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Section
Page
Introduction .................................................................................................................3
Acronyms and Abbreviations ......................................................................................3
Product Options ...........................................................................................................4
Architecture .................................................................................................................6
I/O Interface.................................................................................................................8
Diagnostics ................................................................................................................10
Communication .........................................................................................................10
Control Functions ......................................................................................................12
HMI ...........................................................................................................................16
Typical Turbine Instrumentation ...............................................................................18
Packaging ..................................................................................................................19
Typical Power Requirements.....................................................................................20
Introduction
Most existing transmitters,
sensors, and switches are
compatible with the Mark
VI I/O, and, in some cases,
the I/O is totally
compatible.
The Mark VI is a fully programmable gas turbine controller with its own power
supply, processor, communications, and I/O for turbine control, and protection.
Critical functions, such as emergency overspeed, redundant exhaust overtemperature protection, and backup synchronous check protection are provided by
the backup protection module.
Application software is derived from current control and protection algorithms,
originally designed for new gas turbines, and modified only where it is necessary for
compatibility with the existing site conditions. In addition, the controller has the
speed and capacity to implement many new advanced features such as Dry Low
NOx technology. All Mark VI controllers are shipped with application software and
display software.
DCS
EGD
FSR
GSM
GE Standard Messages
GUI
HMI
Human-Machine Interface
GEI-100538A
PDH
rms
RTD
TMR
UDH
UPS
VME
Product Options
The Mark VI controller is available in two state-of-the-art types: simplex and Triple
Modular Redundant (TMR). These vary in cabinet size and I/O configuration
based on the turbine type, application (generator or mechanical drive), and I/O
required at a particular site.
A simplex controller is available in two sizes:
36x 36 (900 mm x 900 mm), which fits into the standard Mark I or Mark II
controller footprint
54x 36 (1350 mm x 900 mm), which fits into the standard Mark II with ITS
controller footprint. This version also provides increased I/O capacity, as well as
a redundant VME rack-power supply.
The standard size of the TMR unit is 54x 36 (1350 mm x 900 mm), which fits into
the standard Mark IV controller footprint (refer to the following diagram).
Control
Protection
Monitoring
Emergency Overspeed
Emergency Overtemp
Backup Synch Check
Devices on UDH:
HMI, EX2000, Mark VI
<P>
Protection Module
<R> Control Module
P
S
Additional
Communications
(if required)
P.S.
CPU
I/O
P.S.
CPU
I/O
P.S.
CPU
I/O
Ethernet - IONet
TMR only
<S> Control Module
P
S
Additional
Communications
(if required)
Ethernet - IONet
P
S
Ethernet - IONet
System Architecture
GEI-100538A
Architecture
Scalable hardware and software make the Mark VI architecture well-suited for gas
turbine control retrofits.
A TMR system is generally
recommended for base load,
DLN, and cogen
applications.
The TMR and simplex versions of the Mark VI controller have equivalent control
and turbine protection capabilities. The primary difference is running reliability.
Running reliability is based on the percent of I/O used in the system, the percent of
I/O classified as critical, and the amount of redundancy.
TMR systems have the highest running reliability, represented by a longer Mean
Time Between Forced Outage (MTBFO) than other types of controllers.
Select a TMR system when:
Co-generation (cogen) plants where the gas turbine exhaust is the only source of
heat to generate steam for the production process and steam turbines
Turbines are equipped with triplicated field devices, for maximized running
reliability
Using non-base load applications that are not critical to other plant processes
s=.
GEI-100538A
I/O Interface
Terminations support the
existing #12 AWG (3.0
mm2) wires at site with
barrier type terminal blocks
for ease of maintenance.
The Mark VI is designed for direct interface to turbine and generator devices such as
vibration sensors, flame scanners, linear variable differential transformers (LVDT),
magnetic speed pickups, thermocouples, and resistance temperature detectors
(RTD). Direct monitoring of these sensors reduces the need for interposing devices
with their associated single-point failures. Direct connection to a field device reduces
long-term maintenance, and enables diagnostics to directly monitor the health of
devices mounted on the machinery.
