GER-4193A g 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 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Architecture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Triple Redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 I/O Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General Purpose I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Application Specific I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Software Maintenance Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Communication Link Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Time Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Codes and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Printed Wire Board Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 CE – Electromagnetic Compatibility (EMC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 CE – Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Humidity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Elevation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Gas Contaminants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Dust Contaminants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Seismic Universal Building Code (UBC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 � � GE Power Systems GER-4193A (10/00) i SPEEDTRONIC™ Mark VI Turbine Control System � � GE Power Systems GER-4193A (10/00) ii SPEEDTRONIC™ Mark VI Turbine Control System Introduction Architecture The SPEEDTRONIC™ Mark VI turbine control The heart of the control system is the Control is the current state-of-the-art control for GE tur- Module, which is available in either a 13- or 21- bines that have a heritage of more than 30 years slot standard VME card rack. Inputs are of successful operation. It is designed as a com- received by the Control Module through termi- plete integrated control, protection, and moni- nation boards with either barrier or box-type toring system for generator and mechanical terminal blocks and passive signal conditioning. drive applications of gas and steam turbines. It is Each I/O card contains a TMS320C32 DSP also an ideal platform for integrating all power processor to digitally filter the data before con- island and balance-of-plant controls. Hardware version to 32 bit IEEE-854 floating point format. and software are designed with close coordina- The data is then placed in dual port memory tion between GE’s turbine design engineering that is accessible by the on-board C32 DSP on and controls engineering to insure that your con- one side and the VME bus on the other. trol system provides the optimum turbine per- In addition to the I/O cards, the Control formance and you receive a true “system” solu- Module contains an “internal” communication tion. With Mark VI, you receive the benefits of card, a main processor card, and sometimes a GE’s unmatched experience with an advanced flash disk card. Each card takes one slot except turbine control platform. (See Figure 1.) 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: � I/O cards that are contained within its card rack � I/O cards that may be contained in expansion I/O racks called Interface Modules • Over 30 years experience � I/O in backup

Protection Modules • Complete control, protection, and � I/O in other Control Modules used in monitoring triple redundant control • Can be used in variety of applications configurations � The main processor card • Designed by GE turbine and controls engineering The main processor card executes the bulk of the application software at 10, 20, or 40 ms depending on the requirements of the applica- Figure 1. Benefits of Speedtronic™ Mark VI tion. Since most applications require that spe- � � GE Power Systems GER-4193A (10/00) 1 SPEEDTRONIC™ Mark VI Turbine Control System cific parts of the control run at faster rates (i.e. Protection Module, but it is not required for servo loops, pyrometers, etc.), the distributed tripping. processor system between the main processor and the dedicated I/O processors is very impor- Triple Redundancy tant for optimum system performance. A QNX Mark VI control systems are available in operating system is used for real-time applica- Simplex and Triple Redundant forms for small tions with multi-tasking, priority-driven preemp- applications and large integrated systems with tive scheduling, and fast-context switching. control ranging from a single module to many distributed modules. The name Triple Module Communication of data between the Control Redundant (TMR) is derived from the basic Module and other modules within the Mark VI architecture with three completely separate and control system is performed on IONet. The independent Control Modules, power supplies, VCMI card in the Control Module is the IONet and IONets. Mark VI is the third generation of bus master communicating on an Ethernet triple redundant control systems that were pio- 10Base2 network to slave stations. A unique pol- neered by GE in 1983. System throughput ing type protocol (Asynchronous Drives enables operation of up to nine, 21-slot VME Language) is used to make the IONet more racks of I/O cards at 40 ms including voting the deterministic than traditional Ethernet LANs. data. Inputs are voted in