SPEEDTRONIC Mark VI Turbine Control System
Contents
1. Figure 5 Software maintenance tools editors ple nodes based on the UDP IP standard RFC 768 Data can be transmitted Unicast Multicast or Broadcast to peer control systems Data 4K can be shared with up to 10 nodes at 25Hz 40ms A variety of other proprietary protocols are used with EGD to optimize com munication performance on the UDH 40 ms is fast enough to close control loops on the UDH however control loops are normally closed within each unit control Variations of this exist such as transmitting setpoints between turbine controls and generator con trols for voltage matching and var power factor GE Power Systems GER 4193A 10 00 control All trips between units are hardwired even if the UDH is redundant The UDH communication driver is located on the Main Processor Card in the Mark VI This is the same card that executes the turbine appli cation software therefore there are no poten tial communication failure points between the main turbine processor and other controls or monitoring systems on the UDH In TMR sys tems there are three separate processor cards execu ng identical application software from identical databases Two of the UDH drivers are normally connected to one switch and the other UDH driver is connected to the other switch in a star configuration Network topolo gies conform to Ethernet IEEE 802 3 standards The GE networks are a Class C Private Internet ac2. Voltage Resistive Inductive 24Vdc 3 0A 3 0 amps L R 7 ms no suppr 3 0 amps L R 100 ms with suppr 125Vde 0 6A 0 2 amps L R 7 ms no suppr 0 6 amps L R 100 ms with suppr 120 240Vac 6 3A 2 0 amps pf 0 4 DRLY Box 12 CO Same as TRLY but no solenoid circuits Table 1 Discrete 1 0 SPEEDTRONIC Mark VI Turbine Control System TB Type LO Characteristics TBAI Barrier 10 AI 8 4 20ma 250 ohms or 5 10Vde inputs 2AO 2 4 20ma 250 ohms or 1ma 500 ohms inputs Current limited 24V dc provided per input 2 24V 0 2A current limited power sources 1 4 20ma output 500 ohms 1 4 20ma 500 ohms or 0 200ma 50 ohms output TBAO Barrier 16 AO 16 4 20ma outputs 500 ohms DTAI Box 10 AI 8 4 20ma 250 ohms or 5 10Vde inputs 2A0 2 4 20ma 250 ohms or 1ma 500 ohms inputs Current limited 24V dc available per input 1 4 20ma output 500 ohms 1 4 20ma 500 ohms or 0 200ma 50 ohms output DTAO Box 8 AO 8 4 20ma outputs 500 ohms Table 2 Analog 1 0 Termination Board or 2 box type Termination Boards Capacity for monitoring 9 additional thermocouples is provided in the Backup Protection Module See Table 3 TB Type VO TBTC Barrier 24 TC Characteristics Types E J K T grounded or ungrounded HIA fanned paralleled inputs H1B dedicated inputs DTTC Box 12 TC Types E J K T grounded or ungrounded TRTD Barrier 16 RT
3. 1994 Gas Contaminants EN50178 1994 Section A 6 1 4 Table A 2 m Dust Contaminants Exceeds IEC 529 1989 11 IP 20 Seismic Universal Building Code UBC Section 2312 Zone 4 Documentation The following documentation is available for Mark VI Turbine Controls A subset of this doc umentation will be delivered with each control depending on the functional requirements of each system Manuals E System Manual for SPEEDTRONICTM Mark VI Turbine Control GEH 6421 E Control System Toolbox for Configuring a Mark VI Controller GEH 6403 Configuring the Trend Recorder GEH 6408 System Data Base for System Toolbox GEI 100189 System Data Base Browser GEI 100271 Data Historian used for trip history GEI 100278 B Communications To Remote Computers Plant DCS RS232 Modbus Slave From Control Module Modbus Communications Implementation UCOC2000 I O Drivers Chapter 2 GE Power Systems GER 4193A 10 00 Communication Links From HMI RS232 Modbus Master Slave Ethernet Modbus Slave Ethernet TCP IP GSM HMI SPEEDTRONIC Application Manual Chapter 7 GEH 6126 Ethernet TCP IP GEDS Standard Message Format GSM GEI 100165 E Operator Maintenance Interface HMI HMI for SPEEDTRONIC Turbine Controls Application Manual GEH 6126 Cim Edit Operation Manual GFK 1396 User Manual GFK 1180 Cimplicity HMI For Window NT Trending Operators Manual GFK 1260 E Turbine Historian S
4. the termination boards for its field contact inputs and field solenoids Additional 3 2A fuse protection is provided on the termination board TRLY for each solenoid Separate 120Vac feeds are provided from the motor control cen ter for any AC solenoids and ignition trans formers on gas turbines See Table 11 11 SPEEDTRONIC Mark VI Turbine Control System Steady State Freq Load Comments Voltage 125Vdc 10 0 A dc Ripple lt 10V p p 100 to Note 1 144Vdc 120vac 47 63Hz 10 0 A rms Harmonic distortion 596 108 to Note 2 132vac 240vac 47 63Hz 5 0 Arms Harmonic distortion lt 5 200 to Note 3 264vac Table 11 Power requirements Codes and Standards ISO 9001 in accordance with Tick IT by Lloyd s Register Quality Assurance Limited ISO 9000 3 Quality Management and Quality Assurance Standards Part 3 Guidelines for the Appli cation of ISO 9001 to Development Supply and Maintenance of Software Safety Standards UL 508A Safety Standard Industrial Control Equip CSA 22 2 No 14 Industrial Control Equipment Printed Wire Board Assemblies UL 796 Printed Circuit Boards UL recognized PWB manufacturer UL file number E110691 ANSI IPC guidelines ANSI IPC EIA guidelines CE Electromagnetic Compatibility EMC EN 50081 2 Generic Emissions Standards EN 50082 2 1994 Generic Immunity Industrial Environment EN 55011 Radiated and Conducted Emissions IEC 61000 4 2 1995
