Markvie Retrofit

I I

Mark VIe Gas Turbine Control for Retrofit Applications

g GE Energy GEI-100604

2 • Mark VIe Gas Turbine Control for Retrofit Applications GEI-100604

These instructions do not purport to cover all details or variations in equipment, nor to provide for every possible contingency to be met during installation, operation, and maintenance. The information is supplied for informational purposes only, and GE makes no warranty as to the accuracy of the information included herein. Changes, modifications, and/or improvements to equipment and specifications are made periodically and these changes may or may not be reflected herein. It is understood that GE may make changes, modifications, or improvements to the equipment referenced herein or to the document itself at any time. This document is intended for trained personnel familiar with the GE products referenced herein.

GE may have patents or pending patent applications covering subject matter in this document. The furnishing of this document does not provide any license whatsoever to any of these patents. All license inquiries should be directed to the address below. If further information is desired, or if particular problems arise that are not covered sufficiently for the purchaser’s purpose, the matter should be referred to:

GE Energy Post Sales Service 1501 Roanoke Blvd. Salem, VA 24153-6492 USA Phone: 1 888 GE4 SERV (888 434 7378, United States) + 1 540 378 3280 (International) Fax: + 1 540 387 8606 (All) ( + indicates the international access code required when calling from outside the USA)

This document contains proprietary information of General Electric Company, USA and is furnished to its customer solely to assist that customer in the installation, testing, operation, and/or maintenance of the equipment described. This document shall not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the written approval of GE Energy.

GE provides the following document and the information included therein as is and without warranty of any kind, express or implied, including but not limited to any implied statutory warranty of merchantability or fitness for particular purpose.

Issue date: 2004-06-07 2004 by General Electric Company, USA. All rights reserved

CIMPLICITY is a registered trademark of GE Fanuc Automation North America, Inc. CompactPCI is a registered trademark of PICMG. Ethernet is a registered trademark of Xerox Corporation. Honeywell is a registered trademark of Honeywell International Inc. McGraw Edison is a registered trademark of Cooper Industries Inc. Microsoft and Windows are registered trademarks of Microsoft Corporation. NEMA is a registered trademark of the National Electrical Manufacturers Association. QNX is a registered trademark of QNX Software Systems, Ltd. Reuter Stokes is a trademark of GE Energy. Proximitor is a registered trademark of Bently Nevada. ToolboxST is a trademark of General Electric Company, USA.

GEI-100604 Mark VIe Gas Turbine Control for Retrofit Applications • 3

Section Page

Acronyms and Abbreviations ......................................................................................3 Introduction .................................................................................................................4 Compatibility...............................................................................................................4 Product Options...........................................................................................................5 Architecture .................................................................................................................6 Redundancy.................................................................................................................7 Hardware Description..................................................................................................9 I/O Interface ..............................................................................................................12 Control Functions ......................................................................................................14 Operator and Maintenance Tools ..............................................................................17 System Monitoring ....................................................................................................21 Codes and Standards..................................................................................................22

Acronyms and Abbreviations PCI Compact Peripheral Component Interconnection (also Compact PCI)

DCS Distributed Control System

EGD Ethernet Global Data

FSR Fuel Stroke Reference

GSM GE Standard Messages

GUI Graphical User Interface

HMI Human-Machine Interface

IEC International Electro-technical Commission

IEEE Institute of Electrical and Electronics Engineers

IO Net Input-Output Network

LED Light Emitting Diode

LVDT Linear Variable Differential Transformer

NFPA National Fire Protection Association

PDH Plant Data Highway

RMS Root Mean Square

RTD Resistance Temperature Detector

TMR Triple Modular Redundant

UDH Unit Data Highway

UDP/IP User Datagram Protocol / Internet Protocol

UPS Uninterruptible Power Supply


Introduction The Mark VIe is a fully programmable control system that is well suited for retrofit of previous generations of GE and non-GE gas turbine control systems. A high-speed Ethernet IO Network (IO Net) allows distributed I/O and connects distributed I/O cabinets to the Mark VIe controller cabinet. The Mark VIe control can also be designed to provide simplex, dual or triple redundant operation. The simplex and dual architecture options are well suited to the upgrade of existing non-redundant turbine control systems from any manufacturer.

ToolboxSTTM is the software tools specifically for programming, configuring, trending and analyzing diagnostics for a gas turbine. ToolboxST can operate on the same pc as the graphical user interface to provide the user with an engineering workstation and Human Machine Interface capabilities on a single pc.