Contact inputs are normally powered from the 125 V dc battery bus (optional 24
and 48 V dc) through the Mark VI termination boards. Each contact input is optically
isolated and has a 1ms time stamp for Sequence of Events (SOE) monitoring.
Terminations for existing contact inputs can be replaced 1-for-1 or split up for
greater alarm resolution. For example, instead of having several field contacts wired
to a single contact input for the Lube System Trouble alarm on the enunciator
window, they can be separated into multiple contact inputs to provide a separate
alarm message for each problem in the lube oil system.
Contact outputs are from plug-in, magnetic relays with dry, Form-C, contact
outputs. Turbine solenoids are normally powered from the 125 V dc battery bus with
suppression for each solenoid with a 3.2 A slow-blow fuse on each side of the feeder
circuit.
Analog inputs monitor 4 20 mA (250 ), which can be configured for selfpowered, differential inputs, or as sensors that use a +24 V dc supply from the Mark
VI. Selected inputs can be configured for 0 1mA inputs (5,000 ) or 5, 10 V dc
inputs. This interfaces to
Most Mark II generator drive systems already have these transducers; however,
Mark I systems do not. Compressor discharge pressure biases the temperature
control system to improve turbine operation.
Analog outputs can be configured for 4 20 mA output (500 maximum) or 0
200 mA output (50 maximum).
Thermocouple inputs can be grounded or ungrounded. Software linearization is
provided for type J and K thermocouples used on GE gas turbines plus types E, S, or
T thermocouples. Existing control and overtemperature thermocouples are retained
and divided between the Mark VI controller and the backup protection module for
temperature control and overtemperature protection, respectively.
RTD inputs can be grounded or ungrounded. Software linearization is provided for
10 copper, 100/200 platinum, or 120 nickel RTDs. The generator or load
compressor RTDs can be monitored directly by the Mark VI with all turbine and
driven-load temperatures being collected in a common database with other turbinegenerator parameters.
Speed inputs. Redundant, passive, magnetic speed sensors provide an input to the
control module(s) for speed control and overspeed protection. Emergency overspeed
protection is provided electronically; mechanically on older turbines. A separate
backup protection module is provided with separate power supplies, processors, and
I/O cards to provide enhanced machine protection. Overspeed detection by either the
primary or emergency electronic trip systems or the mechanical overspeed bolt
automatically de-energizes the hydraulic solenoids.
Flame inputs. A direct interface is provided for ultra-violet flame scanners that
produce a pulsed output. This eliminates any interposing transducers and enables the
diagnostics to monitor the actual light level. An alarm is initiated if the light level
diminishes below an acceptable level due to carbon or other deposits on the scanner
window.
Integrating servo interface. The Mark VI provides a direct interface to the bipolar
servo actuator and LVDT valve position feedback. Bi-polar integrating servo current
outputs are provided in 10, 20, 40, 80, and 120 mA ranges for fuel valves and Inlet
Guide Vane (IGV) control. Mark VI LVDT excitation is 7.0 Vrms at 3.2 kHz. Pulse
rate inputs are also provided for servo control loops using liquid fuel-flow, pulse-rate
feedback.
Vibration protection. A direct interface is provided for vibration protection sensors,
which are required to trip the turbine. This includes seismic (velocity) type sensors
used on heavy-duty gas turbines and accelerometers on aircraft-derivative gas
turbines. This eliminates the single-point failure of a separate monitoring system, and
allows Mark VI diagnostics to monitor seismic sensors when the turbine is running
or stopped. Aircraft derivative applications primarily use accelerometers, which
produce a velocity signal from external charge amplifiers. The Mark VI contains
speed-tracking filters to isolate the appropriate vibration frequencies of each shaft for
the display, alarm, and trip.