5. Backup Protection Module that is available in Simplex and triple redundant forms The triple redundant version contains three independent sections power supply processor I O that can be replaced while the turbine is running IONet is used to access diagnostic data or for cross tripping Module and the between the Control GE Power Systems GER 4193A 10 00 Protection Module but it is not required for tripping Triple Redundancy Mark VI control systems are available in Simplex and Triple Redundant forms for small applications and large integrated systems with control ranging from a single module to many distributed modules The name Triple Module Redundant TMR is derived from the basic architecture with three completely separate and independent Control Modules power supplies and IONets Mark VI is the third generation of triple redundant control systems that were pio neered by GE in 1983 System throughput enables operation of up to nine 21 slot VME racks of I O cards at 40 ms including voting the data Inputs are voted in software in a scheme called Software Implemented Fault Tolerance SIFT The VCMI card in each Control Module receives inputs from the Control Module back plane and other modules via its own IONet Data from the VCMI cards in each of the three Control Modules is then exchanged and voted prior to transmitting the data to the main processor cards for execution of the application software Outp
6. Controllers H Control 2 Protection 3 Monto TS EN Protection Module Control Module Ethernet 2 i CPU i vo TETTTTTTTETTITTTITIT Redundant Unit LN Data Highway m Required thernet IONet lt S gt Control Module 2 H E pum PS n gt CPU E Wo S L5 Ethernet IONet lt T gt Control Module Ethernet IONet anv i wo Figure 2 Mark VI TMR control configuration 0 Interface There are two types of termination boards One type has two 24 point barriertype terminal blocks that can be unplugged for field mainte nance These are available for Simplex and TMR controls They can accept two 3 0 mm 12AWG wires with 300 volt insulation Another type of termination board used on Simplex controls is mounted on a DIN rail and GE Power Systems GER 4193A 10 00 has one fixed box type terminal block It can accept one 3 0 mm 12AWG wire or two 2 0 mm 14AWG wires with 300 volt insulation I O devices on the equipment can be mounted up to 300 meters 984 feet from the termina tion boards and the termination boards must be within 15 m 49 2 from their correspon ding I O cards Normally the termin
7. Electrostatic Discharge Susceptibility IEC 6100 4 3 1997 Radiated RF Immunity GE Power Systems GER 4193A 10 00 IEC 6100 4 4 1995 Electrical Fast Transient Susceptibility IEC 6100 4 5 1995 Surge Immunity IEC 61000 4 6 1995 Conducted RF Immunity IEC 61000 4 11 1994 Voltage Variation Dips and Interruptions ANSI IEEE C37 90 1 Surge CE Low Voltage Directive EN 61010 1 Electrical Equipment Industrial Machines IEC 529 Intrusion Protection Codes NEMA 1 IP 20 Reference the Mark VI Systems Manual GEH 6421 Chapter 5 for additional codes and stan dards Environment The control is designed for operation in an air conditioned equipment room with convection cooling Special cabinets can be provided for operation in other types of environments Temperature Operating 0 to 45 C 32 to 113 F Storage 40 to 70 C 40 to 158 F The control can be operated at 50 C during maintenance periods to repair air conditioning systems It is recommended that the electronics be operated in a controlled environment to maximize the mean time between failure MTBF on the components Purchased commercial control room equipment such as PCs monitors and printers are typically capable of operating in a control room ambient of 0 to 40 C with convection cooling Humidity 5 to 95 non condensing Exceeds EN50178 1994 12 SPEEDTRONIC Mark VI Turbine Control System Elevation Exceeds EN50178
8. command either from the main processor card to the VTUR card in the Control Module s or from the Backup Protection Module Hydraulic trip solenoids are wired with the negative side of the 24Vdc 125Vdc circuit connected to the TRPG which is driven from the VTUR in the Control Module s and the positive side connected to the TREG which is driven from the VPRO in each section of the Backup Protection Module A typical system trip initiated in the Control Module s will cause the analog control to drive the servo valve actu ators closed which stops fuel or steam flow and de energizes or energizes the hydraulic trip solenoids from the VTUR and TRPG If cross tripping is used or an overspeed condition is detected then the VTUR TRPG will trip one side of the solenoids and the VPTRO TREG will trip the other side of the solenoid s Servo Valve Interface A VSVO card provides 4 servo channels with selectable current drivers feedback from LVDTs LVDRs or ratio metric LVDTs and pulse rate inputs from flow divider feedback used on some liquid fuel systems In TMR applications 3 coil servos are commonly SPEEDTRONIC Mark VI Turbine Control System used to extend the voting of analog outs to the servo coils Two coil servos can also be used One two or three LVDT Rs feedback sensors can be used per servo channel with a high select low select or median select made in software At least 2 LVDT Rs are recommended for TMR applications be