Compatibility The control is designed to install in the existing cabinet location or in distributed locations. A variety of cabinets are available to optimize replacement of existing enclosures. These include standard NEMA® 1 IP20, convection cooled cabinets with front or front and rear access and top and/or bottom cable entrances. Optional custom packaging is also available.

Existing field wiring can be retained or replaced. Barrier type terminal blocks are supplied that support two 3.0mm2 (#12AWG) wires with spade or ring lugs per point for a one-to-one match with the existing wiring. Compression type terminations are also available to meet the scale requirements of dual or simplex turbine control systems.

Mark VIe is designed to interface with most of the original sensors and replace the existing field wires with remote I/O, if needed.

It may be desirable to separate existing contact inputs that are currently wired in parallel to the annunciator since there is no longer any practical limit to the number of drops. Instead of having one alarm for lube oil system trouble, there can now be several alarms to pinpoint the specific origin of the problem. In addition, each contact has a standard 1ms sequence of events (SOE) time stamp to assist troubleshooting. Remote annunciators and meters can be supported with either remote I/O to interface with the existing devices or by replacing them with a monitor or a complete operator station.

Type J (Mark I) and type K (Mark II) thermocouples are supported as well as 10 Ω copper, 100 Ω platinum, and a variety of other RTDs from the generator (grounded) or the load compressor (ungrounded). Analog inputs are provided for 4-20 mA inputs, 0-1 mA generator transducers, and ± 5 or 10 V dc inputs from the original four-wire compressor discharge and fuel gas pressure transducers. Any existing McGraw Edison® flame scanners should be replaced with Reuter Stokes® or Honeywell® scanners.

A primary design feature of GE’s gas turbine controls is the reduction of single point failures by providing a direct interface to the sensors and actuators on the turbine. Besides avoiding single point failures, this practice reduces spare parts, decreases long-term maintenance, and enables advanced diagnostics since the control system can directly monitor sensors. For example, Mark I-IV controls used seismic probes for vibration protection, but separate vibration monitors for Proximitors®. Radial and axial Proximitors can be monitored directly in the Mark VIe with the composite, 1X, and 2X vibration and phase angle data integrated with the rest of the signal database.


Product Options The Mark VIe architecture is well suited for gas turbine control retrofits due to its scalable hardware and software capability. It can be built in a single control cabinet or distributed I/O configuration.

Simplex and redundant are built in versions of the Mark VIe control have equivalent control and turbine protection capabilities. The primary difference between simplex and redundant control systems is running reliability. Control system running reliability is based upon the percent of total I/O used in the system, the percent of used I/O classified as critical and the amount of redundancy built into the control system. Therefore critical devices should be considered for redundancy.

Applications suited to a redundant control system solution include:

• Co-Generation (CoGen) plants where the gas turbine exhaust is the only source of heat to generate steam for the production process.

• Combined cycle plants where plant efficiency requirements are tied to the availability of gas turbine exhaust as the only source of heat to generate steam for steam turbines.

• Customer requires controller or power supply redundancy.

• Generator drive applications where continuous base load operation is required.

• Mechanical drive applications where compressors or pumps are critical to the production process.

Applications suited to a non-redundant control system include:

• Plants where the gas turbine operation is not critical to other plant processes.

• Peaking units where starting reliability is the primary system requirement and continuous long-term operation is not anticipated.

Redundant or non-redundant applications requiring electronic backup protection include:

• Electronic over speed, deceleration, acceleration and locked rotor detection.

• Primary control watchdog with speed difference and stale speed detection.

• Backup sync check for generator drive units.

I —4r —

r sr N

A M


Architecture The Mark VIe communicates with networked I/O over one or multiple Ethernet networks. The controller rack consists of a main processor and one or two power supplies. A QNX® real-time, multitasking operating system is used for the main processor and I/O. Application software is provided in a configurable control block language and is stored in non-volatile memory. Data conforms to IEEE-854 32-bit floating-point format.

The IO Net is a dedicated, full-duplex, point-to-point protocol that provides a deterministic, high-speed 100 MB communications network suitable for local or remote I/O with a fiber interface. It is used to communicate between the main processor(s) and networked I/O blocks, called I/O packs.

100 MB Ethernet is used for communication to local and remote I/O packs. The IO Net is available in single, dual, and triple configuration.

Each I/O pack is mounted on a terminal board with barrier or box type terminal blocks. The I/O pack contains two Ethernet ports, a power supply, a local processor, and a data acquisition board.

