GE Turbine Control Systems

SPEEDTRONICTM Mark VI
Turbine Control

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 3 Generations of Microprocessor Control

Mark IV Mark VI Mark V

1983 1999 1991

3,000 Turbines Running

2
 Phased Product Introduction

1998 Ran Gas & Steam Turbines in GE Plants

“Prototype”

1999 Retrofit Customer Turbine Controls

“Initial Commercial Units”

2000 H ICS, 7FA, Medium ST, IST, LM’s

“New Unit Applications”

2001 7EA, 7FB, 9FA, LST, FPT

“Expanding applications”

2002 9EA, 6FA

“Completing the Product Line”

3
 Mark VI Production facilities

Hardware / Software Integration Test

z Consolidate Production & Testing In-house

z Improve Quality
- Card Design
- Card Manufacturing
- Cabinet Assembly
- Automated Test of Assembled Hardware
- Software Design
- Hardware / Software Integration Test

New Surface Mounted Technology Line New Assembly & Test Facility

4
 Control Applications

Gas Turbines
z Heavy Duty
z Aero Derivatives The Power Island
Steam Turbines z HRSG/Mechanical Auxil.
z Industrial z Balance Of Plant
z Utility z Static Starters
z Generator Protection
Applications
Generator Excitation
z Regulators Drives
z Potential Source z Generator
z Compound Source z Compressor
After-market z Pumps
z Control Retrofits
z Service
z Parts
5
 Product Design Objectives

z Retain
– Control and protection philosophy
– Direct interface to sensors/actuators
– Long Term Support
z Improve
– Flexibility of platform (scaleable)
– Packaging (maintenance)
– Reliability
– Application software tools
– HMI and network interfaces
z Leverage industry standards

Designed to Customer Requirements

6
 Mark VI Benefits

Reliability Triple Modular Redundancy (TMR) offers

highest running reliability
All critical hardware and software triplicated
to eliminate single point failures

Two independent protection systems (over

speed and over temperature)

Direct sensor connections with no

interposing instrumentation reduces single
point failures

All circuit cards have common core hardware

and operating systems resulting in
decreased variation and improved overall
reliability
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 Mark VI Benefits

Flexibility z Modular and scalable design of control

and I/O units enables custom
and configuration for each customer
Common
z Upgradeable controller and I/O cards
Functionality extends product life

z Uses industry standards

– Ethernet ® Networking

– Protocols (EGD, Modbus)

– Window’s ® based human-machine

interface
– VME backplane /architecture

• User-friendly design includes common

human-machine interfaces, control
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screens, and maintenance tools
 Mark VI Benefits

Reduced z Comprehensive diagnostics reduce

Operating system repair time through rapid
Costs troubleshooting

z On-line repair of TMR controllers

minimizes number of forced outages

z Direct sensor interfaces reduce spare

part requirements

z Common operator interfaces and tools

improve operator efficiency and reduce
training needs

z Barrier-type terminal boards designed for

easy access and maintenance
9
Control Architecture

z Control Modules

z I/O Interface

z Packaging

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 Typical TMR Cabinet Lineup (H, 7FA, D11, LST)

• E-coat Primed
• Pebble Gray RAL 7032
Mark VI Mark VI Mark VI
• NEMA 1 Convection Cooled
• Top/Bottom Cable Entrance
Termination Control Termination
• Front Access
Cabinet Cabinet Cabinet
• Depth = 600mm
• Height = 2,324mm

1,600mm 1,000mm 1,600mm

• Terminations • Card Racks • Terminations
• Signal Conditioning • Signal Conditioning
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Center Cabinet

Backup Protection Module

3 Independent Sections

3 Control Modules

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 Cabinet Lineup

Low Level TBs High Level TBs

z Servos z Contact Inputs
z Speed Inputs z PT & CT Inputs
z Vibration z Relays
z 4-20ma I/O
z Thermocouples
z RTDs

13
Control Module

VME Rack: 21 Slots

Power Supply

• Industry Standard VME Rack

• Expandable / Shrinkable
• QNX Operating System
• Processors on Every Card

Cables to Termination
Boards

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Mark VI Circuit Cards

z 1 Slot - VME Cards

z On Board DSP Processors
z Designed to Plant MTBFO Targets
z Designed for Direct Interface to Sensors & Actuators