9. D 3 points RTD grounded or ungrounded 10 ohm copper 100 200 ohm platinum 120 ohm nick HIA fanned paralleled inputs H1B dedicated inputs DTAI Box 8RTD RTDs 3 points RTD grounded or ungrounded 10 ohm copper 100 200 ohm platinum 120 ohm nick Table 3 Temperature Monitoring Application Specific 1 0 In addition to general purpose I O the Mark VI has a large variety of cards that are designed for direct interface to unique sensors and actu ators This reduces or eliminates a substantial amount of interposing instrumentation in many applications As a result many potential single point failures are eliminated in the most critical area for improved running reliability and reduced long term maintenance Direct interface to the sensors and actuators also enables the diagnostics to directly interrogate the devices on the equipment for maximum effectiveness This data is used to analyze device and system performance A subtle benefit of this design is that spare parts inventories are GE Power Systems GER 4193A 10 00 reduced by eliminating peripheral instrumenta tion The VTUR card is designed to integrate several of the unique sensor interfaces used in turbine control systems on a single card In some applications it works in conjunction with the I O interface in the Backup Protection Module described below Speed Pulse Rate Inputs Fourspeed inputs from passive magnetic sensors are monitored
10. GER 4193A GE Power Systems SPEEDTRONIC Mark Vi Turbine Control System Walter Barker Michael Cronin GE Power Systems Schenectady NY SPEEDTRONIC Mark VI Turbine Control System Contents jntroduchon er hoe Ge ye FoU add a Noa 1 PUG OCT A a ee ke aan Bene ae ANI OR Eee ed 1 Triple Redundancy eese Shs Ex AA HR ee eee AA 2 VO Interface EP 3 General Purpose l U 0 0 3 Application Specifice 0 tir 4 Operator Interface ooo 7 Software Maintenance Tools cooler 8 Commune aO c i a nec prete re v dun d en ee 8 COMMUNICGUON ED 10 Time Synchronization llli 10 DIAGNOSHCS 0orueustarecretalores tases gnc reborde ridad 10 POWER 2 ee eine hehe 11 Codes and Standards ooo ooi oii i i i se 12 Safely SlandaidS FEC 12 Printed Wire Board Assemblies 2 2 a ll uasa kr Ra RR 12 CE Electromagnetic Compatibility EMC 0 00 wenn 12 Ge LOW Voltage DIreCtVE sua ee een ae 12 Environment Loo cote een ernennen Pies Regen x 12 empra eed 12 PHONON aserrada asia alarde tee aed 4 12 ECU aro al res pate id da es iia 13 ae RTT ETE Ga Bea oe DU TT T 13 DISC LIN INN ae ren enden IHR ER ED dde 13 Seismic Universal Building Code UBC 222222222220 13 Documentation 0xu u24eu Pied See een a 13 Manal ache ee o TIT 13 fL 13 List of Figures conso duram Qe as ir ri pls b uiui ted e
11. Module Each connector comes with latching fasteners and a unique label identify GE Power Systems GER 4193A 10 00 ing the correct termination point One wire in each connector is dedicated to transmitting an identification message with a bar code serial number board type hardware revision and a connection location to the corresponding I O card in the Control Module Power In many applications the control cabinet is powered from a 125Vdc battery system and short circuit protected external to the control Both sides of the floating 125Vdc bus are con tinuously monitored with respect to ground and a diagnostic alarm is initiated if a ground is detected on either side of the 125Vdc source When a 120 240vac source is used a power converter isolates the source with an isolation transformer and rectifies it to 125Vdc A diode high select circuit chooses the highest of the 125Vdc busses to distribute to the Power Distribution Module A second 120 240vac source can be provided for redundancy Diagnostics produce an undervoltage alarm if either of the AC sources drop below the under voltage setting For gas turbine applications a separate 120 240vac source is required for the ignition transformers with short circuit protec tion of 20A or less The resultant internal 125Vdc is fuse isolated in the Mark VI power distribution module and fed to the internal power supplies for the Control Modules any expansion modules and
12. Windows 95 or NT based PC The same tools are used for EX2000 Generator Excitation Systems and Static Starters See Figure 4 and Figure 5 Communications Communications are provided for internal data transfer within a single Mark VI control com munications between Mark VI controls and peer GE control systems and external commu nications to remote systems such as a plant dis tributed control system DCS The Unit Data Highway UDH is an Ethernet based LAN with peer to peer communication between Mark VI controls EX2000 Generator Excitation Controls Static Starters the GE Fanuc family of PLC based controls HMIs and Historians The network uses Ethernet Global Data EGD which is a message based protocol with support for sharing information with mul SPEEDTRONIC Mark VI Turbine Control System Har ss EGD1 EGD Network Mark VI YO g 15200 5V0H1A 1S200VTCCHAB 1S200VTURHIA IS200VGENHI A IS200vPYPHA SIMPLES HA Start Emak Vi HyperTerminal BB Command Prompt EBGE Control System T amp Document WerdPad Figure 4 Software maintenance tools card configuration ve c A 5 SP FNZICH SZ Ladder Diagram Editor s FNZICH q dea Bes Cancel Hap for Boolean Functions a FMCH 4 PNACHG_SO CHG_SQ s FN3 CHG_SQ cHG SQ P FNA CHG SO CHG SQ IB CHG CARS B 9 CHG SIM
