ITS-Industrial Turbine Services Group Page 1 of 7

OVERVIEW
Reasoning for Complete Turbine Control Compartment (TCC) Retrofit

Existing TCC’s were designed, supplied, erected and commissioned in 1970s, which lack all the required standards
of latest technologies in terms of improved failsafe operation throughout the installed hardware.

Traditionally each system in a TCC was designed to work independently with minimal interfacing with other
systems, thus causing excessive more time taken in information accessing, troubleshooting and reengineering.

In practical sense, partial retrofit of Turbine Control System, AVR or Generator Protection System alone does not
improve the reliability of the gas turbine control system as a whole.

All systems inside the turbine control compartment have been undergoing the same aging process as the turbine
control system, generator control and protection system.

For instance the internal cabling and small parts like MCBs and relays are also aging and may easily lead to
unpredictable problems, causing trips in the worst-case scenario.

In short, any overlooked or deferred improvement, of any part in the whole system, will become the weakest link
and defeat the purpose, time consumed and investment of upgrading.
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Scope of Supply

Engineering, Procurement, Construction and Commissioning of a brand new turbine control compartment (TCC),
including the following components:

- Air-conditioned compartment (matching exiting basement anchor points)

- Turbine Control System
- Marshaling Panel (with isolatable terminating points)
- Automatic Voltage Regulator
- Generator Protection System
- Automatic and Manual Synchronization Panel
- Switchgear & MCC
- Battery charger
- Very Early Smoke Detection Alarm system (VESDA)
- Uninterruptable Power Supply
- Fire fighting system (panel to match existing installed hardware)
- Vibration monitoring system (If probes already installed on turbine)
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Description of the Complete TCC Control System Architecture, Engineering & Design

One single main brand is used throughout the whole system. The concept is to standardize the communication
protocol, simplify programming standards, unify signals identification and minimize the spare parts inventory.

As the turbine control system is the most critical part of the whole TCC, all other systems and components follow
its design in terms of redundancy and failsafe philosophy.

All parts of the system communicate on a redundant bus system. As such, all parts of the system is accessible
using associated HMI. Diagnostics and programming on all systems is carried out on a single engineering
workstation. There is no protocol converter or such device among the systems. All signals in the system are
communicated based on the same timestamp for further processing and archiving. Proprietary communication
protocol is totally not used in this project to gurantee openness.

The whole compartment will be assembled and fully tested in factory. All the internal function tests and loop
checking will be done in the factory with testing results recorded and to be inspected during FAT.

The outline of the compartment will match the existing position of cables, gangways, location of doors and etc.
The required air conditioning system and isolation of the TCC walls has been individually designed according to
existing site conditions.

The communication networks of turbine control system and HMI are firewalled and secured in accordance with
industrial information safety standards. Monitoring and control in remote site can be enabled and implemented
with VPN protocols.
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Advantages of complete TCC retrofit against a “one by one” retrofit

1. The risk of problems (for example wiring mistakes) arise during site installation are reduced to a
minimum.

2. Higher reliability of the whole system due to improved redundancy.

3. Easier maintenance and minimum inventory due to repeated common parts used. Most parts
can be purchased in the open market at the shortest possible time and cost.

4. Better diagnosis capability due to a common bus system and time stamping.

5. Very short site installation timeframe. Downtime is greatly reduced.

6. Centralized engineering and diagnosis point.

7. Less manpower requirement for installation.

8. Overall cost is much lower compared to a “one by one” retrofit of the installed systems.

9. One uniform set of drawings for the whole compartment. Drawings are electronically accessible
in the TMOS HMI internal network.

10. Technical support and consultation for the whole compartment comes from single vendor.
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Failsafe and redundancy concept

The whole system has been designed to match the main redundancy concept of the turbine control system.

Critical systems like AVR, Generator Protection, Synchronizer, Switchgear, Battery Charger and UPS are designed
to have the redundancy concept as well.

The following are the technical specifications of the respective systems:

Turbine Control 1. Designed to operate the gas turbines using the turbine control philosophy same as
System the OEM of Frame 5001 gas turbine.

2. Using dual redundant S7-417H CPU’s, with triple modular redundant IO structure
and redundant inter processors communication highway.

3. Diversified overspeed protection in case there is no mechanical protection

mechanism.
AVR Triple redundant digital AVR, including system related hardware
Generator Redundant Siemens Siprotec Protection relays.
Protection System
Synchronization Siemens Siprotec redundant layout with synchro check function.
System Manual synchronization with additional synchro check protection.
Optional Deadbus synchronizing configuration.
Switchgear & MCC Redundant bus controlled and monitored “smart” switchgear using Siemens breakers,
relays and electronic components.
Battery Charger Redundant design
UPS Redundant design
Fire Fighting System Concept based on installed hardware and manufacturer
Vibration New Bently Nevada BN3500 will be supplied. MODBUS link will be enabled so that
Monitoring signals can be communicated to TMOS HMI.
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Changes of field devices

Field devices has been designed, supplied, installed, calibrated and commissioned to match with the TMR
redundancy concept.

The speed pickups are to be changed to HALL type sensor.

No other major changes to the installed instrumentation are required.

We do not recommend replacing critical switches to transmitters if there are no built-in contacts. The reason is
because they should always be functioning (for example switching on emergency lube oil pump and etc) regardless of
whether the digital control system is online or not. In addition, they should not be reset when the digital control
system reboots.
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Project Time Schedule

The complete turbine control compartment (TCC) will be ready for Factory Acceptance Test within 7 months from
the contract award date, subject to final technical & commercial acceptance.

Shipping transit time including of customs clearance and inland transportation time based on airfreight will be
about 2 weeks, whereas sea freight based will not be longer than 2 months.

Site installation, testing and commissioning will be carried out during a planned 2-week outage.