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Termination Boards – Barrier Type

z Pluggable Terminal Blocks

z Shield Bar Attached To TB
z Latching “D” Type Connectors
z ID Message In Each Connector
- Serial Number
- Revision Number
- Connection Location
z Disconnect switch assembly available

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Termination Boards – Box Type

z Mounted On DIN Rail

- Signal Condition & Termination
z Latching “D” Type Connectors
z ID Message In Each Connector
- Serial Number
- Revision Number
- Connection Location

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 VME Card & Termination Board ID’s from Network

------Rack <T0>, Slot 17, Card Type: VRTD------

Lbl NID States Firmware ID ROM serial # Barcode Hardware Catalog # Connector
--- --- ------ ------------ ------------ ------- -------------------- ---------
1 0 00 6A VRTD-050300C 000000F1F273 3369838 IS200VRTDH1CBA
13 1 00 00 000001919546 4295777 IS200TRTDH1BAA JTA
14 2 00 00 000001919517 4295777 IS200TRTDH1BAA JTB

------Rack <R0>, Slot 18, Card Type: VTCC------

Lbl NID States Firmware ID ROM serial # Barcode Hardware Catalog # Connector
--- --- ------ ------------ ------------ ------- -------------------- ---------
1 0 00 6A VTCC-060201A 0000022B934C 5478162 IS200VTCCH1CBA
13 1 00 00 000001919A54 4315629 IS200TBTCH1BAA JRA
14 2 00 00 000001919A55 4315629 IS200TBTCH1BAA JRB

z Firmware
z ROM Serial #
z Hardware Bar Code
z VME Card Catalog #
z Termination Board Catalog #
z Connector 18
 General Purpose I/O

• Contact Inputs (48 / VME card - 2 TB’s / VME Card) V ac

- 125vdc (Floating) Standard for Turbine Controls o Supply o
- 24vdc Option for BOP Applications
Auto
- Voltage Sensing Contact Inputs (BOP)
125/250vdc, 120/240vac barrier type TBs
- Optical Isolation
} Run
Input
- 1ms time tag on every point (SOE) Load/Motor
• Relay Outputs (24 / VME card - 2 TB’s / VME Card)
- Plug-in, Magnetic Relays
- Dry, Form “C” Contacts & Solenoid Interface (Fused)
- 2 Versions: Coil & Contact Voltage Sensing Diagnostics
• Analog I/O (20/4 / VME card - 2 TB’s / VME Card)
- Inputs: 4-20ma, 0-1ma, +/-5vdc, +/-10vdc
- Outputs: 4-20ma, 0-200ma
• Thermocouple Inputs (24 / VME card - 1 TB / VME Card)
- Grounded or Ungrounded, Software Linearization
- Discrete & Parallel Inputs
• RTD Inputs (16 / VME card - 1 TB / VME Card)
- Grounded or Ungrounded, Software Linearization
- Discrete & Parallel Inputs
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 Control Specific I/O (Direct Interface)

• Servo Channels For Control Valves (4 / VME card - 2 TB’s / VME Card)
- Bi-polar Outputs: +/-10, 20, 40, 80, 120ma
- LVDT or LVDR Feedback, Software Regulation
- (2) Pulse Rate Inputs /VME Card: Flow Divider or LP Speed
• Speed Inputs (4 /VME card - 1 TB / VME Card)
- Passive Magnetic Pickups
- Can Detect 2 rpm Turning Gear Speed
- Separate EOS Module
• Vibration Inputs (16 / VME card - 2 TB’s / VME Card)
- (16) Vibration Inputs /VME card): Seismic, Prox, Acceler, Velomiter
- 1X, 2X, gap detection
- (8) Position & (2) Key Phasors
- Buffered BNC Outputs for Remote Analysis Equipment
• Optical Pyrometer Inputs (2 /VME card) - “H” Applications
- (2) Infrared TBTMS Thermometers (Pyrometers)
- (4) 4-20ma Inputs / Pyrometer (real time, average, peak, average peak)
- Up to 30 Samples / Bucket
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 Turbine Specific I/O (Direct Interface)

• Flame Inputs (8 / VME card)