13. a time link network to one or more HMIs with a time frequency processor board When the HMI receives the time signal it is sent to the Mark VI s using Network Time Protocol NTP which synchronizes the units to within 1ms time coherence Time sources that are supported include IRIG A IRIG B 2137 NASA 36 and local signals Diagnostics Each circuit card in the Control Module con tains system software limit checking high low hardware limit checking and comprehensive diagnostics for abnormal hardware conditions System limit checking consists of 2 limits for every analog input signal which can be set in engineering units for high high high low or low low with the I O Configurator In addition each input limit can be set for latching non latching and enable disable Logic outputs from system limit checking are generated per frame and are available in the database signal space for use in control sequencing and alarm messages High low hardware limit checking is provid ed on each analog input with typically 2 occur rences required before initiating an alarm These limits are not configurable and they are 10 SPEEDTRONIC Mark VI Turbine Control System selected to be outside the normal control requirements range but inside the linear hard ware operational range before the hardware reaches saturation Diagnostic messages for hardware limit checks and all other hardware diagnostics for the card can be acc
14. ation boards are mounted in vertical columns in ter mination cabinets with pre assigned cable lengths and routing to minimize exposure to emi rfi for noise sensitive signals such as speed inputs and servo loops General Purpose I O Discrete I O A VCRC card provides 48 digital inputs and 24 digital outputs The I O is divid ed between 2 Termination Boards for the con tact inputs and another 2 for the relay outputs See Table 1 Analog I O A VAIC card provides 20 analog inputs and 4 analog outputs The I O is divided between 2 Termination Boards A VAOC is ded icated to 16 analog outputs and interfaces with 1 barrier type Termination Board or 2 box type Termination Boards See Table 2 Temperature Monitoring A VICC card pro vides interface to 24 thermocouples and a VRTD card provides interface for 16 RTDs The input cards interface with 1 barrier type Characteristics 70 145Vdc optical isolation Ims SOE 2 5ma point except last 3 input are 10ma point TB Type VO TBCI Barrier 24 CI DTCI Box 24 CI 18 32Vdc optical isolation Ims SOE 2 5ma point except last 3 input are 10ma point TICI Barrier 24 CI 70 145Vdc 200 250Vdc 90 132 Vrms 190 264Vrms 47 63Hz optical isolation Ims SOE 3ma point TRLY Barrier 12CO Plug in magnetic relays dry form C contacts 6 circuits with fused 3 2A suppressed solenoid outputs Form H1B diagnostics for coil current Form HIC diagnostics for contact voltage
15. by the VTUR card Another two speed pulse rate inputs can be monitored by the servo card VSVO which can interface with either passive or active speed sensors Pulse rate inputs on the VSVO are commonly used for flow divider feed back in servo loops The frequency range is 2 14k Hz with sufficient sensitivity at 2 Hz to detect zero speed from a 60 toothed wheel Two additional passive speed sensors can be moni tored by each of the three sections of the Backup Protection Module used for emergency overspeed protection on turbines that do not have a mechanical overspeed bolt IONet is used to communicate diagnostic and process data between the Backup Protection Module and the Control Module s including cross trip ping capability however both modules will ini tiate system trips independent of the IONet See Table 4 and Table 5 Synchronizing The synchronizing system con sists of automatic synchronizing manual syn chronizing and backup synch check protec tion Two single phase PT inputs are provided TB Type VO Characteristies TTUR Barrier 4 Pulse rate Passive magnetic speed sensors 2 14k Hz 2PTs Single phase PTs for synchronizing Synch relays Auto Manual synchronizing interface 2SVM Shaft voltage current monitor TRPG Barrier 3 Trip solenoids side of interface to hydraulic trip solenoids TRPS 8 Flame inputs UV flame scanner inputs Honeywell TRPL DTUR Box 4 Pulse Rate Passive mag
16. cated to the Mark VI on the network rather than using the VGEN card See Table 9 Optical Pyrometer Inputs The VPYR card moni SPEEDTRONIC Mark VI Turbine Control System TB Type YO TGEN Barrier 2 PTs Characteristics 3 Phase PTs 115Vrms 5 66 Hz 3 wire open delta 3 CTs 1 Phase CTs 0 5A 10A over range 5 66 Hz 4Al 4 20ma 250 ohms or 5 10 Vdc inputs Current limited 24Vdc input TRLY Barrier 12 CO Plug in magnetic relays previously described Table 9 VGEN 1 0 terminations from Control Module tors two LAND infrared pyrometers to create a temperature profile of rotating turbine blades Separate current limited 24Vdc and 24Vdc sources are provided for each Pyrometer that returns four 4 20ma inputs Two Keyphasors are used for the shaft reference The VPYR and matching TPYR support 5 100 rpm shaft speeds and can be configured to monitor up to 92 buck ets with 30 samples per bucket See Table 10 Characteristics 8 4 20ma 100 ohms 2 Current limited 24Vde sources 2 Current limited 24V dc sources TB Type VO TPYR Barrier 2 Pyrometers 2 Keyphasor inputs Table 10 VPYR 1 0 terminations from Control Module Operator Interface The operator interface is commonly referred to as the Human Machine Interface HMI It is a PC with a Microsoft Windows NT operating system supporting client server capability a CIMPLICITY graphics displa
