface with standard
plant devices.
• Reduce the outage time for installation
• Produce a payback period based in months rather than years In the case of the TA range all hydraulic control devices are
removed and their functions programmed into the PLC. This
System design greatly improves reliability and aids fault finding.
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
TA control panel
existing fuel valves.
The pre-developed system provides a cost effective solution
without the cost associated with a one-off design.
Turbine Controls Limited
52, Kenilworth Drive T +44 (0)116 271 7248
Oadby, Leicester F +44 (0)116 271 7250
LE2 5LG UK sales@tcluk.net
Or visit us at www.tcluk.net
SMARTStar t

SMARTStart
Gas Turbine Soft Start System
Digitally controlled gas turbine starter system to provide soft
start to DC powered starter motors

Turbine Controls Limited

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SMARTStart Gas Turbine Starter

The TCL SMARTStart system for gas turbine DC starter motors is the existing starter controls. The cubicle includes termination
designed to address the issue of aging starter systems which rely points for all field cables and can be installed in a floor or wall
on electro-mechanical timers and DC contactors. mounted position.
Over time and continued operation these electrical devices
Digital Inputs & Outputs
become unreliable causing:
Digital Inputs Digital Outputs
• Increased start fails
Start Remote Enable
• Reduced component life
Stop Remote Charge By Pass
• Increased down time as spares are difficult to source; particularly
those requiring 120V.dc operating voltages Start Permissive Ready
Start Local Ignition Permissive
Functions Pre-programmed
Stop Local Fire Permissive
The SMARTStart system includes an integrated micro-controller
to provide: Remote Selected Tripped
Local Selected
• Programmable current profile during start up
Emergency Stop
• System diagnostics, to detect starter motor faults
• Interface with the existing control system Reset

• via hardwired inputs & outputs 16 inputs & outputs for user configuration

• Serial communications interface, via Ethernet

Quality Control
System Design
TCL have the following quality control accreditations
In a traditional DC starter electro-mechanical contactors control
• ISO 9001:2008
the motor speed by switching resistors in and out. This causes
high current peaks and mechanical stress during the start cycle. • ISO 14001:2004
• BS OHSAS 18001:2007
The TCL SMARTStart system uses solid state components to
control the current through the starter motor and provide a more • CSA Z299.2-85 Quality control developed for CANDU
progressive increase in the current). This soft start greatly reduces nuclear plant
the stresses on the starter motor, increasing life and reliability. The system software is produced using rigorous quality control
To provide an operator interface with the equipment a HMI is procedures developed during TCL’s experience with developing
mounted on the front panel, providing the following features: software for nuclear power plants.
• Monitoring of system parameters Specification
• Adjustment of set-points, ramp rates, etc. Operating temperature -20oC to 70oC
• Graphical indication of motor current
Storage temperature -40oC to 85oC
• Real time trending of motor current
Heat dissipation 3.1kW max
• Status of digital and analogue signals
Weight 7.7kg
• Alarm indication
Shock operating 30g
• Viewing of PID loop
Shock not operating 50g
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

Turbine Controls Limited

52, Kenilworth Drive T +44 (0)116 271 7248
Oadby, Leicester F +44 (0)116 271 7250
Installation
LE2 5LG UK sales@tcluk.net
The SMARTStart system is assembled in a cubicle sized Or visit us at www.tcluk.net
1,200x800 and is designed to occupy a smaller footprint than
E L E C T R I C A L PA N E L M A N U FA C T U R E

Electrical Panel Manufacture

Design, manufacture, test and installation
of electrical control panels
High quality electrical control panel manufacture

Turbine Controls Limited

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Electrical Panel Manufacture

Design, manufacture, test and installation
of electrical control panels

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:
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.

• Process control and monitoring After Sales

• Fire & gas protection TCL have a dedicated customer support department to provide
• LV & MV switchgear. an after sales support of all installed system. This team is
available to carry out:
Design
• Telephone support
The design is carried out by experienced electrical engineers. • 24/7 Call out and fault finding
We are flexible in our approach allowing the client to determine
• Planned maintenance routines.
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 Quality Control
specification to a full design from scratch, including a site survey.
The deliverables could therefore include: TCL have the following quality control accreditations:

• A site survey at the customers facility • ISO 9001:2008, Quality management

• Production of a design specification • ISO 14001:2004, Environmental management
• General arrangement drawings • BS CHAS 18001:2007, Health and safety management.
• 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.

Single bay process control panel front and rear

Turbine Controls Limited

52, Kenilworth Drive T +44 (0)116 271 7248
Oadby, Leicester F +44 (0)116 271 7250
LE2 5LG UK sales@tcluk.net
Or visit us at www.tcluk.net

Turbine Controls Limited South Africa

36 Ross Street
Potchefstroom
2520 South Africa
Or visit us at www.tclsa.co.za
Control panel manufacture in our workshops
T +27 18 294 4882
F +27 86 670 8683
sales@tclsa.co.za