software in a scheme An optional Genius Bus™ interface can be pro- called Software Implemented Fault Tolerance vided on the main processor card in Mark VI (SIFT). The VCMI card in each Control Simplex controls for communication with the Module receives inputs from the Control GE Fanuc family of remote I/O blocks. These Module back-plane and other modules via “its blocks can be selected with the same software own” IONet. configuration tools that select Mark VI I/O cards, and the data is resident in the same data- Data from the VCMI cards in each of the three base. Control Modules is then exchanged and voted prior to transmitting the data to the main The Control Module is used for control, pro- processor cards for execution of the application tection, and monitoring functions, but some software. Output voting is extended to the tur- applications require backup protection. For bine with three coil servos for control valves and example, backup emergency overspeed protec- 2 out of 3 relays for critical outputs such as tion is always provided for turbines that do not hydraulic trip solenoids. Other forms of output have a mechanical overspeed bolt, and backup voting are available, including a median select synch check protection is commonly provided of 4-20ma outputs for process control and 0- for generator drives. In these applications, the 200ma outputs for positioners. IONet is extended to a Backup Protection Module that is available in Simplex and triple Sensor interface for TMR controls can be either redundant forms. The triple redundant version single, dual, triple redundant, or combinations contains three independent sections (power of redundancy levels. The TMR architecture supply, processor, I/O) that can be replaced supports riding through a single point failure in while the turbine is running. IONet is used to the electronics and repair of the defective card access diagnostic data or for cross-tripping or module while the process is running. Adding between the Control Module and the sensor redundancy increases the fault tolerance � � GE Power Systems GER-4193A (10/00) 2 SPEEDTRONIC™ Mark VI Turbine Control System of the overall “system.” Another TMR feature is has one, fixed, box-type terminal block. It can 2 the ability to distinguish between field sensor accept one 3.0 mm (#12AWG) wire or two 2.0 2 faults and internal electronics faults. mm (#14AWG) wires with 300 volt insulation. Diagnostics continuously monitor the 3 sets of I/O devices on the equipment can be mounted input electronics and alarms any discrepancies up to 300 meters (984 feet) from the termina- between them as an internal fault versus a sen- tion boards, and the termination boards must sor fault. In addition, all three main processors be within 15 m (49.2’) from their correspon- continue to execute the correct “voted” input ding I/O cards. Normally, the termination data. (See Figure 2.) boards are mounted in vertical columns in ter- mination cabinets with pre-assigned cable To Other GE Operator Operator Maintenance / Maintenance To Other GE lengths and routing to minimize exposure to Control Systems Interface Control Systems Interface Communications to DCS Communications To DCS emi-rfi for noise sensitive signals such as speed Unit Unit Data Highway Data Highway 1. RS232 Modbus Slave/Master 1. RS232 Modbus Slave/Master Ethernet Ethernet 2. 2. Ethernet TCP-IP Modbus Slave Ethernet TCP-IP Modbus Slave R CIMPLICITY Display System CIMPLICITY® Display System 3. Ethernet TCP-IP GSM TM inputs and servo loops. Windows NT Operating System 3. Ethernet TCP-IPGSM Windows NT™ Operating System Backup Protection Primary Controllers Backup Protection 1. Emergency Overspeed Primary Controllers 1. Control 1. Emergency Overspeed 1. Control 2. 2. Synch Check Protection Synch Check Protection 2. Protection General Purpose I/O 2. Protection 3. Monitoring 3. Monitoring

Protection Protection Module Module Discrete I/O. A VCRC card provides 48 digital Control Control Module Module Ethernet Ethernet P.S. inputs and 24 digital outputs. The I/O is divid- P.S. CPU X CPU P I/O I/O ed between 2 Termination Boards for the con- S tact inputs and another 2 for the relay outputs. Redundant Unit Redundant Unit Data Highway Data Highway Ethernet Ethernet - IONet - IONet (See Table 1.) (if required) (Required) Analog I/O. A VAIC card provides 20 analog Control Control Module Module P.S. P.S. inputs and 4 analog outputs. The I/O is divided Y CPU CPU P I/O I/O S between 2 Termination Boards. A VAOC is ded- icated to 16 analog outputs and interfaces with Ethernet Ethernet - IONet - IONet 1 barrier-type Termination Board or 2 box-type Control Control Module Module Termination Boards. (See Table 2.) P.S. P.S. Z CPU CPU P Temperature Monitoring. A VTCC card pro- I/O I/O S vides interface to 24 thermocouples, and a VRTD card provides interface for 16 RTDs. The Ethernet Ethernet - IONet - IONet input cards interface with 1 barrier-type Figure 2. Mark VI TMR control configuration TB Type I/O Characteristics TBCI Barrier 24 CI 70-145Vdc, optical isolation, 1ms SOE 2.5ma/point except last 3 input are 10ma / point I/O Interface DTCI Box 24 CI 18-32Vdc, optical isolation, 1ms SOE 2.5ma/point except last 3 input are 10ma/point There are two types of termination boards. One TICI Barrier 24 CI 70-145Vdc, 200-250Vdc, 90-132Vrms, 190-264Vrms (47-63Hz), optical isolation 1ms SOE, 3ma / point TRLY Barrier 12 CO Plug-in, magnetic relays, dry, form “C” contacts type has two 24-point, barrier-type terminal 6 circuits with fused 3.2A, suppressed solenoid outputs Form H1B: diagnostics for coil current blocks that can be unplugged for field mainte- Form H1C: diagnostics for contact voltage Voltage Resistive Inductive nance. These are available for Simplex and 24Vdc 3.0A 3.0 amps L/R = 7 ms, no suppr. 