17. cause each sensor requires an AC excitation source See Table 6 and Table 7 TB Type VO Characteristics TSVO Barrier 2 chnls 2 Servo current sources 6 LVDT LVDR feedback 0 to 7 0 Vrms 4 Excitation sources 7 Vrms 3 2k Hz 2 Pulse rate inputs 2 14k Hz only 2 per VSVO 2 Servo current sources 6 LVDT LVDR feedback 0 to 7 0 Vrms 2 Excitation sources 7 Vrms 3 2k Hz 2 Pulse rate inputs 2 14k Hz only 2 per VSVO Table 6 VSVO 1 0 terminations from Control DSVO Box 2 chnls Module Coil Nominal Coil Mark VI Type Current Resistance Control 1 10 ma 1 000 ohms Simplex amp TMR 2 20 ma 125 ohms Simplex 3 40 ma 62 ohms Simplex 4 40 ma 89 ohms TMR 5 80 ma 22 ohms TMR 6 120 ma 40 ohms Simplex 7 120 ma 75 ohms TMR Table 7 Nominal servo valve ratings Vibration Proximitor Inputs The VVIB card provides a direct interface to seismic velocity Proximitor Velomitor and accelerometer via charge amplifier probes In addition DC position inputs are available for axial measure ments and Keyphasor inputs are provided Displays show the 1X and unfiltered vibration levels and the 1X vibration phase angle 24vdc is supplied from the control to each Proximitor with current limiting per point An optional ter GE Power Systems GER 4193A 10 00 mination board can be provided with active i
18. cording to RFC 1918 Address Allocation for Private Internets February 1996 Internet Assigned Numbers Authority IANA has reserved the following IP address space 192 168 1 1 192 168 255 255 192 168 16 prefix Communication links from the Mark VI to remote computers can be implemented from either an optional RS232 Modbus port on the main processor card in Simplex systems or from a variety of communication drivers from the HMI When the HMI is used for the com munication interface an Ethernet card in the HMI provides an interface to the UDH and a second Ethernet card provides an interface to the remote computer All operator commands that can be issued from an HMI can be issued from a remote computer through the HMI s to the Mark VI s and the remote computer can monitor any application software data in the Mark VI s Approximately 500 data points per control are of interest to a plant control system however about 1 200 SPEEDTRONIC Mark VI Turbine Control System points are commonly accessed through the communication links to support programming screen attributes such as changing the color of a valve when it opens Communication Link Options Communication link options include E An RS 232 port with Modbus Slave RTU or ASCII communications from the Main Processor Card Simplex full capability TMR monitor data only no commands E An RS 232 port with Modbus Master Slave RTU protocol is available fr
19. essed with the software maintenance tools Control System Toolbox A composite logic output is provided in the data base for each card and another logic output is provided to indicate a high low hardware limit fault of any analog input or the associated communications for that signal The alarm management system collects and time stamps the diagnostic alarm messages at frame rate in the Control Module and displays the alarms on the HMI Communication links to a plant DCS can contain both the software system diagnostics and composite hardware diagnostics with varying degrees of capability depending on the protocol s ability to transmit the local time tags Separate manual reset com mands are required for hardware and system software diagnostic alarms assuming that the alarms were originally designated as latching alarms and no alarms will reset if the original cause of the alarm is still present Hardware diagnostic alarms are displayed on the yellow status LED on the card front Each card front includes 3 LEDs and a reset at the top of the card along with serial and parallel ports The LEDs include RUN Green FAIL Red STATUS Yellow Each circuit card and termination board in the system contains a serial number board type and hardware revision that can be displayed 37 pin D type connector cables are used to inter face between the Termination Boards and the J3 and J4 connectors on the bottom of the Control
20. he control run at faster rates i e servo loops pyrometers etc the distributed processor system between the main processor and the dedicated I O processors is very impor tant for optimum system performance A QNX operating system is used for real time applica tions with multi tasking priority driven preemp tive scheduling and fast context switching Communication of data between the Control Module and other modules within the Mark VI control system is performed on IONet The VCMI card in the Control Module is the IONet bus master communicating on an Ethernet 10Base2 network to slave stations A unique pol ing type protocol Asynchronous Drives Language is used to make the IONet more deterministic than traditional Ethernet LANs An optional Genius Bus interface can be pro vided on the main processor card in Mark VI Simplex controls for communication with the GE Fanuc family of remote I O blocks These blocks can be selected with the same software configuration tools that select Mark VI I O cards and the data is resident in the same data base The Control Module is used for control pro tection and monitoring functions but some applications require backup protection For example backup emergency overspeed protec tion is always provided for turbines that do not have a mechanical overspeed bolt and backup synch check protection is commonly provided for generator drives In these applications the IONet is extended to a