Networked I/O for Turbine Control Retrofits (Distributed or in a Single Cabinet)

Speed Vibration Servos Flame Combustion/ DLE

TurbineAuxiliaries Driven Load

• Generator• Compressor• Pump

Remaining Process• Power Island• Balance of Plant

I/O Network - 100 MB

Unit Data Highway

Plant Data Highway

Controller(s)

Operator & MaintenanceStations


Redundancy Every application has different requirements for redundancy depending on the criticality of the process. Three standard product offerings for gas turbine control and monitoring with the Mark VIe control are summarized below:

Table of Standard Mark VIe Control Redundancy Offerings for Gas Turbine Control

Triple Dual Simplex

Internal power distribution

Triple Dual Single

Controllers Triple Dual Single

I/O networks Triple Dual Single

I/O electronics Single, dual or triple Single Single

I/O pack Ethernet ports Single Dual Single

Relative reliability Highest level of running reliability with superior fault detection

Control/network redundancy to reduce control system fault trips

Lowest level of running reliability with good starting reliability

IOPack

Switch

Switch

Controller

Controller

Basic Dual Configuration

IO PackSwitch

Switch

Controller

Controller

Basic Triple Configuration

IO Pack

ckSwitchController IO Pack

IOPackSwitchController

Basic Simplex Configuration


Available redundancy options: • Internal power distribution - This includes the capability to convert external ac

or dc sources to 28 V dc. N+1 power distribution redundancy is also available as an option.

• Controller redundancy - Multiple controllers can be in a single controller rack to separate fuel control from compressor control or to separate auxiliary systems control from turbine control, etc. For example, in a TMR system, two processors per controller rack yields two separate TMR systems connected to their own set of I/O packs.

• I/O pack redundancy - Variable on TMR systems based upon the criticality of the I/O. An option for triple redundancy on I/O packs is also available in dual systems to provide additional output reliability.

System Architecture Control system redundancy is provided for internal power distribution as well as controller, I/O pack and Ethernet networking. Power distribution and Ethernet network redundancy is repeated in accordance with the level of system redundancy when I/O distribution is required. Although simplex systems are illustrated below, the number of Ethernet switches and power supplies is dependent upon system redundancy.

System with Mark VIe Electronics in One Cabinet

System with Mark VIe Electronics Distributed

Controller

UCCA

SwitchIO Net - Cat. 5100 m / 328'

IO Net - Cat. 5100 m / 328'

Pack

Field Wire300 m / 984' Field Device

TB

28 V dc PowerDistribution

Controller Cabinet

Controller

UCCA

SwitchIO Net - Cat. 5100 m / 328' Switch

IO Net - Cat. 5100 m / 328'

PackField Wire300 m / 984'

Field Device

TB



Controller Cabinet Distributed IO Cabinet

I/ONet - Cat. 5100m / 328'

or100FX Fiber

2,000 m /6,600'

H!


Hardware Description Controller

The Mark VIe uses CompactPCI architecture and runs the QNX realtime operating system.

The Mark VIe controller runs the application code and is the IO Net bus master for communication with the I/O packs. The controller communicates with I/O packs solely via IO Net.

The rack and its contents are rated for NFPA Class 1, Div. 2 with an operating range of 0 to 60°C. Boards are front-loaded, vertical, and held in position by their connectors with guides on both sides and a faceplate that screws into the rack.

A 28 V dc power supply is located on the right side of the rack, with an on-off switch directly above. If redundant supplies are required, a second supply can be provided in the location of the on-off switch. Either supply can be inserted or removed from the rack without disturbing controller operation.

Optional controllers can be added to separate the application software for different pieces of equipment. For example, the fuel control can run in one controller and the compressor control can run in a second controller, if required to meet customer specifications to use multiple processors.

Mark VIe Compact PCI Controller Rack


IO Net Switches manage the communication traffic to eliminate collisions and increase network determinism.

Communication between the controller and the I/O packs is performed with the internal IO Net. This is a 100 MB Ethernet network available in simplex, dual, and triple configurations. Ethernet Global Data (EGD) and other protocols are used for communication. EGD is based on the UDP/IP standard (RFC 768). EGD packets are broadcast at the system frame rate from the controller to the I/O packs, which respond with input data. Industrial grade switches are used for the IO Net that meet the codes, standards, performance, and environmental criteria for industrial applications, including an operating temperature of -30 to 65°C (-22 to 149°F). Switches have provision for redundant 10 to 30 V dc power sources (200/400 mA) and are DIN rail-mounted. LEDs indicate the status of the IO Net link, speed, activity, and duplex.

