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The turbine control based on S7 Technology

Older control systems such as the Speedtronic Mark I or II, cannot support today’s demands for a modern turbine
control. For example, they are not capable of controlling the complicated requirements for DLN (Dry Low NOx) –
NOx reduction processes.
The MACH 7 is a fail safe programmable control, that supports all gas turbine processes, including the existing
auxiliaries, for protection, control, and operation. The highly efficient performance makes it possible to extend
the controls to include high complex control problems of auxiliary components, which become necessary due to
new developments, environmental regulations, etc. without any problems.

Technical Specification

Our control concept is based on the highly efficient modular, expandable SPS – platform for complex automation
solutions, especially tailored for the actual requirements in the power generation industry.

The control structure has been proven and tested worldwide in plants, systems, and processes where a high
standard of safety and reliability is required and must be guaranteed. (Aviation, chemical processes, nuclear
power plants, military applications, etc.)

An open, free programmable system, that is easily expandable in regard to extra control functions.

All regulation and control parameters for presently known functions, like DLN, water and steam injection,
compressor surge control, etc., are included in the control and can be easily activated if required.

All the plant parameters (digital and analog values, process and diagnostic alarms) are put on a local plant
“Industrial Data Highway” (Industrial Ethernet), a standardized bus system. The initial conditioning of the data is
the basis for further signal processing.

All control components are under a continuous self-diagnosis that can determine a problem before it has an
influence in the process.

The processor can be repaired while in operation or even replaced. After a repair or replacement, the processor
will be automatically put in the “HOT STANDBY MODUS“.

Extremely high performance.

Highest availability and reliability.

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Flexibility through a simple realization of a de-centralized structure and extensive communications possibilities.

Broad and clear organization of standard components. Data information and functional descriptions are included
in the delivery.

The control is composed of only standard components. An economical solution to a complete spare part
inventory is possible. Due to the standard components used, the customer has an overview of all the spare parts

No ventilator required.

Easily expandable bus system without any influence on the existing equipment.

Change out of I/O modules while under power is possible.

Software updates as well as software changes can be made during operation.

Resolution of analog values average between 0.0015% and 0.025% (16 – 12 bit).

The layout of the I/O for any turbine application includes a minimum of 20% spare inputs and outputs.

All project data signals can be stored in a central databank as well as a decentralized databank (long term data

Time synchronizing of the system can be accomplished with either radio controlled clock or a GPS signal.

Input signals and protocol logging are time-tagged with millisecond exactness.

The time lag between an issued command and the feedback from a control center, for example, is under 1 second.

Connections to normal office networks are possible.

Data can be exported in ASCII, XML, or Excel format for further analysis.

Data visualization over a WEB Server possible.

Real-Time and LongTime-Trending with numerous extra functions.

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CPU Used

The Mach 7 Turbine Control uses Siemens Processor S7-417-4H.

Inputs / Outputs with respect to the Functional Modules

The selection of inputs / outputs and functional modules is determined by the turbine and the functional
application. Inputs as well as outputs are terminated on the redundant I/O modules as to priority (critical for fail
safe operation). The I/O modules used are standard SIMATIC S7 modules. With a de-centralized control structure,
the gas turbine signals as well as the local auxiliary equipment are processed with the standard modules (ET200M)
and the data communication to the processor is carried out over the Profibus DP 12 Mbit. A safe and failure-free
operational data exchange between the I/O modules is guaranteed. The MACH 7 was designed with respect to the
turbine type, with a minimum of 20% spare input and output signals. This guarantees there is always enough
capacity for later modifications, or perhaps adding the control of external accessory functions or the addition of
new hardware. Even after the spare 20% capacity is used, the control can be expanded by connecting extra
modules, making the capacity virtually unlimited. The theoretical upper limit adhering to the active redundancy
as well as the software redundancy lies at 131,072 digit inputs/outputs and 8,192 analog inputs/outputs.

Functioning principles of the internal as well as the external communications

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MACH7 suitable gas turbines

Control Panel Hardware

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Panel layouts for a typical Mark I to Mark VI retrofit

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