21. netic speed sensors 2 14k Hz DRLY Box 12 Relays Form C contacts previously described DTRT Transition board between VTUR amp DRLY Table 4 VTUR 1 0 terminations from Control Module SPEEDTRONIC Mark VI Turbine Control System TB Type YO Characteristics TPRO Barrier 9 Pulse rate Passive magnetic speed sensors 2 14k Hz 2 PTs Single phase PTs for backup synch check 3 Analog inputs 1 4 20ma 250 ohm or 5 10Vde inputs 2 4 20ma 250 ohm Thermocouples grounded or ungrounded 9 TC inputs TREG Barrier 3 Trip solenoids TRES 8 Trip contact in TREL side of interface to hydraulic trip solenoids 1 E stop 24Vdc amp 7 Manual trips 125 Vde Table 5 VPRO I O terminations from Backup Protection Module on the TTUR Termination Board to monitor the generator and line busses via the VTUR card Turbine speed is matched to the line fre quency and the generator and line voltages are matched prior to giving a command to close the breaker via the TTUR An external synch check relay is connected in series with the internal K25P synch permissive relay and the K25 auto synch relay via the TTUR Feedback of the actual breaker closing time is provided by a 52G a contact from the generator breaker not an auxiliary relay to update the database An internal K25A synch check relay is provided on the TTUR however the backup phase slip calculation for this relay is performed in the Backup Pr
22. om the HMI E An RS 232 485 converter half duplex can be supplied to convert the RS 232 link for a multi drop network E Modbus protocol can be supplied on an Ethernet physical layer with TCP IP for faster communication rates from the HMI E Ethernet TCP IP can be supplied with a GSM application layer to support the transmission of the local high resolution time tags in the control to a DCS from the HMI This link offers spontaneous transmission of alarms and events and common request messages that can be sent to the HMI including control commands and alarm queue commands Typical commands include momentary logical commands and analog setpoint target commands Alarm queue commands consist of silence plant alarm horn and reset commands as well as alarm dump requests that cause the entire alarm queue to be transmitted from the Mark VI to the DCS GE Power Systems GER 4193A 10 00 M Additional master communication drivers are available from the HMI Time Synchronization Time synchronization is available to synchro nize all controls and HMIs on the UDH to a Global Time Source GTS Typical GTSs are Global Positioning Satellite GPS receivers such as the StarTime GPS Clock or other time processing hardware The preferred time sources are Universal Time Coordinated UTC or GPS however the time synchronization option also supports a GTS using local time as its base time reference The GIS supplies
23. otection Module or via an external backup synch check relay Manual synchronizing is available from an oper ator station on the network or from a synchro scope Shaft Voltage and Current Monitor Voltage can build up across the oil film of bearings until a discharge occurs Repeated discharge and arc ing can cause a pitted and roughened bearing surface that will eventually fail through acceler ated mechanical wear The VTUR TTUR can continuously monitor the shaft to ground volt age and current and alarm at excessive levels Test circuits are provided to check the alarm functions and the continuity of wiring to the brush assembly that is mounted between the turbine and the generator GE Power Systems GER 4193A 10 00 Flame Detection The existence of flame either can be calculated from turbine parameters that are already being monitored or from a direct interface to Reuter Stokes or Honeywell type flame detectors These detectors monitor the flame in the combustion chamber by detecting UV radiation emitted by the flame The Reuter Stokes detectors produce a 4 20ma input For Honeywell flame scanners the Mark VI supplies the 335Vdc excitation and the VTUR TRPG monitors the pulses of current being generated This determines if carbon buildup or other contaminates on the scanner window are caus ing reduced light detection Trip System On turbines that do not have a mechanical overspeed bolt the control can issue a trip