I/O Packs An on-board temperature sensor provides continuous monitoring of the environment in remote locations.

I/O packs with the Mark VIe controller have a processor board and a data acquisition board that is unique to the type of device to which it is connected. I/O packs on each terminal board digitize the signal, perform algorithms, and communicate with Mark VIe controller. The I/O processor board (BPPB) and data acquisition board are rated for NFPA Class 1, Div. 2 with an operating range of -30 to 65°C (-22 to 149°F).

The I/O pack has a temperature sensor that is accurate to within ±2°C (±3.6°F). Every I/O pack temperature is available in the database and can be used to generate an alarm.

General Purpose I/O Turbine-Specific I/O

Discrete Speed and overspeedAnalog Servo controlThermocouple Vibration and positionRTD Synchronizing

BPPBPower SupplyProcessor2 Ethernets

DataAcquisitionBoard

I/O pack

I


Mark VIe architecture provides online replacement capability for I/O packs. This is equivalent to "hot swap" in rock-based systems.

A power supply provides a regulated 28 V dc power feed to each I/O pack. The negative side of the 28 V dc is grounded through the I/O pack metal enclosure and its mounting base. The positive side has solid-state circuit protection built-into the I/O pack with a nominal 2 A trip point. Every I/O pack communicates directly on IO Net, which enables each I/O pack to be replaced individually without affecting any other I/O in the system. Also, the I/O pack can be replaced without disconnecting any field wiring.

Terminal Blocks Signal flow begins with a sensor connected to a terminal block on a board. Two types of Mark VIe terminal boards are available: T and S type. Mark VIe terminal boards are normally arranged in vertical columns of high and low level wiring that can be accessed from top and/or bottom cable entrances. A shield strip can be provided to the left of the metal base where the board is mounted.

Terminations support the existing #12 AWG (3.0 mm2) wires at site with barrier type terminal blocks for ease of maintenance.

T type boards contain two 24-point, barrier type, removable terminal blocks. Each point can accept two 3.0 mm2 (#12AWG) wires with 300 V insulation per point with spade or ring type lugs. In addition, captive clamps are provided for terminating bare wires. Screw spacing is 9.53 mm (0.375 in.) minimum, center-to-center.

S type boards allow only one I/O pack. Three versions of S type boards are available: fixed terminal blocks, removable terminal blocks and a version is available for mounting of custom blocks such as spring-cage or insulation displacement. S type boards have box type terminal blocks that accept one 3.0 mm2 (#12AWG) wire or two 2.0 mm2 (#14AWG) wires with 300 V insulation per point. Screw spacing is 5.08 mm (0.2 in.) minimum, center-to-center.

T Type Barrier Terminal Board with Three I/O Packs

S Type Box Terminal Boardwith One I/O Pack


I/O Interface The Mark VIe control is designed for direct interface to turbine and generator

devices such as vibration sensors, flame scanners, linear variable differential transformers (LVDT), magnetic speed pickups, thermocouples, and resistance temperature detectors (RTD). Direct monitoring of these sensors reduces the need for interposing devices with their associated single-point failures. Direct connection to a field device reduces long-term maintenance, and enables diagnostics to directly monitor the health of devices mounted on the machinery.

Contact input and output IO packs have LED open/closed status indicators.

Contact inputs are powered from the 125 V dc battery bus (optional 24 or 48 V dc) through the Mark VIe terminal boards. Each contact input is optically isolated and has a 1ms time stamp for sequence of events monitoring.

Terminations for existing contact inputs can be replaced one-for-one or split up for greater alarm resolution. For example, instead of having several field contacts wired to a single contact input, they can be separated into multiple contact inputs to provide a separate alarm message for each problem in the lube oil system.

Other solenoid power option are also available.

Contact outputs are from plug-in, magnetic relays with dry, Form-C, contacting outputs (optional solid state outputs). Turbine solenoids are normally powered from the 125 V dc battery bus with suppression for each solenoid with a 3.2 A slow-blow fuse on each side of the feeder circuit.

Analog inputs monitor 4 – 20 mA (250 Ω), which can be configured for self-powered, differential inputs, or as sensors that use a +24 V dc supply from the Mark VIe control. Selected inputs can be configured for 0 – 1mA inputs (5,000 Ω) or ±5, 10 V dc inputs. This interfaces to

• Existing 0 – 1mA generator MW and MVAR transducers

• Existing 0 – 5 V dc gas fuel and compressor discharge pressure transducers

Most Mark II generator drive systems already have these transducers; however, Mark I systems do not. Compressor discharge pressure biases the temperature control system to improve turbine operation.

