Turbine retrofit need deep knowledge in automation and machine control, we are experienced in retrofitting different type of gas turbine compressor and generators like project 7108.
The project 7108 was about retrofit a power plant in a zinc factory by changing control system technology.
The customer were dependent to a source of power from another plant, an aluminium complex next to this zinc plant were feeding their required power. This dependency was an issue for them in peak of production period; they intended to have their own in-house power station and provided a second-hand Solar-Mars 12 MW gas turbo generator.
Although its engine was in good condition but the control panel was damaged and almost ruined due to water leakage into its storage container. The customer had limited budget and request a cost effective solution.
We changed the turbine control system to a Siemens technology and replaced ABB Advant Master by Siemens S7-400 and wincc. There were not any advantage to stay on ABB technology and implement a cutover migration.
Aslo, Woodward 2301 electronic load sharing and speed control board eliminated and we wrote its function in the Siemens PLC.
Writing new logic for old turbine is the biggest challenge in a retrofitting project but in this project aside from complicated logic for start/stop sequence, protection, fueling and combustion chamber safety, turbine governing and speed control there were wide range of obsoleted Analogue signal type in this old machine that make the PLC hardware design tricky.
By completing this project, the customer could have new modern control system with low maintenance cost, they had fast return on their investment and not only were not dependent to 3rd parties anymore but also could make money by selling excess power.