2 3.0 amps L/R = 100 ms, with suppr TMR controls. They can accept two 3.0 mm 125Vdc 0.6A 0.2 amps L/R = 7 ms, no suppr. (#12AWG) wires with 300 volt insulation. 0.6 amps L/R = 100 ms, with suppr 120/240Vac 6/3A 2.0 amps pf = 0.4 Another type of termination board used on DRLY Box 12 CO Same as TRLY, but no solenoid circuits Simplex controls is mounted on a DIN rail and Table 1. Discrete I/O � � GE Power Systems GER-4193A (10/00) 3 Software Voting Software Voting SPEEDTRONIC™ Mark VI Turbine Control System reduced by eliminating peripheral instrumenta- Analog I/O tion. The VTUR card is designed to integrate TB Type I/O Characteristics several of the unique sensor interfaces used in TBAI Barrier 10 AI (8) 4-20ma (250 ohms) or +/-5,10Vdc inputs 2 AO (2) 4-20ma (250 ohms) or +/-1ma (500 ohms) inputs turbine control systems on a single card. In Current limited +24Vdc provided per input (2) +24V, 0.2A current limited power sources some applications, it works in conjunction with (1) 4-20ma output (500 ohms) (1) 4-20ma (500 ohms) or 0-200ma (50 ohms) output the I/O interface in the Backup Protection TBAO Barrier 16 AO (16) 4-20ma outputs (500 ohms) DTAI Box 10 AI (8) 4-20ma (250 ohms) or +/-5,10Vdc inputs Module described below. 2 AO (2) 4-20ma (250 ohms) or +/-1ma (500 ohms) inputs Current limited +24Vdc available per input Speed (Pulse Rate) Inputs. Four-speed inputs (1) 4-20ma output (500 ohms) (1) 4-20ma (500 ohms) or 0-200ma (50 ohms) output from passive magnetic sensors are monitored by DTAO Box 8 AO (8) 4-20ma outputs (500 ohms) the VTUR card. Another two-speed (pulse rate) Table 2. Analog I/O inputs can be monitored by the servo card VSVO which can interface with either passive or Termination Board or 2 box-type Termination active speed sensors. Pulse rate inputs on the Boards. Capacity for monitoring 9 additional VSVO are commonly used for flow-divider feed- thermocouples is provided in the Backup back in servo loops. The frequency range is 2- Protection Module. (See Table 3.) 14k Hz with sufficient sensitivity at 2 Hz to detect zero speed from a 60-toothed wheel. Two Temperature Monitoring additional passive speed sensors can be moni- TB Type I/O Characteristics TBTC Barrier 24 TC Types: E, J, K, T, grounded or ungrounded tored by “each” of the three sections of the H1A fanned (paralleled) inputs, H1B dedicated inputs DTTC Box 12 TC Types: E, J, K, T, grounded or ungrounded Backup Protection Module used for emergency TRTD Barrier 16 RTD 3 points/RTD, grounded or ungrounded 10 ohm copper, 100/200 ohm platinum, 120 ohm nick overspeed protection on turbines that do not H1A fanned (paralleled) inputs, H1B dedicated inputs DTAI Box 8 RTD RTDs, 3 points/RTD, grounded or ungrounded have a mechanical overspeed bolt. IONet is 10 ohm copper, 100/200 ohm platinum, 120 ohm nick used to communicate diagnostic and process Table 3. Temperature Monitoring data between the Backup Protection Module and the Control Module(s) including cross-trip- ping capability; however, both modules will ini- Application Specific I/O tiate system trips independent of the IONet. In addition to general purpose I/O, the Mark (See Table 4 and Table 5.) VI has a large variety of cards that are designed Synchronizing. The synchronizing system con- for direct interface to unique sensors and actu- sists of automatic synchronizing, manual syn- ators. This reduces or eliminates a substantial chronizing, and backup synch check protec- amount of interposing instrumentation in tion. Two single-phase PT inputs are provided many applications. As a result, many potential VTUR I/O Terminations from Control Module single-point failures are eliminated in the most TB Type I/O Characteristics critical area for improved running reliability TTUR Barrier 4 Pulse rate Passive magnetic speed sensors (2-14k Hz) 2 PTs Single phase PTs for synchronizing and reduced long-term maintenance. Direct Synch relays Auto/Manual synchronizing interface 2 SVM Shaft voltage / current monitor interface to the sensors and actuators also TRPG* Barrier 3 Trip solenoids (-) side of interface to hydraulic trip solenoids TRPS* 8 Flame inputs UV flame scanner inputs (Honeywell) enables the diagnostics to directly interrogate TRPL* DTUR Box 4 Pulse Rate Passive magnetic speed sensors (2-14k Hz) the devices on the equipment for maximum DRLY Box 12 Relays Form “C” contacts – previously described DTRT Transition board between VTUR & DRLY effectiveness. This data is used to analyze device and system performance. A subtle benefit of Table 4. VTUR I/O terminations from Control this design is that spare-parts inventories are Module � � GE Power Systems GER-4193A (10/00) 4 SPEEDTRONIC™ Mark VI Turbine Control System Flame