ITS Products and Services

8/6/2019 ITS Products and Services

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Products and Services

Email: Info @ turbineservices.asia





• Older control systems, for example the Speedtronic Mark I or II, cannot

fulfil the demands of a modern gas turbine control such as complicated

control functions like DLN (Dry Low NOx)

• The MACH7 is a flexible and scalable programmable control processor that

can monitor, control, and regulate all the gas turbine processes including

all the existing peripherals.

• Due to its flexibility, it is possible to easily add at anytime very complicated

control tasks and algorithms, that result from new developments or

environmental regulation laws and etc, or inputs from other systems.

OVERVIEW



Technical Design

Parameters

• Our control concept is based on the efficient modular expandable SPS – platformfor complex automation solutions, specifically designed for use in the powergenerating industry.

• Based on open and flexible programmable system, that is easily expandable in

regard to adding extra control functions.

• The control can have a maximum of 131,072 digital signals and 8,182 analoguesignals

• All control components are under continuous self-diagnosis that can determine a

problem before it has any impact to the process.

• The processor can be repaired while in operation or even replaced. After a repairor replacement, the processor will be automatically put in the “HOT STANDBYMODE”.

• The control is only composed of 4 to 5 different standard components. This implies

economical solution to a complete spare part inventory is possible.



PANEL CONFIGURATION

• The Mach 7 panel is as big as a Mark IV panel

• Optional panel mount operator interface.



LAYOUT of REDUNDANCY

• Mach 7 employs the principle of active redundancy (“HOT STANDBY”)

which has been thoroughly tested and used in the state of the art process

control worldwide



PROCESSOR ACTIVE REDUNDANCY

• Critical control sequences and turbine protection are run in separate

“Tasks”. Both processors <P1> and <P2> are continuously active during

operation.

• The lead processor is assumed by the first processor booted-up. The

second one will automatically be set in the “Hot Standby” mode.

• In the event of a fault there is a bump less transfer to the still functioning

backup device for control of the process.

• <P1> and <P2> are configured in two completely separated standard built

cores with their own separate power supplies. The redundant

communication between the single processors is accomplished through

double runs of fibre optic cable.



COMM ACTIVE REDUNDANCY

• The communicator processors <C1> and <C2> are located in each of the cores of

the processors <P1> and <P2>. The <C> processors are responsible for the data

transfer to the Turbine Monitoring System

• They too follow the “Hot Standby” principle so the lead <C> processor handles the

communication to the operator terminals thereby relieving the lead <P> processor

from the memory intensive communication work.

• In the case of a fault, there is a bump less transfer of work to the still functioning

backup device.

• All components of the controls can be changed during operation. When the CPU is

changed, it will automatically be configured and reload all the actual programs and

data.

• Adding or removal of different cores, DP-Slaves and memory chips as well as

making configuration changes are all possible during operation.



HARDWARE DESIGN

CPU• In the Mach7 turbine control, the processor 417-4H is

exclusively used, which at this being the best available suited

for this type of process control application.



HARDWARE DESIGN

IO and Functions Cores

• The selection of the input, output or function core hardware is dependent upon

the turbine as well as the functions required.

• Depending on the “importance” of the signal, the input and output signals will be

distributed to the different modules.

• The used cores are the standard cores from SIMATIC S7.

• With a decentralized control structure, the gas turbine signals as well as any

additional local skids, are processed in the required standard built type (ET200M)

and the data is then transmitted to the processor through double redundant bus

cables (fibre optic).

• Short and clearly laid out cable connections between the field devices and the I/Omodules facilitates a condition for safe and problem free data exchange between

the I/O modules



HARDWARE DESIGN

IO and Functions Cores

• The amount of input and output signals in the MACH7 is dependent on the type of

turbine plus 20% planned spares. This way there is enough reserve capacity that

can be used for future added turbine functions or including a variety of diverse

related devices without the need to add new modules.

• After the 20% reserves are used, the capacity of I/O is almost unlimited through

additional cores. The theoretical upper limit is 131,072 digital input/output signals

as well as 8,192 analog input/output signals.



