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In today’s rapidly evolving power generation landscape, integrated plant controls are becoming essential to ensuring seamless, efficient, and resilient operations.

By moving away from non-integrated distributed control systems and adopting an integrated approach, power facilities can achieve smoother startup sequencing, more responsive load management, and improved plant turndown—leading to more reliable and cost-effective operations.

This blog will explore the key benefits of integrated plant controls for power generation, including faster installations, reduced costs, and more efficient operations. We’ll delve into topics like seamless plant startup sequencing, resilient load response, and improved plant turndown, while also addressing important considerations such as lifecycle cost management, cybersecurity, and business continuity planning. In addition, we’ll highlight GE Vernova’s comprehensive services, including technical support, preventive maintenance, and parts management, all designed to enhance the long-term value and performance of your integrated plant controls.

Integrated plant controls: Key benefits

Seamless plant startup
 Plant startup sequencing enables a fully automatic, plant-wide startup sequence, moving beyond individual equipment or semi-automatic system-level startups. Integrating the plant and turbine controls allows for a single button to start the facility and allows operators to see the status of each step in the process to make sure the system is getting to load.

With an integrated plant startup sequencing, the power train is synchronized with all Balance of Plant (BOP) systems, providing a comprehensive startup process, as well as offering real-time insights into each step, all accessible at the operator's fingertips. In addition, GE Vernova can leverage its extensive OEM asset knowledge, allowing for the most efficient startup, reducing the fuel needed for startup.

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Efficient plant turndown
Through closely coupled controls across various systems, including turbine control, steam turbine, and critical water-steam cycle equipment, integrated plant controls provide a single system to bring the plant into safe operating conditions in the correct sequence​. 

With OEM controls to provide unique insights into the limits of the assets to bring them down safely​, operators can see the status of each step in the process​ and eliminate handoffs between systems to improve the speed of response​.

An improved plant turndown can help reduce the plant load from the powertrain and relevant auxiliaries in a fuel-efficient manner, all while maintaining operations within emission parameters.

Resilient load response
Integrating the plant and turbine controls allows improved response time to unexpected operating conditions​. Resilient load response creates common logic that allows the system to withstand a sudden loss of load and quickly return to normal operating conditions​—which can help prevent the system from going into an overspeed and potential trip conditions​. With a common system across the turbine generator system and balance of the plant, operators can see the system response in real-time.​

Integrated plant controls bring the plant to a safe state much faster. The speed of response is significantly enhanced with tightly integrated controls, allowing the plant not only to quickly reach a safe mode but also to be ready to ramp up again as soon as possible, minimizing the duration of disruption.

Other things to consider

Lifecycle cost management
Lifecycle costs will differ by customer. For some, lifecycle management costs are a capital expenditure considered along with control system or HMI upgrades. For others, these costs are part of operating expenses and must be budgeted yearly. Key topics to consider when planning lifecycle costs include inventory and obsolescence management, average service life per unit, hardware life, and the vintage of control systems. Customers should plan for incremental or comprehensive upgrades depending on which control system they operate—for example, a current protection system like Mark VIe versus a legacy Mark control system. Additional considerations that are essential for budgeting lifecycle costs include technical support readiness, preventive maintenance plans and their frequency, workforce training, and maintaining cybersecurity compliance. These topics are vital for budgeting lifecycle costs.

 

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Planning for lifecycle costs is crucial in maintaining control systems. An integrated control system helps manage inventory, obsolescence, and technical support costs, helping control both capital and operating expenditures. GE Vernova offers comprehensive lifecycle management services, including incremental upgrades and preventive maintenance plans, to help ensure the long-term sustainability of your control systems.

Enhanced risk management

When it comes to risk management, there isn’t a “one size fits all” approach. Your plant’s risks will vary based on your power plant operating profile, in-house capabilities, the age of your control systems, the operating system installed on HMIs, and more.

Depending on the outcomes of your risk assessment, you will need to address short-term issues like technical support, technical and people readiness, inventory assessment and ordering, record parts, cyber risks, and compliance with cybersecurity standards. There are also long-term issues that should be addressed, including having a preventive maintenance plan in place, maintaining the cybersecurity posture, assessing resources and capabilities, training staff, and managing equipment obsolescence.

