Emerson Solutions for Siemens/Westinghouse Gas Turbines

Features

• Fully engineered and field-proven retrofit for Siemens-Westinghouse gas turbines equipped with Emerson WDPF or Siemens Teleperm™ XP (TXP) control systems
• Ovation-based solution with powerful redundant processors specifically designed to meet the needs of DLN/ULN and non-DLN units
• User-friendly tools and direct access to turbine logic facilitates in-house maintenance
• Integrates governor, sequencer and safety functions with Ovation turbine control
• Incorporates control enhancements that enable:
  • Better operator decision making
  • Improved unit operation, performance and starting reliability
  • Simplified troubleshooting and maintenance
• Comprehensive suite of integrated products and services that support cybersecurity programs and obligations
• Flexible architecture easily unifies turbine and balance-of-plant systems for comprehensive plant control
• Options available for generator excitation, vibration prediction, instrumentation upgrades, wireless monitoring and simulation

Image Description: A visual representation shows a gas turbine plant installation with control room monitors displaying turbine operational data, illustrating the packaged retrofit solution for Siemens Teleperm XP and Westinghouse WDPF controls.

Introduction

Emerson acquired the Westinghouse Turbine Control Group in 1997 and has since provided innovative upgrade solutions for W501 D-F-G turbines and mature Westinghouse W191-W251 fleets. Over decades, Emerson has combined former OEM expertise with advanced technology to modernize most of the W501 fleet to the state-of-the-art Ovation™ system.

Emerson's gas turbine control portfolio includes system upgrades providing reliable and efficient control on hundreds of W501 model gas turbines, up to G class. The retrofit program covers turbine control development, application enhancements, project-specific content, installation, commissioning, and lifecycle support for W501 gas turbines.

Ovation W501 Gas Turbine Retrofit Application

Emerson's Ovation W501 gas turbine control retrofit replaces original TME/TXP/WDPF turbine control systems with new enhancements for reliable, flexible, and safer operation. The Ovation solution integrates governor, sequencer, and protection control functions, including:

• Turbine control and sequencing
• Turbine fuel control (governor)
• DLN/ULN control
• Turbine protection
• Fuel transfers
• Turbine monitoring
• Vibration monitoring
• Generator monitoring, control, and protection
• Manual and automatic synchronizing
• Remote monitoring & communications

Native I/O modules directly interface the Ovation system to speed detectors, LVDT, servo-valves, RTD, thermocouples, and other turbine instruments, providing full diagnostics down to the I/O level. This direct interface ensures integrated control of all turbine systems, including:

• Variable guide vane actuators
• Fuel systems – diffusion and DLN
• Water injection systems
• Flame detection systems (sensor-based or temperature-based algorithm)
• Starter systems
• Lube and hydraulic oil systems
• Overspeed protection system

Emerson maintains a version-controlled library of turbine-specific control algorithms, developed over years of implementation and field-proven in hundreds of applications. This ensures software standardization, eases testing, improves revision control, and reduces commissioning time. Ovation's turbine control supports all operational modes of the original TXP/WDPF system.

Image Description: A panel retrofit example shows a close-up of a control panel, highlighting the replacement of internal wiring and equipment with new subpanels and plug-in wire harnesses for seamless integration with existing field terminal boards.

TXP Panel Retrofit

The Ovation upgrade is a direct replacement for TXP control systems. Original TXP panels are retained, while back panels, side-mounted equipment, and internal wiring are replaced with drop-in subpanels containing Ovation equipment and plug-in wire harnesses that adapt to existing field terminal boards. The Ovation solution replaces Simadyn, Teleperm, and S5-95F safety sub-systems while retaining existing field wiring and turbine instruments, eliminating legacy control components and mitigating obsolescence risks. Full factory testing of the complete control assembly reduces commissioning risks. The measuring cabinet for vibration monitor, overspeed protection, and flame detection may be retained or replaced.

WDPF Migration

Emerson offers proven solutions to migrate legacy WDPF systems to Ovation, including DPU-only and I/O replacements. Similar to TXP replacements, vibration monitor, overspeed protection, and flame detection equipment can be retained or replaced.

Ovation System Enhancements

Enhanced operator decision making

• Unit operation maintenance summary automatically updates factored hours/starts.
• Smart dashboard displays start/trip data and gross, net, and auxiliary MWH per run.
• Automatic turbine trip reports via Ovation Process Historian.
• Enhanced exhaust display with color-coded tabular views of combustion data.
• Generator capability monitor shows capability curve with automatic alarming outside of generator limits.

