Case study of an upgrade for the GCP & AVR system as part of a revamp project of the overall turbine package.

The challenge

The original equipment was installed approximately 40 years and was not part of the control system upgrade in 2004.

The customer was primarily interested in replacing the equipment due to component obsolescence. We were requested to engineer a like for like replacement using the latest state of the art components and incorporating modern day generator control philosophy, thus increasing the package reliability and availability. 

The new GCP & AVR panel had to interface to the control system that was retrofitted circa 2004 and was also required to accommodate and house remote I/O modules from the existing Load Management System.

Our solution

To design, build and test a replacement GCP and AVR panel having the same functionality as the old panel, but using the latest available components.


  • Provision of new Drawings in AutoCAD format.
  • Provision of new GCP & AVR Panel and Associated Electronics to match the current Controls System that was retrofitted circa 2004.
  • Provision for the remote I/O modules and power distribution equipment required for the existing Load Management System.
  • Provision of test procedure and point to point wiring schedule.
  • Witness Test of completed GCP & AVR Panel.




Our attention to detail corrected many of the faults of the original drawings and provided enhancements to the original starter panel design thus ensuring the replacement starter panel will provide functionality for years to come. We offer like for like component replacement in an existing Starter Panel or a proven replacement design for any failing Avon Starter Panels in the Field.