Analog outputs can be configured for 4 – 20 mA output (500 Ω maximum) or 0 – 200 mA output (50 Ω maximum).

Temperature input linear equation tables are assigned on per channel basis for thermocouple and RTDs.

Thermocouple inputs can be grounded or ungrounded. Software linearization is provided for type J and K thermocouples used on GE gas turbines plus types E, S, or T thermocouples. Existing control and over temperature thermocouples are retained and divided between the Mark VIe controller and the backup protection module for temperature control and over temperature protection, respectively.

RTD inputs can be grounded or ungrounded. Software linearization is provided for 10 Ω copper, 100/200 Ω platinum, or 120 Ω nickel RTDs. The generator or load compressor RTDs can be monitored directly by the Mark VIe with all turbine and driven-load temperatures being collected in a common database with other turbine-generator parameters.


Direct interface to turbine specific devices provide the user with improved visibility to sensors and turbine parameters.

Speed input direct interface provides redundant, magnetic speed sensor inputs to the controllers for speed control and overspeed protection. Backup protection is provided with separate processors, and terminal boards to automatically de-energize the fuel solenoids.

Flame input direct interface is provided for ultra-violet flame scanners that produce a pulsed output. This eliminates any interposing transducers and enables the diagnostics to monitor the actual light level. An alarm is initiated if the light level diminishes below an acceptable level due to carbon or other deposits on the scanner window.

Integrating servos have a direct interface to the bipolar servo actuator and LVDT valve position feedback. Bi-polar servo current outputs are provided in 10, 20, 40, 80, and 120 mA ranges for fuel valves and Inlet Guide Vane (IGV) control. Mark VIe LVDT excitation is 7.0 Vrms at 3.2 kHz. Pulse rate inputs are also provided for servo control loops using liquid fuel-flow, pulse-rate feedback.

Vibration protection has a direct interface for vibration protection sensors. This includes seismic (velocity) type sensors used on heavy-duty gas turbines and accelerometers on aircraft-derivative gas turbines. This eliminates the single-point failure of a separate monitoring system, and allows Mark VIe diagnostics to monitor seismic sensors when the turbine is running or stopped. The Mark VIe contains accelerometer speed-tracking filters to isolate the appropriate vibration frequencies of each shaft for the display, alarm, and protection.

Proximitor input direct interface for monitoring keyphasor, radial proximitor, and axial proximitor data is available in a common database with all turbine parameters. The fundamental (1X), first harmonic (2X), and composite vibration signals are collected by the Mark VIe and displayed with both magnitude and phase angle on the Human-Machine Interface (HMI). Active isolators provide buffered outputs to BNC connectors on the Mark VIe terminal boards for temporary connection to portable vibration analysis equipment.

Redundant backup synch check protection is available through a separate Mark VIe I/O pack.

Synchronizing interface uses generator and line potential transformers to match the generator frequency (turbine speed) to the line frequency and match the generator voltage to the line voltage through commands to the generator excitation control. The Mark VIe provides backup sync check protection, closes the generator breaker, and monitors actual breaker closure time.


Control Functions The control functions below are typical and individual applications may vary. Nozzle control for two-shaft machines and load compressor controls are also supported by Mark VIe control.

Startup control is an open-loop system that increases the fuel stroke reference as the turbine startup sequence progresses to preassigned plateaus.

Acceleration control adjusts the fuel stroke reference according to the rate of change of the turbine speed to reduce the thermal shock to the hot gas path parts of the turbine.

Speed control uses the median speed from three speed sensors and separate shaft speed-control algorithms for each shaft in multi-shaft machine applications. The Mark VIe varies shaft speed reference to control real power (megawatt) output in mechanical and generator drive application.

Generator load control compares the load setpoint with the MW feedback and adjusts the speed setpoint to regulate load. Mark VIe maintains a constant generator shaft speed to meet the electrical power demand and also controls the generator field through the use of VAR/Power Factor (PF) control algorithms to generate excitation raise and lower commands. A spinning reserve selection allows the machine to start automatically and await an operator input to synchronize to the grid. Selection of fast load start or pre-selected load raises the output to the pre-selected load setpoint limit. Selection of base or peak raises this setpoint to the maximum limit.

