Customizations Modifications & Upgrades

Tailored engineering solutions that boost efficiency, enhance reliability, and extend plant life, designed in collaboration with your team for lasting impact.

Extend Asset Life. Improve Performance. Solve Legacy Challenges.

At Hughes Technical Services, we help power plants modernize and adapt. Whether you’re facing obsolete equipment, performance bottlenecks, or evolving regulatory requirements, our team delivers engineered modifications and tailored upgrades that reduce risk and improve reliability, without the need for a full OEM replacement.

Hardware Modifications

Retrofit of outdated mechanical or electrical components
Servo and actuator replacement (OEM or custom-built)
Instrumentation and valve conversions
Field wiring redesign and replacement

Control System Upgrades

Logic rewrites and sequence optimization
Replacement of legacy platforms (P13, ALSPA™)
New control cabinet builds and panel rewiring
Integration of modern HMIs and remote access capabilities

System Customizations

Application-specific modifications (e.g., dual-fuel systems, emissions tuning)
Balance-of-plant control updates
Custom firmware and settings for new operating conditions
Support for heat rate and start-up optimizations

Our Services

Explore Our Solutions

Ready to improve performance or solve a legacy problem? Let’s design the right solution for your plant.

How We Work

Assess

Site evaluation, asset review, and operating needs

Engineer

Custom hardware, logic, or system-level upgrades

Implement

Installation, testing, and full documentation

Support

Post-install tuning, training, and remote support

Common Challenges We Solve

Obsolete or unsupported OEM systems
Spares no longer available
Repeated equipment failures
Integration issues after repowers or retrofits
New safety or environmental regulations

Why Choose HTS for Custom Upgrades?

Expert engineers with hands-on turbine experience
Field-proven solutions developed around real-world plant needs
Seamless integration with commissioning and mechanical teams
Not tied to any OEM — we work in your best interest

Advanced System Upgrades You Can Rely On

Explore a range of specialized upgrades and retrofits designed to extend equipment life, improve performance, and ensure compliance across your plant’s most critical systems.From calibration to complex control systems, our team delivers dependable solutions tailored to your plant’s needs.

BOV Fiber Optic Upgrade

Replace existing Numar proximity switches with high temperature fiber optic cables and thermocouples to identify valve seat leaks

Applicable Unit Configurations: GT11N, GT11N1, GT13D, GT13E1, GT13E2

BOV Air Block Upgrade

Replaces existing air over hydraulic block to direct piping to BOV’s by way or solenoids that are routed in a 2oo3 pressure switch configuration

Applicable Unit Configurations: GT11N, GT11N1

Flame Detection Upgrade

Rack mounted upgrade that replaces ABB DFS flame monitors with BFI (Flamonitec)

Applicable Unit Configurations: GT11N2, GT13E2, GT24, GT26
CFC2000 – Configurable Optical controller that uses proprietary Flamonitec software to change thresholds and can be used as high speed historian

Applicable Unit Configurations: GT11N, GT11N1, GT11N2, GT13E2, GT24, GT26

Flame Intensity Upgrade

Magnetic device that plugs directly into existing FireEye flame detections that allows for intensity to be displayed on HMI for trending and monitoring

Applicable Unit Configurations: GT11N, GT11N1, GT11N2

ATOs Upgrade

Upgrading existing obsolete ATOs rack mounted modules to new din-rail mounted modules. Includes removal of existing system, installing and rewiring new modules, commissioning and bias adjustment performed with customer.

Applicable Unit Configurations: GT11N2, GT24, GT26

Pulsation Monitoring Upgrade

Upgrading existing pulsation

Switch-Over Device Upgrade

Removal of existing cascading relays and replicating in existing control system utilizing interposing relays

Applicable Unit Configurations: Any units that have SFC switch-over device currently installed

SFC Upgrade

Upgrade front end controllers of currently installed SFC

Applicable Unit Configurations: All Alstom/ABB units

AVR Upgrade

Upgrade existing AVR

Applicable Unit Configurations: All Alstom/ABB units

PLC to Customer Control System

Any PLC that is currently within the plant (i.e. CCW, Ventilation, Water Wash, Fogging, etc.) to be wired to the existing control system and displayed on current HMI for operators to view and control.

Applicable Unit Configurations: GT11, GT13, GT24, GT26

Ventilation System Upgrades

Replacing existing remote PLC and adding logic into existing control system

Applicable Unit Configurations: GT11, GT13, GT24, GT26

Customer Requested Logic Modifications

Applicable Platforms; Advant, Progress 3 (P13), BlueLine (P13), Alspa, P320, P400, GE Fanuc, MarkV, MarkVI, MarkVIe

Mark V to Mark VIe Conversions

Procurement of parts, logic conversions, installation and commissioning

Data Acquisition Upgrade – Canary

Installation of high speed historian capable of recording data at control system bus speeds. High compression rate allows for large amounts of data to be recorded without compromising hard drive space

Upgrade from DEPP 3.1 and DEPP2000
Applicable Platforms: P13 and Advant

HMI Upgrades – iFix

HTS HMI Information (pdf)

Intraplant Bus Upgrades (P13)

Upgrades the existing IP bus to new fiber optic, redundant IP utilizing DH01’s and DH02’s

NOx Trimmer Modifications

Controls modifications along with real time data from CEMS and pulsations systems to auto tune the unit to stay within CEMS compliance and below pulsation thresholds

Applicable Unit Configurations: GT11N, GT11N1, GT11N2

Water Bias Modifications

Integrated logic for systems that utilize water to control Nox. This allows customers to

Hydraulic Block Upgrades

Engineer and retrofit hydraulic trip blocks and EHCs for gas turbine and steam turbine units

Perform all engineering drawings, logic modifications, and commissioning

Applicable Unit Configurations: GT11N and various ABB Steam Turbines

Voith Servo Retrofits

I/H Conversions for any applicable EHC as well as engineered servo retrofits in conjunction with Voith.