Improved unit operation and performance

• Unit start profile compares startup/coast-down times to a baseline for identifying blade tip rub and other issues.
• Gas turbine performance indicator includes megawatt capability predictions and real-time heat rate/efficiency calculations.
• Easy-to-read combustion monitor identifies hot/cold spots.
• Rate of change algorithm for improved thermocouple rejection.
• Automatic turning gear scheduling reduces disc wear and blade problems.
• Manual synchronization from Ovation operator workstations.
• Manual bias of water injection improves NOx control.
• Automatic droop tests and frequency response.
• Off-line wash IGV logic for effective compressor cleaning.
• Part load exhaust temperature control optimization for increased steam production in combined cycle operation.

Simplified troubleshooting and maintenance

• Dedicated start permissives and trip displays for fast problem identification.
• High-speed trending to pinpoint event data.
• Overspeed testing from the HMI.
• Fuel valve calibration from the HMI.
• Monitoring of 125 VDC battery voltage.

Improved control and protection

• 2oo3 logic for speed sensor fault detection and rejection for reliable measurements and trip avoidance.
• Fuel oil ignition logic updates for improved unit starting reliability.
• Improved water injection and flame-out protection logic.
• Combustion dynamic monitoring system for monitoring combustion dynamics and protecting from unsafe operation.
• Updated fuel gas logic to avoid unwanted trips.
• Fuel gas schedule improvements and starting reliability enhancements.
• SIL3 rated overspeed protection using Emerson's CSI6300 system.
• Improved vibration monitoring using Emerson's Ovation Machinery Health™ Monitor or Advanced Turbo Guard (ATG) monitoring system.
• On-line machinery health prediction system.

Emerson - MHPSA Alliance

To enhance its 501-gas turbine market offering, Emerson partnered with Mitsubishi Hitachi Power Systems America (MHPSA) to provide comprehensive solutions covering controls, uprates, enhancements, long-term agreements, parts, and outage services. MHPSA, a former Westinghouse licensee, participated in the design of W501 product lines and leverages its OEM knowledge for advanced technology in the Siemens-Westinghouse 501 fleet upgrade program. MHPSA solutions for W501 gas turbines feature improved reliability part upgrades to address existing fleet issues.

Examples of additional upgrades or modifications for improved gas turbine performance:

• Flexible long-term service agreements
• Engineering studies and service bulletin implementation
• Improved parts to fix known issues and extend outage intervals, including:
  • Compressor hook fit and diaphragm repair/upgrades; weld repair or upgrade to new diaphragms
  • Compressor anti-rotation screw fix
  • Upgraded blades for row 1 and 2 for extended parts life and reduced repair costs
  • Upgraded vanes for rows 1–4 based on MPHSA 501G technology
  • Row 4 blade root springs to minimize disc and blade root wear
  • Upgraded belly bands for quick replacement and high reliability
  • Upgraded exhaust cylinder for longer service life
• Turbine uprates including F4 uprate for 501F:
  • Up to +5% megawatts
  • Up to -0.8% heat rate
• Part load exhaust temperature optimization for improved combined cycle efficiency
• Remote monitoring 24/7

The combination of Ovation control enhancements and MHPSA parts upgrades offers superior fuel efficiency, output, performance, and service life compared to contemporaries.

Image Description: Diagrams illustrate turbine components, showing rows of vanes and blades (e.g., Turbine row 4 vane, Turbine row 2 ring segment, Turbine row 1 blade). A caption notes that the MHPSA F4 upgrade for a 501F can produce 5% increased power output and 0.8% improvement on heat rate.

Integrated Combined Cycle Control

The Ovation platform is well-suited for combined cycle plant control applications, including steam turbine, heat recovery steam generator (HRSG), balance-of-plant (BOP), and auxiliary controls. Controlling the entire power block with a single automation platform enhances reliability and offers opportunities for operational improvement, such as increased plant efficiencies, megawatt production, and long-term operation and maintenance savings.

Ovation - Designed for Power

Emerson's Ovation technology is the foundation of its gas turbine control solution, designed to:

• Eliminate obsolescence concerns by using commercially available technology.
• Provide intuitive built-in diagnostics for quick problem identification.
• Secure operations with standard features addressing cybersecurity concerns.
• Simplify configuration and maintenance with integrated user-friendly engineering tools.

Summary

Emerson addresses the evolving power industry by offering solutions to increase the performance and reliability of W501 generating assets. In alliance with MHPSA, Emerson provides a comprehensive solution for these units. The Ovation retrofit for Westinghouse mature models and 501D-F-G gas turbines was developed by Emerson's specialized gas turbine solutions group, with experts possessing years of experience in turbine control design and support, dating back to original Westinghouse turbine design work. Emerson is committed to long-term product support and cost-effective migration paths to reduce lifecycle costs and keep pace with technological advancements.

Image Description: Examples of Ovation W501F graphic interfaces are shown, including displays for generator capability curves, lubrication oil systems, and starter systems, demonstrating the system's visualization capabilities.