Detection. The existence of flame either VPRO I/O Terminations from Backup Protection Module can be calculated from turbine parameters that TB Type I/O Characteristics TPRO Barrier 9 Pulse rate Passive magnetic speed sensors (2-14k Hz) are already being monitored or from a direct 2 PTs Single phase PTs for backup synch check 3 Analog inputs (1) 4-20ma (250 ohm) or +/-5,10Vdc inputs interface to Reuter Stokes or Honeywell-type (2) 4-20ma (250 ohm) 9 TC inputs Thermocouples, grounded or ungrounded flame detectors. These detectors monitor the TREG* Barrier 3 Trip solenoids (+) side of interface to hydraulic trip solenoids TRES* 8 Trip contact in 1 E-stop (24Vdc) & 7 Manual trips (125Vdc) flame in the combustion chamber by detecting TREL* UV radiation emitted by the flame. The Reuter Table 5. VPRO I/O terminations from Backup Stokes detectors produce a 4-20ma input. For Protection Module Honeywell flame scanners, the Mark VI supplies the 335Vdc excitation and the VTUR / TRPG on the TTUR Termination Board to monitor monitors the pulses of current being generated. the generator and line busses via the VTUR This determines if carbon buildup or other card. Turbine speed is matched to the line fre- contaminates on the scanner window are caus- quency, and the generator and line voltages are ing reduced light detection. matched prior to giving a command to close the breaker via the TTUR. Trip System. On turbines that do not have a mechanical overspeed bolt, the control can An external synch check relay is connected in issue a trip command either from the main series with the internal K25P synch permissive processor card to the VTUR card in the Control relay and the K25 auto synch relay via the Module(s) or from the Backup Protection TTUR. Feedback of the actual breaker closing Module. Hydraulic trip solenoids are wired with time is provided by a 52G/a contact from the the negative side of the 24Vdc/125Vdc circuit generator breaker (not an auxiliary relay) to connected to the TRPG, which is driven from update the database. An internal K25A synch the VTUR in the Control Module(s) and the check relay is provided on the TTUR; however, positive side connected to the TREG which is the backup phase / slip calculation for this relay driven from the VPRO in each section of the is performed in the Backup Protection Module Backup Protection Module. A typical system trip or via an external backup synch check relay. initiated in the Control Module(s) will cause Manual synchronizing is available from an oper- the analog control to drive the servo valve actu- ator station on the network or from a synchro- ators closed, which stops fuel or steam flow and scope. de-energizes (or energizes) the hydraulic trip Shaft Voltage and Current Monitor. Voltage can solenoids from the VTUR and TRPG. If cross- build up across the oil film of bearings until a tripping is used or an overspeed condition is discharge occurs. Repeated discharge and arc- detected, then the VTUR/TRPG will trip one ing can cause a pitted and roughened bearing side of the solenoids and the VPTRO/TREG surface that will eventually fail through acceler- will trip the other side of the solenoid(s). ated mechanical wear. The VTUR / TTUR can continuously monitor the shaft-to- ground volt- Servo Valve Interface. A VSVO card provides 4 age and current, and alarm at excessive levels. servo channels with selectable current drivers, Test circuits are provided to check the alarm feedback from LVDTs, LVDRs, or ratio metric functions and the continuity of wiring to the LVDTs, and pulse-rate inputs from flow divider brush assembly that is mounted between the feedback used on some liquid fuel systems. In turbine and the generator. TMR applications, 3 coil servos are commonly � � GE Power Systems GER-4193A (10/00) 5 SPEEDTRONIC™ Mark VI Turbine Control System used to extend the voting of analog outs to the mination board can be provided with active iso- servo coils. Two coil servos can also be used. lation amplifiers to buffer the sensor signals One, two, or three LVDT/Rs feedback sensors from BNC connectors. These connectors can be can be used per servo channel with a high select, used to access real-time data by remote vibra- low select, or median select made in software. At tion analysis equipment. In addition, a direct least 2 LVDT/Rs are recommended for TMR plug connection is available from the termina- applications because each sensor requires an AC tion board to a Bently Nevada 3500 monitor. excitation source. (See Table 6 and Table 7.) The 16 vibration inputs, 8 DC position inputs, and 2 Keyphasor inputs on the VVIB are divid- TB TB Ty Typ pe e I/O I/O C Ch har arac act te er ri is st ti ic cs s ed between 2 TVIB termination boards for T TS SV VO O Barri Barrie er r 2 2 c ch hn nl ls s. . (2 (2) S ) Se erv rvo o c cu urr rre en nt t s so ou ur rces ces (6 (6) L ) LV VD DT T/ /L LV VD DR R feed feedb ba ac ck k 3,000 rpm and 3,600 rpm applications. Faster 0 0 t to o 7 7. .0 0 V Vr rm ms s shaft speeds may require faster sampling rates (4 (4) E ) Ex xc ci it ta at ti io on n s so ou ur rc ce es s 7 7 V Vr rm ms s, , 3. 