GEI-100538A
Synchronizing interface includes one generator PT and one line PT to match the
generator frequency (turbine speed) to the line frequency and match the generator
voltage to the line voltage through commands to the generator excitation control.
The Mark VI monitors actual breaker closure time and self-corrects each time the
breaker closes.
Diagnostics
Mark VI diagnostics include power-up, background, and manually initiated
diagnostic routines capable of identifying both control panel, sensor, and output
device faults. These faults are identified down to the VME board and terminal board
level for the panel, and to the circuit level for sensors and actuators.
Communication
The Mark VI uses the following communication networks.
Unit Data Highwat (UDH) is an Ethernet-based network that provides peer-topeer communication between the Mark VI and a GE generator excitation
control. The network uses Ethernet Global Data (EGD), a message-based
protocol with support for sharing information with multiple nodes based on the
UDP/IP standard. Data can be transmitted unicast or broadcast to peer
controllers on a network with up to 10 network nodes at 25 Hz.
Administration messages
Ethernet TCP/IP
Modbus
RS-232C/RS-485
Modbus
Plant DCS
IRIG-B
Time Sync
HMI
Operator
Station
HMI
Operator
Station
Ethernet UDP/IP
Gas Turbine
Control
Mark VI
Generator
Excitation
EX2100
Typical Network for Mark VI and EX2100 with Direct Connect to DCS Option
GEI-100538A
Control Functions
The control functions below are typical for a single-shaft generator drive application.
Nozzle control for two-shaft machines and load compressor controls are also
supported by Mark VI.
Startup control is an open-loop system that increases the fuel stroke reference as the
turbine startup sequence progresses to preassigned plateaus.
Acceleration control adjusts the fuel stroke reference according to the rate of
change of the turbine speed to reduce the thermal shock to the hot gas path parts of
the turbine.
Speed control uses the median speed from three speed sensors for droop and
isochronous speed control with an automatic transfer to isochronous upon loss of the
tie-line breaker. Separate shaft speed-control algorithms are provided for each shaft
in multi-shaft machine applications. The Mark VI varies shaft speed to control real
power (megawatt) output in a mechanical (compressor or pump) drive application. In
a generator drive application, the Mark VI maintains a constant generator shaft speed
to meet the electrical power demand and also controls the generator field through the
use of VAR/Power Factor (PF) control algorithms to generate excitation raise and
lower commands.
Generator load control compares the load setpoint with the MW feedback from a
single-phase transducer and adjusts the speed setpoint to regulate the load. A
Spinning Reserve selection allows the machine to start automatically and await an
operator input to synchronize to the grid. Selection of Fast Load Start or Preselected Load raises the output to the Pre-selected Load setpoint limit. Selection of
base or peak raises this setpoint to the maximum limit.
Exhaust temperature control algorithms sort the input from each thermocouple
from the highest to the lowest temperature. They automatically reject bad
thermocouple data, average the remaining data values, and execute the control
algorithm based upon the average calculated temperature. Redundant transducers
monitor the compressor discharge pressure and bias the temperature control to
correct for ambient conditions and the corresponding variations in mass flow.
Inlet guide vane control modulates the position of the compressor stator vanes to
provide optimum compressor and unit operation. During startup, the guide vanes
open as the turbine speed increases. When the unit is online, the guide vanes
modulate to control turbine airflow temperature to optimize combustion system and
combine-cycle performance.
Fuel control is a reference from the governor and feedback of the fuel control
valves. The Fuel Stroke Reference (FSR) is determined by the turbine parameter
(speed, temperature, and so on) calling for the least fuel. FSR calculation occurs in
the main processor, then is transmitted to the servo valve cards on the backplane of
the control module(s). Liquid fuel control establishes the FSR of the bypass valve.