With integrated plant controls from GE Vernova, you will have comprehensive risk assessments tailored to the unique operating profiles of your power plant. This approach includes evaluating technical support readiness, inventory, cyber risks, and compliance with cybersecurity standards. Engage with us as early as possible to benefit from a comprehensive risk profile that covers your entire plant.

Integrated cybersecurity
With increasing cyber threats, securing industrial control systems is paramount. GE Vernova’s advanced cybersecurity measures include patch validation programs, remote patching services, and comprehensive cybersecurity assessments. These measures ensure that systems remain secure and compliant with industry standards.

Reach out to us to:

  • Elevate your cybersecurity awareness
  • Identify potential cybersecurity vulnerabilities
  • Develop a roadmap of actions and mitigations
  • OT-specific controls for industrial control system environments
  • Industry-recognized assessment framework
  • Onsite and remote patching services

Business Continuity
At the end of the day, customers care about having a more reliable power plant. There are several key issues you should consider in the event that you run into an issue:

  • How fast can I solve the problem?
  • Do I have trained maintenance personnel at the facility to solve problems?
  • If I don't have capable people onsite, do I have timely access to expertise, considering the industry-wide shortage of qualified personnel?
  • Do I have the necessary parts in stock for quick replacement and restart of the power plant?
  • Am I prepared for disaster recovery?

Having a plan to address business continuity is crucial to minimizing plant downtime and maintaining higher reliability. With an integrated plant control system from GE Vernova, you can proactively address key issues like rapid problem resolution, availability of trained personnel, and disaster recovery readiness. Our service offerings also support your needs with 24/7 technical support and virtual assistance.

Additional GE Vernova offerings

Technical Support and Training
GE Vernova helps customers stay ahead of technical issues with a suite of services and training based on global customer feedback, with a goal of reducing downtime by keeping control systems healthy, secure, and updated.

Our services include:

  • Technical support via phone, email, and remote diagnostics.
  • Preventive maintenance to avoid planned downtime.
  • Parts coverage, including repair and return, new parts, remanufactured parts, and a PartSmart subscription program.

In addition, GE Vernova offers tailored training programs to help maintain a skilled workforce capable of handling advanced control systems. Our training academy offers various formats to suit different needs, enhancing overall plant performance and knowledge.

Parts and inventory management
GE Vernova's parts-related offerings provide efficient, secure, and updated solutions for control systems:

  • PartSmart program
    Agreed parts are stocked at our Colorado facility for same-day pickup, which is ideal for customers needing quick delivery without maintaining inventory. This reduces upfront costs, avoids on-site storage, and ensures quick replenishment. The warranty starts upon purchase, and GE Vernova manages obsolescence risk.
  • Certified card repairs
    Offers remanufactured, repaired, and exchanged production cards using OEM test fixtures in an ISO 9001 certified repair center. Technicians are IPC certified, and firmware is upgraded on all repaired cards to maintain the older fleet with OEM standards.
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Efficient management of spare parts and inventory is vital for reducing operational costs and minimizing downtime. The PartSmart program offers vendor-managed inventory solutions, ensuring parts are readily available without the high upfront costs associated with traditional spare part storage. This approach reduces obsolescence risks and optimizes warranty usage.

In closing

GE Vernova’s integrated plant controls deliver numerous benefits, from faster installation and reduced costs to more efficient operations and enhanced risk management. With our extensive range of services, we can help you get the most value of your integrated plant controls, helping ensure your power plant operates at its best while maintaining long-term sustainability and security. Reach out to the GE Vernova team to learn how we can support your plant's unique needs and help improve performance and reliability.

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 Chris Long

Chief Commercial Officer for GE Vernova’s Control Solutions and Services business

In this role, Chris is responsible for commercial strategy to drive excellence and controls growth in collaboration with the broader Gas Power and other GE Vernova businesses. 