3.2k Hz 2k Hz on the VVIB processor, resulting in reduced ( (2 2) ) P Pu ul ls se e r ra at te e i in np pu ut ts s ( (2 2- -14k Hz 14k Hz) ) vibration inputs from 16-to-8. (See Table 8.) *o *onl nly 2 y 2 pe per r VS VSV VO O D DS SV VO O Bo Box x 2 2 c ch hn nl ls s. . (2 (2) S ) Se erv rvo o c cu urr rre en nt t s so ou ur rces ces (6 (6) L ) LV VD DT T/ /L LV VD DR R feed feedb ba ac ck k 0 0 t to o 7 7. .0 0 V Vr rm ms s VVIB I/O Terminations from Control Module (2 (2) E ) Ex xc ci it ta at ti io on n s so ou ur rc ce es s TB Type I/O Characteristics 7 7 V Vr rm ms s, , 3. 3.2k Hz 2k Hz TVIB Barrier 8 Vibr. Seismic, Proximitor, ( (2 2) ) P Pu ul ls se e r ra at te e i in np pu ut ts s ( (2 2- -14k Hz 14k Hz) ) Velomitor, accelerometer *o *onl nly 2 y 2 pe per r VS VSV VO O charge amplifier Table 6. VSVO I/O terminations from Control DC inputs 4 Pos. Module Keyphasor 1 KP Current limited –24Vdc provided per probe Nominal Servo Valve Ratings Coil Nominal Coil Mark VI Table 8. VVIB I/O terminations from Control Type Current Resistance Control Module #1 +/- 10 ma 1,000 ohms Simplex & TMR #2 +/- 20 ma 125 ohms Simplex #3 +/- 40 ma 62 ohms Simplex Three phase PT and CT monitoring. The VGEN #4 +/- 40 ma 89 ohms TMR card serves a dual role as an interface for 3 #5 +/- 80 ma 22 ohms TMR #6 +/- 120 ma 40 ohms Simplex phase PTs and 1 phase CTs as well as a special- #7 +/- 120 ma 75 ohms TMR ized control for Power-Load Unbalance and Table 7. Nominal servo valve ratings 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 Vibration / Proximitor® Inputs. The VVIB card inputs and the TRLY Termination Board for provides a direct interface to seismic (velocity), relay outputs to the fast acting solenoids. 4- Proximitor®, Velomitor®, and accelerometer 20ma inputs are also provided on the TGEN for (via charge amplifier) probes. In addition, DC monitoring pressure transducers. If an EX2000 position inputs are available for axial measure- Generator Excitation System is controlling the ments and Keyphasor® inputs are provided. generator, then 3 phase PT and CT data is com- Displays show the 1X and unfiltered vibration municated to the Mark VI on the network levels and the 1X vibration phase angle. -24vdc rather than using the VGEN card. (See Table 9.) is supplied from the control to each Proximitor Optical Pyrometer Inputs. The VPYR card moni- with current limiting per point. An optional ter- � � GE Power Systems GER-4193A (10/00) 6 SPEEDTRONIC™ Mark VI Turbine Control System � A backup operator interface to the TB Type I/O Characteristics plant DCS operator interface TGEN Barrier 2 PTs 3 Phase PTs, 115Vrms 5-66 Hz, 3 wire, open delta � A gateway for communication links to 3 CTs 1 Phase CTs, 0-5A other control systems (10A over range) 5-66 Hz 4 AI 4-20ma (250 ohms) � A permanent or temporary or +/-5,10Vdc inputs maintenance station Current limited +24Vdc/input TRLY Barrier 12 CO Plug-in magnetic relays � An engineer’s workstation previously described Table 9. VGEN I/O 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.) Figure 3. Operator interface graphics: TB Type I/O Characteristics TPYR Barrier 2 Pyrometers (8) 4-20ma (100 ohms) 7FA Mark VI (2) Current limited +24Vdc sources All control and protection is resident in the (2) Current limited Mark VI control, which allows the HMI to be a -24Vdc sources non-essential component of the control system. (2) Keyphasor inputs It can be reinitialized or replaced with the Table 10. VPYR I/O terminations from Control process running with no impact on the control Module system. The HMI communicates with the main processor card in the Control Module via the Operator Interface Ethernet based Unit Data Highway (UDH). All The operator interface is commonly referred to analog and digital data in the Mark VI is acces- as the Human Machine Interface (HMI). It is a sible for HMI screens including the high reso- PC with a Microsoft® Windows NT® operating lution time tags for alarms and events. system supporting client/server capability, a System (process) alarms and diagnostics alarms CIMPLICITY® graphics display system, a for fault conditions are time tagged at frame Control System Toolbox for maintenance, and a rate (10/20/40 ms) in the Mark VI control and software interface for the Mark VI and other transmitted to the HMI alarm management sys- control systems on the network. (See Figure 3.) tem. System events are time tagged at frame It can be applied as: rate, and Sequence of Events (SOE) for contact � The primary operator interface for inputs are time tagged at 1ms on the contact one or multiple units input card in the Control Module. Alarms can � � GE Power Systems GER-4193A (10/00) 7 SPEEDTRONIC™ Mark VI Turbine Control System be sorted according to ID, Resource, Device, made with password protection (5 levels) and Time, and Priority. Operators can add com- downloaded to the Control Module while the ments to alarm messages or link specific alarm process is running. All application software is messages to supporting graphics. stored in the Control Module in non-volatile flash memory. Data is displayed in either English or Metric engineering units with a one-second refresh Application software is executed sequentially rate and a maximum of one second to repaint a and represented in its dynamic state in a ladder typical display graphic. Operator commands diagram format. Maintenance