Customer: Turbomachinery Solutions Provider, United States

Background:

Turbine controllers are crucial components in modern turbomachinery, providing precise control and real-time monitoring capabilities to optimize performance and reduce downtime. Our client, a leading provider of advanced turbomachinery solutions in the United States, required product development engineering services for the design and development of a cutting-edge control system for their turbines. The system needed to provide precision control and real-time monitoring capabilities while integrating seamlessly with existing equipment and systems. Our team was tasked with delivering a solution that would meet these requirements while adhering to strict quality and safety standards.

Our team has collaborated in designing and developing a state-of-the-art control system that leverages cutting-edge algorithms to improve efficiency and optimize performance.

Engagement Model:

The overall project was completed under a monthly retainer model, which allowed us to work closely with the client to ensure that their requirements were met on an ongoing basis. This approach enabled us to provide timely and responsive support throughout the design and engineering process, adjusting and refining as necessary to meet the client’s needs.

Design and Engineering:

To meet the requirements of our client, our team leveraged our expertise in engineering and design to develop a state-of-the-art controller for the turbine. We used AutoCAD to create detailed General Arrangement (GA) drawings, Bill of Materials (BOMs), wiring schematics, and other documentation necessary for the design and construction of the controller.

The control system is equipped with a Siemens S7-1500 Programmable Logic Controller (PLC) and a Unified Comfort Panel HMI for real-time monitoring and control. Our team developed the PLC program using TIA Portal, a powerful engineering software suite for industrial automation and control systems. This allowed us to create a control algorithm that maintains generator output while simultaneously adjusting the turbine Wicket gates and runner blades to optimize performance for any given water flow and head.

The controller we developed works seamlessly with any dual-regulated Kaplan turbine and includes key sections such as a startup procedure (both manual and automatic), various interlocks (hardwired and software-based), alarm management, and more. These features ensure that the controller operates safely and efficiently, minimizing downtime and maximizing performance.

Overall, our design and engineering services helped our client to modernize their control system with a cutting-edge solution that improves efficiency and performance while adhering to the strictest safety and quality standards.

Testing:

Once the Product was developed and engineered, it was integrated with various instruments and equipment such as RTDs, heaters, VFDs, level sensors, and flow meters. The system was then thoroughly tested under various operating conditions to ensure its functionality and reliability.

The testing process was carried out remotely, utilizing the remote access facility that was designed into the system. This allowed us to access the control system from our location and conduct testing as if we were on-site with the client.

The testing covered a range of operating conditions, including normal operating ranges as well as challenging scenarios. The system was tested for start-up procedures, shutdown procedures, interlocks, alarms, and other key functions. During testing, we were able to identify and resolve any issues that arose, ensuring that the control system performed optimally under all operating conditions.

Conclusion:

A successful standardized controller was developed using CONSYST’s product engineering expertise, providing a tailor-made turbine control system that met their unique requirements. Our testing and optimization processes ensured that the system performed optimally under various operating conditions and was seamlessly integrated with various instruments and equipment. Our engagement model, a monthly retainer, provided our client with flexibility and cost-effectiveness. By leveraging our innovative approach, expertise, and customer-centric focus, we delivered a solution that exceeded our client’s expectations and helped them achieve their business goals.