Compressor load control uses the concept of Integrated Turbine Compressor Control (ITCC) and combines turbine prime mover and load compressor surge controls in a single control system. Mark VIe is capable of load sharing single stage and multiple stage compressors; as well as providing process controller capability for pressure, temperature, level or flow parameters. The surge control and protection algorithms allow operation closer to the surge line by anticipating surge events and taking corrective action to prevent surge events before they occur.

Exhaust temperature control algorithms sort the input from each thermocouple from the highest to the lowest temperature. They automatically reject bad thermocouple data, average the remaining data values, and execute the control algorithm based upon the average calculated temperature. Redundant transducers monitor the compressor discharge pressure and bias the temperature control to correct for ambient conditions and the corresponding variations in mass flow.

Inlet guide vane control modulates the position of the compressor stator vanes to provide optimum compressor and unit operation. During startup, the guide vanes open as the turbine speed increases. When the unit is online, the guide vanes modulate to control turbine airflow temperature to optimize combustion system and combined cycle performance.

Emissions control is available with diluent (water or steam) injection via a multi-nozzle quiet combustor to quench flame temperature and reduce thermal NOx formation. Dry Low Nox (DLN) control using lean-burning, pre-mixed flame combustors is available without the need for water or steam injection.


Fuel control is a reference from the governor and feedback of the fuel control valves. The Fuel Stroke Reference (FSR) is determined by the turbine parameter (speed, temperature, and so on) calling for the least fuel. Liquid fuel control establishes the FSR of the bypass valve and is proportional to turbine speed (Fuel Flow = Speed X FSR). Gas fuel control uses a Gas Control Valve (GCV), where fuel flow is a function of pressure (Fuel Flow = Fuel Pressure X FSR). A Speed Ratio Valve (SRV) opens as a turbine speed function, so gas fuel pressure becomes a function of speed. This allows the liquid and gas fuel control systems to have the same characteristic. The fuel control also supports single electric gas fuel metering valve operation for Frame 3 and Frame 5 gas turbines, as well as aero derivative gas turbines.

Gas Fuel

Servo90SR

LVDT96SR

TSVC

Stop/SpeedRatio Valve

Terminal Boards

PSVO Board

A/D

Main Processor

FPRG

TNH (Speed)

Constants

LogicSoftwareRegulator D/A

96FG

Gas FuelPressure

TBAIPAIC BoardD/A

+

-

Servo65GC

LVDT96GC

TSVC

Gas ControlValvePSVO Board

A/D

FSROUT

FSR2

LogicSoftwareRegulator D/A

CombustionChamber

Servo65FP

TSVC

LiquidFuel Flow

PSVO Board

A/D

SoftwareRegulator

FlowDivider

Liquid Fuel

Pulse77FD

D/A

FSROUT

Logic

TNH (Speed)

FSR1

FuelSplitterFSR

Logic

Controller

Liquid FuelControl Valve

IONet

Typical Dual Fuel Control System


Sequencing Turbine control can include automated startup and shutdown sequences customized to meet operator requirements, as well as control and monitoring of all gas turbine auxiliary and support systems. Operators can have the turbine automatically start and synchronize or sequence to intermediate hold points by selecting Crank, Fire, or Auto without enabling automatic synchronization. All ramp rates and time delays are pre-programmed for optimum performance. Timers and counters record long-term turbine operating information that can include:

• Total fired time

• Separate DLN operating mode timers

• Manually initiated starts

• Total starts

• Fast load starts

• Fired starts

• Emergency trips

This automation enables operation from a remote site with the assurance that the turbine is fully protected. Diagnostics capture a record of abnormal conditions.

Protection Turbine control initiates an alarm if an abnormal condition is detected. If the condition exceeds a predefined trip level, the turbine control drives the gas/liquid control valves to a zero-flow position and de-energizes the fuel shut-off solenoids.

Diagnostics monitor the speed and acceleration, and then verify that all sensors are active. Primary protection is implemented by the controller(s), while backup protection is provided by backup protection I/O packs and terminal boards.