personnel can can be issued by either incrementing / decre- add, delete, or change analog loops, sequenc- menting a setpoint or entering a numerical ing logic, tuning constants, etc. Data points can value for the new setpoint. Responses to these be selected and “dragged” on the screen from commands can be observed on the screen one one block to another to simplify editing. Other second from the time the command was issued. features include logic forcing, analog forcing, Security for HMI users is important to restrict and trending at frame rate. Application soft- access to certain maintenance functions such as ware documentation is created directly from editors and tuning capability, and to limit cer- the source code and printed at the site. This tain operations. A system called “User includes the primary elementary diagram, I/O Accounts” is provided to limit access or use of assignments, the settings of tuning constants, particular HMI features. This is done through etc. The software maintenance tools (Control the Windows NT User Manager administration System Toolbox) are available in the HMI and program that supports five user account levels. as a separate software package for virtually any Windows 95 or NT based PC. The same tools Software Maintenance Tools are used for EX2000 Generator Excitation Systems, and Static Starters. (See Figure 4 and The Mark VI is a fully programmable control Figure 5.) system. Application software is created from in- house software automation tools which select Communications proven GE control and protection algorithms and integrate them with the I/O, sequencing, Communications are provided for internal data and displays for each application. A library of transfer within a single Mark VI control; com- software is provided with general-purpose munications between Mark VI controls and blocks, math blocks, macros, and application peer GE control systems; and external commu- specific blocks. It uses 32-bit floating point data nications to remote systems such as a plant dis- (IEEE-854) in a QNX operating system with tributed control system (DCS). real-time applications, multitasking, priority- The Unit Data Highway (UDH) is an Ethernet- driven preemptive scheduling, and fast context based LAN with peer-to-peer communication switching. between Mark VI controls, EX2000 Generator Software frame rates of 10, 20, and 40 ms are Excitation Controls, Static Starters, the GE supported. This is the elapsed time that it takes Fanuc family of PLC based controls, HMIs, and to read inputs, condition the inputs, execute Historians. The network uses Ethernet Global the application software, and send outputs. Data (EGD) which is a message-based protocol Changes to the application software can be with support for sharing information with mul- � � GE Power Systems GER-4193A (10/00) 8 SPEEDTRONIC™ Mark VI Turbine Control System 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 executing identical application software from identical databases. Two of the UDH drivers are normally connected to one switch, and the Figure 4. Software maintenance tools – card other UDH driver is connected to the other configuration switch in a star configuration. Network topolo- gies conform to Ethernet IEEE 802.3 standards. The GE networks are a Class “C” Private Internet according 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/ Relay Ladder Diagram Editor for Boolean Functions 16 prefix). Communication links from the Mark VI to remote computers can be implemented from either an optional RS232 Modbus port on the Figure 5. Software maintenance tools – editors main processor card in Simplex systems, or from a variety of communication drivers from tiple nodes based on the UDP/IP standard the HMI. When the HMI is used for the com- (RFC 768). Data can be transmitted Unicast, munication interface, an Ethernet card in the Multicast or Broadcast to peer control systems. HMI provides an interface to the UDH, and a Data (4K) can be shared with up to 10 nodes at second Ethernet card provides an interface to 25Hz (40ms). A variety of other proprietary the remote computer. protocols are used with EGD to optimize com- munication performance on the UDH. All operator commands that can be issued from an HMI can be issued from a remote computer 40 ms is fast enough to close control loops on through the HMI(s) to the Mark VI(s), and the the UDH; however, control loops are normally remote computer can monitor any application closed within each unit control. Variations of software data in the Mark VI(s). Approximately this exist, such as transmitting setpoints 500 data points per control are of interest to a between turbine controls and generator con- plant control system; however, about 1,200 trols for voltage matching and var/power-factor � � GE Power Systems GER-4193A (10/00) 9 SPEEDTRONIC™ Mark VI Turbine Control System points are commonly accessed through the � Additional “master” communication communication links to support programming drivers are available from the HMI. screen attributes such as changing the color of a valve when it opens. Time Synchronization Time synchronization is available to synchro- Communication Link Options nize all controls and HMIs on the UDH to a Communication