24. quence of Events SOE for contact inputs are time tagged at Ims on the contact input card in the Control Module Alarms can SPEEDTRONIC Mark VI Turbine Control System be sorted according to ID Resource Device Time and Priority Operators can add com ments to alarm messages or link specific alarm messages to supporting graphics Data is displayed in either English or Metric engineering units with a one second refresh rate and a maximum of one second to repaint a typical display graphic Operator commands can be issued by either incrementing decre menting a setpoint or entering a numerical value for the new setpoint Responses to these commands can be observed on the screen one second from the time the command was issued Security for HMI users is important to restrict access to certain maintenance functions such as editors and tuning capability and to limit cer called User Accounts is provided to limit access or use of tain operations A system particular HMI features This is done through the Windows NT User Manager administration program that supports five user account levels Software Maintenance Tools The Mark VI is a fully programmable control system Application software is created from in house software automation tools which select proven GE control and protection algorithms and integrate them with the I O sequencing and displays for each application A library of software is provided with general pu
25. rack Inputs are received by the Control Module through termi nation boards with either barrier or box type terminal blocks and passive signal conditioning Each I O card contains a TMS320C32 DSP processor to digitally filter the data before con version to 32 bit IEEE 854 floating point format The data is then placed in dual port memory that is accessible by the on board C32 DSP on one side and the VME bus on the other In addition to the I O cards the Control Module contains an internal communication card a main processor card and sometimes a flash disk card Each card takes one slot except for the main processor that takes two slots Cards are manufactured with surface mounted technology and conformal coated per IPC CC 830 I O data is transmitted on the VME backplane between the I O cards and the VCMI card located in slot 1 The VCMI is used for inter nal communications between E I O cards that are contained within its card rack E 1 O cards that may be contained in expansion I O racks called Interface Modules E I O in backup lt P gt Protection Modules Bi I O in other Control Modules used in triple redundant control configurations E The main processor card The main processor card executes the bulk of the application software at 10 20 or 40 ms depending on the requirements of the applica tion Since most applications require that spe SPEEDTRONIC Mark VI Turbine Control System cific parts of t
26. rpose blocks math blocks macros and application specific blocks It uses 32 bit floating point data IEEE 854 in a QNX operating system with real time applications multitasking priority driven preemptive scheduling and fast context switching Software frame rates of 10 20 and 40 ms are supported This is the elapsed time that it takes to read inputs condition the inputs execute the application software and send outputs Changes to the application software can be GE Power Systems GER 4193A 10 00 made with password protection 5 levels and downloaded to the Control Module while the process is running All application software is stored in the Control Module in non volatile flash memory Application software is executed sequentially and represented in its dynamic state in a ladder diagram format Maintenance personnel can add delete or change analog loops sequenc ing logic tuning constants etc Data points can be selected and dragged on the screen from one block to another to simplify editing Other features include logic forcing analog forcing and trending at frame rate Application soft ware documentation is created directly from the source code and printed at the site This includes the primary elementary diagram I O assignments the settings of tuning constants etc The software maintenance tools Control System Toolbox are available in the HMI and as a separate software package for virtually any
27. so lation amplifiers to buffer the sensor signals from BNC connectors These connectors can be used to access real time data by remote vibra tion analysis equipment In addition a direct plug connection is available from the termina tion board to a Bently Nevada 3500 monitor The 16 vibration inputs 8 DC position inputs and 2 Keyphasor inputs on the VVIB are divid ed between 2 TVIB termination boards for 3 000 rpm and 3 600 rpm applications Faster shaft speeds may require faster sampling rates on the VVIB processor resulting in reduced vibration inputs from 16 to 8 See Table 8 TB Type vO Characteristics TVIB Barrier 8 Vibr Seismic Proximitor Velomitor accelerometer charge amplifier 4 Pos DC inputs 1KP Keyphasor Current limited 24Vdc provided per probe Table8 VVIB 1 0 terminations from Control Module Three phase PT and CT monitoring The VGEN card serves a dual role as an interface for 3 phase PTs and 1 phase CTs as well as a special ized control for Power Load Unbalance and Early Valve Actuation on large reheat steam tur bines The I O interface is split between the TGEN Termination Board for the PT and CT inputs and the TRLY Termination Board for relay outputs to the fast acting solenoids 4 20ma inputs are also provided on the TGEN for monitoring pressure transducers If an EX2000 Generator Excitation System is controlling the generator then 3 phase PT and CT data is com muni