- Honeywell: 335vdc Excitation Provided By Mark VI
- Reuter Stokes: 4-20ma Inputs
- Low Light Intensity Diagnostics
• Shaft Voltage / Current Monitor
• Automatic Synchronizing
- (2) Single Phase PTs (Speed Matching & Voltage Matching)
- Separate Synch Check Protection (Triple Redundant)
- Manual Synch From Operator Interface (HMI)
• Generator Card
- (2) 3 Phase PT Inputs
- (3) 1 Phase CT Inputs
- Power Load Unbalance & Early Valve Actuation
- (4) Analog Inputs: 4-20ma, +/-5vdc, +/-10vdc
- (12) Relay Outputs

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 Simplex Control

Operator / Maintenance
Station
Control Modules Backup Protection

NT: Client / Server

IONet - Ethernet
CIMPLICITYR GUI
I/O Networks: Serial, Profibus,
TB Ethernet, etc.
I/O

I/O

Unit Data Highway

Ethernet
Peer-to-Peer
Communications

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 Triple Modular Redundant (TMR)

Operator / Maintenance
Station
Control Modules
z 3 Independent Control Modules
z 40ms or 20ms Execution
z All Critical Inputs & Outputs are TMR
NT: Client / Server Capability
CIMPLICITYR GUI IONet - Ethernet - Sensors Can Be Triple, Dual, or Single
z High-Select of 3 Power Sources to
Sensors
z Software Voting of All Inputs
z Diagnostics Monitor Any Disagreements
Unit Data Highway z Diagnostics Distinguish Between
Ethernet Internal & External Faults
Peer-to-Peer
Communications z On-line Repair of VME Cards
- No Need to “Force” Data Points During
Change-out
z On-line Download of Changes
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 VCMI UCVX
1 2 3 4 5 6
I/O Data On Backplane

V
O Application
T Software
E

I/O From Other Modules

VCMI UCVX
1 2 3 4 5 6
Voting Data I/O Data On Backplane

V
O Application
T Software
E

I/O From Other Modules

VCMI UCVX
1 2 3 4 5 6
I/O Data On Backplane

V
O Application
T Software
E

I/O From Other Modules

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Example of Voting Contact Inputs

Internal Vote 2/3 Vote 2/3

Contact TB "Fanned" I/O Card "Each" "Field"
Connectors Contact Contacts
<R>

VCRC VCMI UCV_

TBCI
IONet Application
<S> Software

VCRC VCMI UCV_

IONet Application
<T> Software

* Redundant field contacts

VCRC VCMI UCV_
terminate on separate TB's.
Example: 63QT1, 63QT2,
63QA Application
Software
 Standard Example of Voting Servo Channels

Valve No Voting
Valve
Stroke Of Servo * LVDT feedback goes to all three
Regulators
Reference Outputs processors
<R>

UCV_ VCMI VSVO Hydraulic

3 Coil Cylinder
TSVO Servo Valve
IONet
<S> Coil 1 LVDTs

UCV_ VCMI VSVO Coil 2

Coil 3
IONet
<T>
3.2kHz, 7 Vrms Excitation

UCV_ VCMI VSVO

LVDT Feedback*
 Triplicated TSVO Example of Voting Servo Channels

Valve No Voting
Valve TSVO
Stroke Of Servo
Regulators * LVDT feedback paralleled back to all three
Reference Outputs
terminal boards
<R>

UCV_ VCMI VSVO Hydraulic

3 Coil Cylinder
Servo Valve
IONet
<S> Coil 1 LVDTs

UCV_ VCMI VSVO Coil 2

Coil 3
IONet
<T>

UCV_ VCMI VSVO

3.2kHz, 7 Vrms Excitation

* LVDT Feedback
Example of Voting 4-20ma Proportional Outputs

No Voting Analog
Process
Of Analog Output
Reference
Outputs Card
<R> VAIC = 20 AI & 4 AO
VAOC = 16 AO
UCV_ VCMI VAIC

TBAI
IONet
<S>
4-20ma
UCV_ VCMI VAIC

IONet
<T> Load
Sharing
UCV_ VCMI VAIC Output

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Example of Voting Contact Outputs

No Voting Relay
Process
Of Digital Output
Reference
Outputs Card
<R>

UCV_ VCMI VCRC

TRLY
IONet
<S>

UCV_ VCMI VCRC RD

IONet
<T>
Contact Rating
0.6A at 125Vdc
UCV_ VCMI VCRC 3.0 A at 24Vdc
3.0 A at 120/240Vac