link options include: Global Time Source (GTS). Typical GTSs are � An RS-232 port with Modbus Slave Global Positioning Satellite (GPS) receivers RTU or ASCII communications from such as the StarTime GPS Clock or other time- the Main Processor Card. (Simplex: processing hardware. The preferred time full capability. TMR: monitor data only sources are Universal Time Coordinated (UTC) – no commands) or GPS; however, the time synchronization option also supports a GTS using local time as � An RS-232 port with Modbus Master / its base time reference. The GTS supplies a Slave RTU protocol is available from time-link network to one or more HMIs with a the HMI. time/frequency processor board. When the � An RS-232/485 converter (half- HMI receives the time signal, it is sent to the duplex) can be supplied to convert Mark VI(s) using Network Time Protocol the RS-232 link for a multi-drop (NTP) which synchronizes the units to within network. +/-1ms time coherence. Time sources that are � Modbus protocol can be supplied on supported include IRIG-A, IRIG-B, 2137, NASA- an Ethernet physical layer with TCP-IP 36, and local signals. for faster communication rates from the HMI. Diagnostics � Ethernet TCP-IP can be supplied with Each circuit card in the Control Module con- a GSM application layer to support the tains system (software) limit checking, high/low transmission of the local high- (hardware) limit checking, and comprehensive resolution time tags in the control to a diagnostics for abnormal hardware conditions. DCS from the HMI. This link offers System limit checking consists of 2 limits for spontaneous transmission of alarms every analog input signal, which can be set in and events, and common request engineering units for high/high, high/low, or messages that can be sent to the HMI low/low with the I/O Configurator. In addition, including control commands and each input limit can be set for latching/non- alarm queue commands. Typical latching and enable/disable. Logic outputs commands include momentary logical from system limit checking are generated per commands and analog “setpoint frame and are available in the database (signal target” commands. Alarm queue space) for use in control sequencing and alarm commands consist of silence (plant messages. alarm horn) and reset commands as High/low (hardware) limit checking is provid- well as alarm dump requests that cause ed on each analog input with typically 2 occur- the entire alarm queue to be rences required before initiating an alarm. transmitted from the Mark VI to the These limits are not configurable, and they are DCS. � � GE Power Systems GER-4193A (10/00) 10 SPEEDTRONIC™ Mark VI Turbine Control System selected to be outside the normal control ing the correct termination point. One wire in requirements range but inside the linear hard- each connector is dedicated to transmitting an ware operational range (before the hardware identification message with a bar-code serial reaches saturation). Diagnostic messages for number, board type, hardware revision, and a hardware limit checks and all other hardware connection location to the corresponding I/O diagnostics for the card can be accessed with card in the Control Module. the software maintenance tools (Control System Toolbox). A composite logic output is provided Power in the data base for each card, and another In many applications, the control cabinet is logic output is provided to indicate a high/low powered from a 125Vdc battery system and (hardware) limit fault of any analog input or short circuit protected external to the control. the associated communications for that signal. Both sides of the floating 125Vdc bus are con- The alarm management system collects and tinuously monitored with respect to ground, time stamps the diagnostic alarm messages at and a diagnostic alarm is initiated if a ground is frame rate in the Control Module and displays detected on either side of the 125Vdc source. the alarms on the HMI. Communication links When a 120/240vac source is used, a power to a plant DCS can contain both the software converter isolates the source with an isolation (system) diagnostics and composite hardware transformer and rectifies it to 125Vdc. A diode diagnostics with varying degrees of capability high select circuit chooses the highest of the depending on the protocol’s ability to transmit 125Vdc busses to distribute to the Power the local time tags. Separate manual reset com- Distribution Module. A second 120/240vac mands are required for hardware and system source can be provided for redundancy. (software) diagnostic alarms assuming that the Diagnostics produce an under-voltage alarm if alarms were originally designated as latching either of the AC sources drop below the under- alarms, and no alarms will reset if the original voltage setting. For gas turbine applications, a cause of the alarm is still present. separate 120/240vac source is required for the Hardware diagnostic alarms are displayed on ignition transformers with short circuit protec- the yellow “status” LED on the card front. Each tion of 20A or less. card front includes 3 LEDs and a reset at the top of the card along with serial and parallel The resultant “internal” 125Vdc is fuse-isolated ports. The