Fuel flow is proportional to the speed (Fuel Flow = Speed X FSR). Gas fuel control
uses a Gas Control Valve (GCV), where fuel flow is a function of pressure (Fuel
Flow = Fuel Pressure X FSR). An added Stop/speed Ratio Valve (SRV) opens as a
turbine speed function, so pressure becomes a function of speed and the liquid fuel
control system and the gas fuel control systems have the same characteristic.
Control Module
Main Processor
Constants
FPRG
Logic
TNH (Speed)
VCMI
Card
Termination
Board
VSVO Card
Software
Regulator
Servo
90SR
D/A
TSVO
+
-
LVDT
96SR
A/D
VAIC Card
TBAI
D/A
FSROUT
Software
Regulator
Gas Fuel
Pressure
96FG
Gas Control
Valve
VSVO Card
Logic
Stop/Speed
Ratio Valve
Servo
65GC
D/A
TSVO
LVDT
96GC
A/D
FSR2
Combustion
Chamber
Logic
Fuel
Splitter
FSR
Stop/Speed
Ratio Valve
FSR1
Pulse
77FD
A/D
VSVO Card
FSROUT
Flow
Divider
TSVO
TNH (Speed)
Logic
Software
Regulator
Servo
65FP
D/A
Liquid Fuel
GEI-100538A
Sequencing
Turbine control can include automated startup and shutdown sequences customized
to meet operator requirements, as well as control and monitoring of all gas turbine
auxiliary and support systems. Operators can have the turbine automatically
sequence to intermediate hold points by selecting Crank, Fire, or Auto without
enabling automatic synchronization. All ramp rates and time delays are preprogrammed for optimum performance. Timers and counters record long-term
turbine operating information that can include:
Total starts
Fired starts
Emergency trips
This automation enables gas-turbine operation from a remote site with the assurance
that the turbine fully protected. Diagnostics capture a record of any abnormal
conditions.
Protection
Turbine control monitors all control and protection parameters and initiates an alarm
if an abnormal condition is detected. If the condition exceeds a predefined trip level,
the turbine control drives the gas/liquid control valves to a zero-flow position and deenergizes the fuel shut-off solenoids. All control, protection, and monitoring
algorithms are contained in the control modules for efficiency in sharing common
data. The protection module includes standard backup turbine protection that meets
OEM tripping reliability requirements for turbine overspeed, overtemperature, and
sync-check protection.
In a typical installation, a trip solenoid is powered from the 125 V dc floating battery
bus with:
Contacts from the control module in series with the negative side of the bus
Contacts from the backup protection module in series with the positive side of
the bus
Additionally, diagnostic and
trip data is communicated
between the control module
and the backup protection
modules on the triple
redundant I/O Nets for
cross-tripping.
Diagnostics monitor:
Contact from each relay
Voltage directly across the trip solenoid
Overspeed protection includes a primary overspeed monitoring system in the three
control modules and an emergency overspeed monitoring system in the backup
protection module that replaces the mechanical overspeed bolt used on older
turbines. The control module and each section of the backup protection module
monitors magnetic speed sensors from 2.0 rpm on a 60-tooth wheel. Diagnostics
monitor the speed and acceleration, then exchange the data between the control
module and the protection module on startup to verify that all sensors are active.
Types
Pre-ignition
Post-ignition
Loss of flame
High exhaust temperature
Exhaust thermocouples open
Compressor bleed valve position trouble
Load tunnel temperature high
Gas fuel hydraulic pressure low
Turbine lube oil header temperature high
Turbine electronic overspeed
GEI-100538A
HMI
Engineering workstation
All control and protection is resident in the Mark VI controller, which allows the
HMI to be a non-essential component. With the turbine running, it can be
reinitialized or replaced with no impact on the controller. The HMI communicates
with the processor in the controller through the UDH.
Gas turbine control screens show a diagram of the turbine with the primary control
parameters. The diagram is repeated on most of the screens to provide a visual image
of the turbines performance while changing screens.
