An utility plant in the Philippines upgraded their gas turbine control systems by engaging Schneider Electric. The 20-year-old Allen Bradley PLCs controlling three Mitsubishi gas turbines and Brush generators were replaced along with electrical, mechanical, fire & gas, and instrumentation systems to improve safety, integrity and reliability while reducing costs. Schneider Electric designed an integrated Triconex TMR control system with Wonderware HMI that improved performance through enhanced diagnostics and load sharing between generator sets. The upgrades modernized plant assets and increased operational efficiency and reliability.

1. Overview:
In the Philippines, a Utility Plant within a Refinery operates Gas Turbines
that were originally packaged by US Turbines each comprising of MHI
MF-111B turbines and Brush generators. Obsolete Allen Bradley PLC
Series 5 were still in service performing the operating sequencing and fuel
control functions of the turbine-generator sets. Schneider Electric was
awarded as the Main Automation Contractor (MAC) the upgrade project.
The scope of retrofit included the turbine controls, safeguarding and fire
& gas systems, automatic voltage regulator, electrical protection systems,
mechanical equipment, and field instrumentation to address safety,
integrity, reliability issues while achieving operation cost reductions.
Challenges:
Documentation: The existing systems had been commissioned
twenty years earlier and documentation was lacking accurate as-built
information.
Integration: Initial biggest challenge was the review and re-design
of complex interfacing of the existing system that comprised of
numerous third party instruments and devices.
Safety: To understand and address the safety enhancements for all
of instruments associated with the upgrade project.
System Reliability: Customer highlighted known reliability issues that
they wanted to address during the project. Such as the unreliable
start-up performance, online switching of firing mode issues, DeNOx
system performance, improving the safeguarding instrumentation
reliability, and electromagnetic compatibility related to earthing and
signal segregation. Mechanical reliability improvement required the
replacement of existing the pneumatic actuated Inlet Guide Vane
(IGV) that was known to be unable to achieve the desired opening
position accurately.
Installation & Commissioning: Significant engineering effort was
deployed to help the end-user recover the lack of accurate as-built
plant data, including discrepancies between drawings and actual
switch gear wiring. The commissioning schedule did not allow for
site delay or any online disturbances to the power network for the
operating plant.
Location: Electrical and mechanical installation was done at a remote
site location with limited local skilled resources and readily available
installation materials.
Gas Turbine Generators Control System Philippines
Turbomachinery Control
Case Study
Summary
PROJECT AT A GLANCE:
Location: Philippines
refinery operates gas turbines that were
originally packaged by US Turbines,
each comprised of Mitsubishi turbines
and Brush generators. An obsolete Allen
Bradley PLC Series 5 was still performing
the operating sequencing and fuel control
functions of the turbine-generator sets.
safeguarding systems, fire and gas
systems, automatic voltage regulator,
electrical protection systems, mechanical
equipment, and field instrumentation.
These upgrades improved safety,
integrity, and reliability while reducing
operating costs.
CUSTOMER BENEFITS:
Improved safety and integrity
A utility plant in Philippines upgraded their obsolete technology and improved operational capacity by engaging Schneider
Electric to retrofit their three gas turbine control systems, upgrade electrical and mechanical equipment, replace fire & gas
and field instrumentation.

2. For prompt support, call +65 6829 8123
or email APAC.TMC@schneider-electric.om
Schneider Electric: 15 Changi Business Park Central 1 Singapore 486057 Tel: +65 6829 8888
means, electronic or mechanical, including photocopying, recording, broadcasting, or by any information storage or retrieval systems, without permission in writing from Schneider Electric Singapore.
Solutions:
Control System: Schneider Electric designed and engineered an Integrated Gas Turbine and Generator Control
System built on a Triconex Triple Modular Redundant (TMR) system and Wonderware InTouch Human-Machine
Interface (HMI) that provided improved system reliability and enhanced diagnostic awareness for operations.
Load Sharing: Schneider Electric replaced out-of-date Woodward real power sensor with an embedded software
based load sharing system that integrated three generator sets.
Synchronization:
provided fast response and achieved highly successful Circuit Breaker close rate with minimum disturbance to plant
operations.
Fire & Gas System: The existing fire & gas system was completely replaced including detectors with the Triconex
TMR System.
Auto Voltage Regulator: The existing automatic voltage regulator (AVR) systems was upgraded to a dual redundant
modular AVR configuration that was designed with independent controllers and power circuits.
IGV Actuator: The problematic existing pneumatic actuated IGV was retrofitted with a reliable and precise hydraulic
actuator system.
Cabinets and Instruments: Schneider Electric supplied new cabinets, field devices, and supervised the site installation,
retrofits and startup commissioning.
Results:
Improved Performance: The integrated control system and unit operations significantly improved reliability and
operational performance. Successful single gas turbine firing and start-ups are now achieved while achieving a
reduction of nuisance trip events.
Modernized Assets:
simplified the system maintenance in terms of cost, local support availability and quick turnaround of hardware spares.
With the enhanced diagnostics provided by the new control systems the overall plant’s performance has improved. The
Enhanced reliability & Efficiency: Due to the upgraded Gas Turbine Control system which used a robust and versatile
combination of logic to handle numerous operating scenarios, it has improved the plant’s reliability and operational
efficiency.
Customer Satisfaction: The end-user was extremely satisfied with Schneider Electric’s professional engineering and
project management – from the solution design, configuration and testing through to site installation, startup, training,
local support and service for system handover.
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