LEDs include: RUN: Green; FAIL: in the Mark VI power distribution module and Red; STATUS: Yellow. fed to the internal power supplies for the Control Modules, any expansion modules, and Each circuit card and termination board in the the termination boards for its field contact system contains a serial number, board type, inputs and field solenoids. Additional 3.2A fuse and hardware revision that can be displayed; 37 protection is provided on the termination pin “D” type connector cables are used to inter- board TRLY for each solenoid. Separate 120Vac face between the Termination Boards and the feeds are provided from the motor control cen- J3 and J4 connectors on the bottom of the ter for any AC solenoids and ignition trans- Control Module. Each connector comes with formers on gas turbines. (See Table 11.) latching fasteners and a unique label identify- � � GE Power Systems GER-4193A (10/00) 11 SPEEDTRONIC™ Mark VI Turbine Control System IEC 6100-4-4: 1995 Steady Electrical Fast Transient Susceptibility State Freq. Load Comments IEC 6100-4-5: 1995 Voltage Surge Immunity 125Vdc 10.0 A dc Ripple <= 10V p-p (100 to Note 1 IEC 61000-4-6: 1995 144Vdc) Conducted RF Immunity 120vac 47 - 63Hz 10.0 A rms Harmonic distortion < 5% IEC 61000-4-11: 1994 (108 to Note 2 132vac) Voltage Variation, Dips, and Interruptions 240vac 47 - 63 Hz 5.0 A rms Harmonic distortion < 5 % ANSI/IEEE C37.90.1 (200 to Note 3 Surge 264vac) Table 11. Power requirements CE - Low Voltage Directive EN 61010-1 Electrical Equipment, Industrial Machines Codes and Standards IEC 529 ISO 9001 in accordance with Tick IT by Lloyd's Intrusion Protection Codes/NEMA 1/IP 20 Register Quality Assurance Limited. ISO 9000- Reference the Mark VI Systems Manual GEH- 3 Quality Management and Quality Assurance 6421, Chapter 5 for additional codes and stan- Standards, Part 3: Guidelines for the Appli- dards. cation of ISO 9001 to Development Supply and Maintenance of Software. Environment Safety Standards The control is designed for operation in an air- conditioned equipment room with convection UL 508A Safety Standard Industrial Control cooling. Special cabinets can be provided for Equip. operation in other types of environments. CSA 22.2 No. 14 Industrial Control Equipment Temperature: Printed Wire Board Assemblies Operating 0° to +45°C +32° to +113°F UL 796 Printed Circuit Boards Storage -40° to +70°C -40° to +158°F UL recognized PWB manufacturer, The control can be operated at 50∞C during UL file number E110691 maintenance periods to repair air-conditioning ANSI IPC guidelines systems. It is recommended that the electronics ANSI IPC/EIA guidelines be operated in a controlled environment to maximize the mean-time-between-failure CE - Electromagnetic Compatibility (EMC) (MTBF) on the components. EN 50081-2 Generic Emissions Standards Purchased commercial control room equipment EN 50082-2:1994 such as PCs, monitors, and printers are typically Generic Immunity Industrial Environment capable of operating in a control room ambient EN 55011 of 0° to +40°C with convection cooling. Radiated and Conducted Emissions IEC 61000-4-2:1995 Humidity Electrostatic Discharge Susceptibility 5% to 95% non-condensing IEC 6100-4-3: 1997 Radiated RF Immunity Exceeds EN50178: 1994 � � GE Power Systems GER-4193A (10/00) 12 SPEEDTRONIC™ Mark VI Turbine Control System Communication Links From HMI: Elevation RS232 Modbus Master/Slave, Ethernet Exceeds EN50178: 1994 Modbus Slave, Ethernet TCP-IP GSM HMI Gas Contaminants SPEEDTRONIC™ Application Manual - EN50178: 1994 Section A.6.1.4 Table A.2 (m) Chapter 7 (GEH-6126), Ethernet TCP-IP GEDS Standard Dust Contaminants Message Format (GSM) (GEI-100165) Exceeds IEC 529: 1989-11 (IP-20) � Operator/Maintenance Interface HMI Seismic Universal Building Code (UBC) HMI for SPEEDTRONIC™ Turbine Section 2312 Zone 4 Controls Application Manual (GEH-6126) Documentation Cim Edit Operation Manual (GFK-1396) The following documentation is available for Mark VI Turbine Controls. A subset of this doc- User Manual (GFK-1180) umentation will be delivered with each control Cimplicity HMI For Windows NT depending on the functional requirements of Trending Operators each system. Manual (GFK-1260) Manuals � Turbine Historian System Guide � System Manual for SPEEDTRONICTM (GEH-6421) Mark VI Turbine Control (GEH-6421) � Standard Blockware Library (SBLIB) � Control System Toolbox, for � Turbine Blockware Library Configuring a Mark VI Controller (TURBLIB) (GEH-6403) Drawings Configuring the Trend Recorder (GEH- � Equipment Outline Drawing AutoCAD 6408) R14 System Data Base for System Toolbox � Equipment Layout Drawing AutoCAD (GEI-100189) R14 System Data Base Browser (GEI-100271) � I/O Termination List (Excel Data Historian (used for trip history) Spreadsheet) (GEI-100278) � Network one-line diagram (if � Communications To Remote applicable) Computers / Plant DCS � Application Software Diagram RS232 Modbus Slave From Control (printout from source code) Module � Data List For Communication Link To Modbus Communications DCS Implementation UCOC2000 - I/O Drivers, Chapter 2 � � GE Power Systems GER-4193A (10/00) 13 SPEEDTRONIC™ Mark VI Turbine Control System List of Figures Figure 1. 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