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 Typical 207FA Network Configuration

Plant Data Highway - Ethernet

IRIG-B
Time Synch

DCS Protocols
Ethernet TCP-IP GSM
Ethernet TCP-IP Modbus Local Local
Engineer's
RS232/485 Modbus Operator Operator
Station
Station Station
Gas Turbine #1 Gas Turbine #2 Steam Turbine
Unit Data Highway - Ethernet Network Time Protocol NTP

Gas Turbine Generator Gas Turbine Generator Static Starter Steam Turbine Generator
Control Excitation Control Excitation Control Excitation
Mark VI EX2000 Mark VI EX2000 Mark VI EX2000

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 Communications

• IONet (Internal to Mark VI)

- Ethernet (Coax, 10 Base 2) ADL Protocol Request Response Protocol (TCP/IP)
Ethernet Global Data (UDP/IP)
- Supports Control at 40ms
100
40ms, 64 bytes, 10MB
• Unit Data Highway (Mark VI, EX2000/2100, LCI) 80
- Ethernet (UTP Cat 5 or Fiber) EGD Protocol
- Peer-To-Peer Communications (40ms)

% Utilization
60
- +/-1ms Time Coherence (NTP Protocol) TCP/IP
40
• Plant Data Highway
- Ethernet TCP-IP Protocol 20
EGD (UDP/IP)
0
• External Communication Links

10

12

14
4

8
2

6
- RS232 Modbus Master / Slave
Number of Nodes
- Ethernet TCP-IP Modbus Slave
- Ethernet TCP-IP GSM (time tags, event driven messages, periodic data)
- Other Links Supported By CIMPLICITYTM GUI
- External Time Synch: Usually with IRIG-B

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 207FA Network Configuration With GE ICS

Plant Data Highway

Ethernet TCP/IP Operator Console - Control Room

OSM
Historian Unit HMI Unit HMI
Server Server
*GEPS (Gateway) (Gateway)
Unit Data Highway Software

Ethernet EGD

Mark VI EX2100 Mark VI Mark VI EX2100 Mark VI LCI

GT Control Generator HRSG & GT Control Generator HRSG & Static Starter
#1 Excitation Mech. Aux. #1 #2 Excitation Mech. Aux. #2
& Protection & Protection
Unit Data Highway

Ethernet EGD

Mark VI EX2100 Mark VI Mark VI PLC PLC

• Common Screens
• Common Maintenance Tools
ST Control
#1
Generator
Excitation
Common BOP
#1
Common BOP
#2
• Common Spare Parts
& Protection • Reduced Training
• Single Point of Responsibility
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I/O Architecture

• General Purpose I/O

• Turbine Specific I/O Interface
• Power Requirements

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Direct Interface To Sensors & Actuators

No Interposing Instrumentation

Mark VI

• Eliminates Failure Points Examples:

Examples:
• Reduces Maintenance -- Servos
Servos
• Fewer Spare Parts -- Vibration
Vibration Sensors
Sensors
• Better Diagnostics -- Synchronizing
Synchronizing
-- Flame
Flame Scanners
Scanners
-- Optical
Optical Pyrometers
Pyrometers

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 Software Maintenance Tools

Software maintenance tools allow Features

users to change parameters and z Same maintenance tools for all
applications to meet their specific control applications
operating needs. – Turbine Control
– Gen. Excitation Control
z Fully programmable
– Standard application from GE
– Technicians can customize to
meet site-specific needs
z Extensive editing capability
– Analog loops
Relay Ladder Diagram Editor
– Sequencing logic
for Boolean Functions
– Tuning constants
z Drag and drop features simplify
software editing

35
Diagnostics

The Mark VI includes

extensive built-in
diagnostics to identify
control panel, sensor and
output device faults.

Features
z System includes “power-
up”, background and
manually initiated routines
z Control panel faults
identified down to the VME
card and terminal board
level
z Sensor/actuator faults
identified down to the
circuit level

36
Hardware Maintenance Tools

Hardware maintenance tools

allow users to change Mark VI
control settings to meet their
specific operating needs.

Features
z System displays multiple
racks for easy lookup
z Technicians may add or
delete hardware as
needed:
– Racks
– I/O cards
– Terminal boards

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