Typical Gas Turbine Trip Protection System

Pre-ignition Post-ignition Protective Status

Auxiliary check (Servos)

Seal oil dc motor undervoltage

Dc lube oil pump undervoltage

Startup fuel flow excessive

Failure to ignite

Loss of flame

High exhaust temperature

Exhaust thermocouples open

Compressor bleed valve position trouble

Load tunnel temperature high

Gas fuel hydraulic pressure low

Turbine lube oil header temperature high

Turbine electronic overspeed

Starting device trouble

Inlet guide vane trouble

Manual trip

Control speed signal lost

Exhaust pressure high

Protective speed signal trouble

Control speed signal trouble

Breaker failure trip lockout

Vibration trip

Loss of protection HP speed inputs

Customer trip

Control system fault

Low lube oil pressure

Fire indication

Generator lockout trip


Operator and Maintenance Tools Operator Interface The HMI is the operator interface. It is a pc with a Microsoft® Windows®-based operating system, client/server capability, CIMPLICITY® Graphical User Interface (GUI) and software maintenance tools (ToolboxST). It can be applied as:

• Primary operator station for one unit or the entire plant

• Maintenance station gateway

• Engineers station

• Gateway for communications

All local and remote data in the Mark VIe is accessible for screens with high-resolution time tags for alarms and events.

The HMI communicates with the main processor board in the Mark VIe controller(s) through the Unit Data Highway (UDH) and to third party control and monitoring systems via the Plant Data Highway (PDH). All control and protection is resident in the Mark VIe controller, which allows the HMI to be a non-essential component. With the turbine running, the HMI can be reinitialized or replaced with no impact on the controller.

System (process) alarms for fault conditions are time tagged at frame rate in the controller(s) and transmitted to the HMI alarm management system. System events are time tagged at frame rate, and sequence of events (SOE) for contact inputs are time tagged at 1ms in the I/O packs. Alarms can be sorted according to ID, resource, device, time, and priority. Operators can add comments to alarm messages or link specific alarm messages to supporting graphics. A standard alarm/event log stores data for 30 days and can be sorted in chronological order or according to the frequency of occurrence.

A trip history function stores key control parameters, alarms, and events for the last 30 trips. A configurable set of data is collected continuously in the controller and saved automatically for upload and analysis. Data is displayed in English or Metric engineering units with a one second update rate and one second to repaint a typical display graphic. Operator commands can be issued to increment/decrement a setpoint or a numerical value can be entered for a new setpoint.

Gas turbine control screens display a diagram of the turbine with the primary control parameters. The diagram is repeated on most of the screens to provide a visual image of the turbine’s performance while changing screens.

Typical Gas Turbine Screens

Control Screens Monitor Screens Auxiliaries Tests

Startup Bearing temperature Flame Overspeed test

Motors Exhaust temperature Water wash

FSR control Generator RTDs Start check

Generator/exciter Wheelspace temperature Trip diagram

Synchronizing Seismic vibration Timers


If startup permissives were not satisfied, the message, Not Ready to Start displays and a message in the alarm field that identifies the reason. Additionally, when the Aux button is clicked and the Start Check screen is selected, it displays graphical information for the Start Check/Ready to Start permissives.

A message reminds you to investigate the nature of the latched trip prior to clicking Master Reset.

To access trip conditions that display in the alarm field and trip diagram click the Aux button and select the Trip Diagram screen. A trip during startup displays the message, Not Ready to Start.

Mark VIe control also allows you to change a numeric setpoint, such as Megawatts for a generator drive or Speed Reference for a mechanical drive, by entering a setpoint value rather than issuing continuous discrete raise/lower commands. The setpoint is compared with acceptable limits and the present output to determine a suitable ramp rate to the new target.

The Mark VIe control supports trending displays for comparing operating parameters. A startup trend can be set with pre-assigned parameters, such as mean Exhaust Gas Temperature, speed, maximum vibration, Compressor Discharge Pressure, and Fuel Stroke Reference. More detailed information and trending are provided on supporting screens, along with the capability to create customized trends.

Typical Turbine Instrumentation

Buttons on the right side of all screens produce sub-menus of category-specific screens.

The main screen is the Startup screen. Since the gas turbine control provides fully automatic startup including all interfaces to auxiliary systems, all basic commands and all primary control parameters and status conditions start from this screen.

For example, the Start command can be sent to the Mark VIe control when Ready to Start displays in the startup status field. A pop-up window displays above the Startup button for verification. Upon verification, the application software checks the startup permissives and starts a sequence that displays, Starting and Sequence in Progress messages.

1

I

m 0 ,fl..U.idIM U

• O..flCMó........U— 10ucs34 U.tPCALS*...d SS,.,..S1._

—


Software Maintenance Tools (ToolboxST) Mark VIe control is a fully programmable control system, which uses proven GE control and protection algorithms integrated with the custom I/O, sequencing, and displays for each application. Multiple block libraries are provided with general-purpose blocks, math blocks, macros (user blocks), and application-specific blocks.