Typical Gas Turbine Screens
Control
Screens
Startup
Motors
FSR control
Generator/exciter
Synchronizing
Monitor
Screens
Bearing
temperature
Exhaust
temperature
Generator RTDs
Wheelspace
temperature
Seismic vibration
Auxiliaries
Flame
Tests
Overspeed
test
Water wash
Start check
Trip diagram
Timers
The main screen is the Startup screen. Since the gas turbine control provides fully
automatic startup including all interfaces to auxiliary systems, all basic commands
and all primary control parameters and status conditions start from this screen.
For example, the Start command can be sent to the Mark VI when Ready to Start
displays in the startup status field. A pop-up window displays above the Start-up
button for verification. Upon verification, the application software checks the startup
permissives and starts a sequence that displays Starting and Sequence in Progress
messages.
If startup permissives were not satisfied, the message Not Ready to Start displays,
with a message in the alarm field that identifies the reason. Additionally, when the
Aux button is clicked and the Start Check screen is selected, it displays graphical
information for the Start Check/Ready to Start permissives.
Trip conditions that display in the alarm field and in the Trip Diagram are accessed
by clicking the Aux button and selecting the Trip Diagram screen. A trip during
startup causes the message Not Ready to Start.
Mark VI also allows you to change a numeric setpoint, such as Megawatts (MW) for
a generator drive or Speed Reference (TNPREF) for a mechanical drive, by entering
a setpoint value rather than issuing continuous discrete raise/lower commands. The
Mark VI application compares the requested setpoint with acceptable limits and the
present output to determine a suitable ramp rate to the new target.
o 00
vi a
000
GEI-100538A
Parameter
Device Type
28FD
Flame detector
Flame scanner
39V-x
Vibration sensor
Velocity pickup
65FP
Torque motor
65GC
Torque motor
65NZ
Torque motor
77FD
Magnetic pickup
77NH
Magnetic pickup
77NL
90SR
Torque motor
90TV
Torque motor
96FG-2
Transducer
96GC
LVDT
96NC
LVDT
96SR
LVDT
96TV
LVDT
CTDA
CTIF
Thermocouple
Thermocouple
Thermocouple
Device Type
12HA
Limit switch
20FG
Solenoid valve
20FL
Solenoid valve
26FD
Temperature switch
GEI-100538A
26QN
Temperature switch
33CS
Starting clutch
Limit switch
33FL
Limit switch
33HR
Ratchet position
Limit switch
45F-x
Fire detector
Temperature switch
63AD
Pressure switch
63FD
Pressure switch
63FG
Pressure switch
63HG
Pressure switch
63HL
Pressure switch
63LF1
Pressure switch
63LF2
Pressure switch
Pressure switch
63QL
Pressure switch
63TF
Pressure switch
71QH
Pressure switch
71QL
Level switch
71WL
Level switch
Packaging
Mark VI packages can be customized to meet any site requirement. Package options
that fit into the Mark I, Mark II and Mark IV footprints are shown below.
Component
Description
Card Backplane
Cabinet
Cable Entrance
Material
Sheet steel
Terminal Blocks
Width
Dimensions
- Cabinet Option #1 36" (900 mm)
- Cabinet Option #2
GEI-100538A
Depth
Height
Weight
A separate
uninterruptible power
supply (UPS) is required
to power the HMI and
network equipment.
Steady-state Voltage
Termination boards for the field contact inputs and the turbine solenoids
Additional 3.2 A fuse protection is provided on the termination board for each
solenoid. A 120 V ac feed is provided for ignition transformers. Control cabinet
power specifications are shown below.
Frequency
Load
Comments
10 A dc
47 - 63 Hz
15 A rms
47 - 63 Hz
7.5 A rms
GE Energy
1502 Roanoke Blvd.
Salem, VA 24153-6492 USA
+1 540 387 7000
www.geenergy.com
GEI-100538A
Revised 051109
Issued 020525