28. ut voting is extended to the tur bine with three coil servos for control valves and 2 out of 3 relays for critical outputs such as hydraulic trip solenoids Other forms of output voting are available including a median select of 420ma outputs for process control and 0 200ma outputs for positioners Sensor interface for TMR controls can be either single dual triple redundant or combinations of redundancy levels The TMR architecture supports riding through a single point failure in the electronics and repair of the defective card or module while the process is running Adding sensor redundancy increases the fault tolerance SPEEDTRONIC Mark VI Turbine Control System of the overall system Another TMR feature is the ability to distinguish between field sensor faults and internal electronics faults Diagnostics continuously monitor the 3 sets of input electronics and alarms any discrepancies between them as an internal fault versus a sen sor fault In addition all three main processors continue to execute the correct voted input data See Figure 2 To Other GE Operator Maintenance Control Systems Interface LJ Communications to DCS Unit Data Highway 1 RS232 Modbus Slave Master Ethernet 2 Ethernet TCP IP Modbus Slave CIMPLICITYG Display System 3 Ethernet TCP IPGSM Windows NT Operating System Backup Protection 1 Emergency Overspeed 2 Synch Check Protection Primary
29. w hen ties 14 FSEOF TADOS os A NA ada decis ebay 14 GE Power Systems GER 4193A 10 00 1 SPEEDTRONIC Mark VI Turbine Control System GE Power Systems GER 4193A 10 00 ii SPEEDTRONIC Mark VI Turbine Control System Introduction The SPEEDTRONIC Mark VI turbine control is the current state of the art control for GE tur bines that have a heritage of more than 30 years of successful operation It is designed as a com plete integrated control protection and moni toring system for generator and mechanical drive applications of gas and steam turbines It is also an ideal platform for integrating all power island and balance of plant controls Hardware and software are designed with close coordina tion between GE s turbine design engineering and controls engineering to insure that your con trol system provides the optimum turbine per formance and you receive a true system solu tion With Mark VI you receive the benefits of GE s unmatched experience with an advanced turbine control platform See Figure 1 e Over 30 years experience Complete control protection and monitoring e Can be used in variety of applications Designed by GE turbine and controls engineering Figure 1 Benefits of Speedtronic Mark VI GE Power Systems GER 4193A 10 00 Architecture The heart of the control system is the Control Module which is available in either a 13 or 21 slot standard VME card
30. y system a Control System Toolbox for maintenance and a software interface for the Mark VI and other control systems on the network See Figure 3 It can be applied as E The primary operator interface for one or multiple units GE Power Systems GER 4193A 10 00 E A backup operator interface to the plant DCS operator interface E A gateway for communication links to other control systems E A permanent or temporary maintenance station B An engineer s workstation Fast Start genfexciter Stop IGV Control motors synch Figure 3 Operator interface graphics 7FA Mark VI All control and protection is resident in the Mark VI control which allows the HMI to be a non essential component of the control system It can be reinitialized or replaced with the process running with no impact on the control system The HMI communicates with the main processor card in the Control Module via the Ethernet based Unit Data Highway UDH All analog and digital data in the Mark VI is acces sible for HMI screens including the high reso lution time tags for alarms and events System process alarms and diagnostics alarms for fault conditions are time tagged at frame rate 10 20 40 ms in the Mark VI control and transmitted to the HMI alarm management sys tem System events are time tagged at frame rate and Se
31. ystem Guide GEH 6421 E Standard Blockware Library SBLIB E Turbine Blockware Library TURBLIB Drawings E Equipment Outline Drawing AutoCAD R14 E Equipment Layout Drawing AutoCAD R14 B I O Termination List Excel Spreadsheet E Network one line diagram if applicable Bi Application Software Diagram printout from source code E Data List For Communication Link To DCS 13 SPEEDTRONIC Mark VI Turbine Control System List of Figures Figure l Benefits of Speedtronic Mark VI Figure 2 Mark VI TMR control configuration Figure 3 Operator interface graphics 7FA Mark VI Figure 4 Software maintenance tools card configuration Figure 5 Software maintenance tools editors List of Tables Table 1 Discrete I O Table 2 Analog I O Table 3 Temperature Monitoring Table 4 VTUR I O terminations from Control Module Table 5 VPRO I O terminations from Backup Protection Module Table 6 VSVO I O terminations from Control Module Table 7 Nominal servo valve ratings Table 8 VVIB I O terminations from Control Module Table 9 VGEN I O terminations from Control Module Table 10 VPYR I O terminations from Control Module Table 11 Power requirements GE Power Systems GER 4193A 10 00 14
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