The application software is password protected and can be downloaded while the system is running. In redundant control systems, the application software in each controller is identical and represented as a single program to maintenance personnel. Downloads of changes can be automatically distributed to redundant controllers by the control system, and differences are monitored by diagnostics. All application software is stored in non-volatile memory.

Application software is run sequentially and dynamic data is shown in function block and ladder diagram formats. Maintenance personnel can add, delete, or change analog loops, sequencing, I/O assignments, and tuning constants. To simplify editing, use the drag-and-drop operation to move data points on the screen from one block to another.

Editing Tools (ToolboxST)

Features- Field programmable- Floating point- Dynamic data display- Drag & drop points- Math blocks- Macros (User Blocks)- Function and ladder blocks- Multiple block libraries- Editors for: - Application software - I/O assignments - Tuning constants

- Password protection- Boolean and analog forcing


Points can also be dragged from the application software diagrams onto trends. Other features include Boolean (digital) forcing, analog forcing, and trending at the running frame rate of the application software.

Application software documentation is created directly from source code and can be compiled and printed. This includes the application software diagram, I/O assignments, the settings of tuning constants, etc. The software maintenance tools are available for use in the Mark VIe HMI or as a separate software package on a Windows-based PC.

Trending Tools (ToolboxST)

Features- Automatic upload of capture blocks- Micro-second resolution- Drag and Drop of variables to trender- Browser for variables selection- 100's of signals per trend

- Mask-unmask of selected variables- Video type forward-reverse- Left-right drag of time axis- Dual cursor

- Delta, min, max, average- Stacked traces- Alarm messages on trip trend- Events log linked to trend- Export to .CSV


System Monitoring High/low (hardware) limit checking is provided for each analog input. These limits and are selected to be outside the normal operating range but inside the linear hardware operational range (before the hardware reaches saturation). A composite diagnostic alarm state is provided in the database for each I/O pack and a separate logic state is provided to indicate an input channel fault.

Diagnostic and system (process) alarms are time-stamped in the controller(s) and transmitted to operator and maintenance stations. Communication links to a plant DCS can contain software (system) and composite hardware diagnostics.

Diagnostic LEDs are provided on I/O packs. Standard LEDs indicate power status, attention (abnormality detected), Ethernet link connected, and Ethernet link communicating. LEDs on discrete I/O packs also indicate the status of each point. Terminal boards have an electronic ID that contains the board name, revision, and a unique serial number. When power is applied to the I/O pack, it reads the terminal board ID and uses this information for system asset management.

Plant-level control systems integrate the diagnostic data from the individual turbine and generator controls with the overall plant. This allows maintenance personnel to identify the defective control node, switch, or station and locate the device needing service.

Plant Network Diagnostics

Network Diagnostics for:

Engineers stationsSwitches on:- Plant data highway- Unit data highway- IO NetControl nodes

- Boards within nodes- I/O packs

Operator stationsMaintenance stations

---

--


Codes and Standards

Safety Standards EN 61010-1 Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use, Part 1: General Requirements CAN/CSA 22.2 No. 1010.1-92 Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use, Part 1: General Requirements ANSI/ISA S82.02.01 1999 Safety Standard for Electrical and Electronic Test, Measuring, Controlling, and Related Equipment – General Requirements

Printed wire board assemblies UL 796 Printed Circuit Boards ANSI IPC Guidelines ANSI IPC/EIA Guidelines

Electromagnetic Compatibility (EMC) EMC Directive 89/336/EEC as amended by 92/31/EEC and 93/68/EEC

EN 55081-2 General Emission Standard EN 50082-2 Generic Immunity Industrial Environment EN 55011 Radiated and Conducted Emissions IEC 61000-4-2 Electrostatic Discharge Susceptibility IEC 61000-4-3 Radiated RF Immunity IEC 61000-4-4 Electrical Fast Transit Susceptibility IEC 61000-4-5 Surge Immunity IEC 61000-4-6 Conducted RF Immunity IEC61000-4-11Voltage Variation, Dips & Interruptions ANSI/IEEE C37.90.1 Surge

Low-Voltage Directive 72/23/EEC EN 61010-1 Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use, Part 1: General Requirements

ATEX Directive 94/9/EC EN 50021 Electrical Apparatus for Potentially Explosive Atmospheres

General Electric Company 1502 Roanoke Blvd. Salem, VA 24153-6492 USA +1 540 387 7000 www.geenergy.com

GEI-100604 040607

GE Energy g

Markvie Retrofit

Documents

Transcript of Markvie Retrofit