Chris has 18 years of experience in Gas Power controls. He joined GE as a controls engineer in 2006 with early assignments focused on the development of our OpFlex solutions for the F-class fleet.  After a stint in NPI program management, Chris spent a decade in progressively responsible controls engineering leadership roles.  

In 2020, Chris shifted to the controls product management executive leading the strategy and re-vitalization of the MarkVIe controls product line, as well as the acquisition and integration of the Nexus Controls business.  As of February of this 2024, Chris has led the global sales & commercial operations for the Control Solutions & Services business. 

Chris holds a B.S. in Chemical Engineering from Clemson University, a PhD in Chemical Engineering focused on Industrial Process Controls and an MBA from the University of South Carolina. 

Frequently asked questions

Learn more about integrated plant controls

How can integrated plant controls allow for greater flexibility of operations and help complement renewables?

Integrated plant controls enhance flexibility and operational efficiency, which is increasingly important with the rise of renewable energy sources. Combined cycle power plants, for instance, have shifted from base-loaded duty cycles to more frequent start-stop operations and lower load operations several times a day. Additionally, plant controls facilitate fuel-efficient operations while staying within emissions limits, which is crucial as plants adapt to higher renewable penetration. 

Is there a difference between integrating a plant control system in a new plant versus replacing existing controls on an existing plant? If so, what are the differences?

For a new plant, integration is generally more straightforward because the control system can be planned and designed from the ground up. Design considerations can include integrated plant controls from the outset, making the process more efficient.

In contrast, replacing controls on an existing plant involves additional complexities. These include understanding the existing control philosophies, cabling, networking, cybersecurity setups, and equipment parameters. However, this process can be managed effectively, often by implementing changes in a phased manner during scheduled shutdowns or outages to ensure a smooth transition.

Can generation and BOP (Balance of Plant) equipment be integrated into a single plant controller, and can the controller be operated remotely?

Integrating generation and BOP equipment into a common system (not necessarily a single controller) is achievable and beneficial. Remote operation feasibility depends on several factors:

  • Control vs. Monitoring: Deciding whether remote access is for control or monitoring influences the complexity and security measures required.
  • Cybersecurity: Ensuring robust cybersecurity measures to protect against threats is crucial. This includes access controls, network security, and monitoring for potential threats.
  • System Integration: Being able to communicate with various protocols commonly found in plant environments such as DNP 3, OPC UA, Foundation Fieldbus, IEC 61850, and Modbus allows seamless integration of diverse equipment into a unified control system.

What should be considered for the successful implementation of integrated plant controls and remote operations?

  • Understanding Existing Controls Architecture: For existing plants, knowledge of current control systems, cabling, and network setups is essential.
  • Phased Implementation: Implementing controls in phases, especially for existing plants, ensures smooth transitions and minimizes disruptions.
  • Cybersecurity: Robust security measures are critical to protect against cyber threats and ensure safe operations.
  • Data Integrity: Ensuring high-quality, consistent data is crucial for effective AI and predictive maintenance applications.
  • Operational Goals: Clearly defining operational goals and desired outcomes helps tailor the integration and remote operation strategies effectively.

Webinars

Hear from our experts

  • Stay ahead of obsolescence
  • Integrated Plant Controls
  • Maintaining your control system

Expert discussion

Stay ahead of obsolescence: Lifecycle Reviews for the Mark VIe

Wednesday, November 13th 3pm MYT, 11am Berlin, 11am NYC

Lifecycle Reviews can help you plan for obsolescence and maintenance, providing crucial insights for your strategy. Join our expert discussion to discover how modular upgrades can extend the service life of your Mark VIe, keeping it secure and efficient for the future.

Register today

On-demand webinar

Unlock operational excellence with Integrated Plant Controls for power generation

Join our experts for a detailed look at Integrated Plant Controls as they provide insights on benefits, customer examples, and cybersecurity importance. Discover streamlined operations, diverse equipment adaptability, and compliance assurance.

Watch now

Webinar

In control: Maintaining your control system throughout its lifecycle

While every facet of your plant is crucial, one important piece is your turbomachinery control system. If something goes wrong, the effects can compound quickly—along with the costs. Join us to learn about ways to keep your system running effectively.

On-demand webinar

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