TECHNICAL SPECIFICATIONS

STANDARD CONTROL PANEL HARDWARE

Control Panel RITTAL HxWxD 2000x1200x500 1 Siemens S7400H (2x CPU 417-4, 2x CP443-1, separate power supplies) 1 Active Redundant Processors connected with fiber optic X ET200M Module for redundant IO with 2x IM153-2 6 DC-DC Converter redundant (125VDC / 24VDC) 3 Redundant Power Supplies for all Modules X Galvanic Isolation for I/O Signals X No Ventilator Required X Fiber Optic Switch Module for Fiber Optic Ring 2 Vibration Measurement Signal conditioning 12 Flame Detector Signal conditioning for Honeywell UV Flame Detector 8 SIMATIC Panel PC 670 15" TFT 1024x768 touch pad Keyboard, Mouse 1 Internal Wiring (I/O Terminals, Power Supplies, Modules) X Internal Bus Wiring (Profibus, Ind. Ethernet, OSM, Video Server) X Internal Panel I/Os (Door open / closed, Temperature, Lighting) X



TECHNICAL SPECIFICATIONS EXAMPLE OF PROCESS SEQUENCE SOFTWARE

Standard Software for GE Gas Turbines X 2 out of 3 Voting with generating middle value for 3 redundant Field I/Os X Exhaust Temperature Control X Speed (Frequency) Control for Island Operating Mode X Double Electronic Overspeed Protection Circuits X Software for Steam Injection X Software for Water Injection X Software for DLN1 Control X 17 th Stage Compressor Protection (MS 6001) X Software for Inlet Air Heating X Software for Anti Icing X Flame Monitoring X Exhaust Temperature Monitoring X Wheelspace Temperature Monitoring X Bearing Oil Drain Temperature Monitoring X Bearing Metal Temperature Monitoring X Generator Temperature Monitoring X Vibration Monitoring X Inlet Guide Vane Control X On-Line / Off-Line Compressor Water Wash X Numerous Turbine Protection Functions X Variable Fast Start Calculations with Self Adjustment X TMOS Turbine Monitoring System for Operator Turbine Control X



TECHNICAL SPECIFICATIONS

Standard Inputs / Outputs of the MACH7



MACH 7 IO NETWORKs

• The networking uses a PROFIBUS DP Optical Link

with a bus speed capable of 12 Mbit/s.

• Advantages of Fiber Optic Technology:

– Unaffected by electromagnetic interference

– No influence from outside disturbances

– No grounding problems

– Galvanically isolated

– Easy cable routing

– Limited weight



417-4H CPU TECHICAL SPECIFICATIONS



MACH 7 HARDWARE RELIABILITY

• Reliability can be reflected with average time of Failure-free operation during a

mission or Mean Time Between Failure

• Statistical MTBF can be used to judge the reliability of a system and/or component

• MTBF of MACH 7 (or S7) components are calculated based IEC 61709 standard

Components Function MTBF (years)

CPU 417-4H CPU 34.5

IM 153-2 Comm. Module of ET200M 47.6

FM 350-2 Pulse Counter 35.7

SM 321 Digital Inputs 30.6

PS 407 Power Supply 60

Reference: Siemens website

https://support.automation.siemens.com/WW/llisapi.dll?func=cslib.csinfo&lang=en&objid=168184

90&caller=view



TYPES OF TURBINES SUPPORTED



TYPICAL MACH 7 PANEL ORGANIZATION



ET200M 2oO3 VOTING RACK

ARRANGEMENT EXAMPLE



FUNCTIONAL DIAGRAM

(2oO3 reading, 1 to 3 writing)



ET200M INPUT and/or OUTPUT

MODULE ARRANGEMENT EXAMPLE



NON-REDUNDANT IO

FUNCTIONAL DIAGRAM



EXAMPLE of MACH 7 IMPLEMENTAION



INSTALLED BASES

Installed Systems : 21

Installed Power : About 667 MW at ISO

Peak Load Power : About 667 MW at ISO

Characteristics : Approved and used for black

start and net reconstruction



TMOS – Visualizing, Archiving & Diagnosis

System

• TMOS – Turbine MOnitoring System has all the characteristics

that a future oriented digital system must possess.

• TMOS was designed especially for the maintenance, display,

and monitoring of gas turbine data.• The use of TMOS is not limited to only the turbine operation,

but can also be applied to other processes (such as boilers,

generators, compressors, balance of plant, etc.).

•

Integration with plant Local Area Network enable data sharingwith network users

• Components based on Server and Client models

• Windows based and dual LCD displays with multiple windows

support



TMOS CAPABILITY OVERVIEW

DCS



TMOS COMMUNICATION CAPABILITY

• TMOS can communicate and control the following systems:

– GE Speedtronic Mark IV

– GE Speedtronic Mark V / Mark V LM

– GE Speedtronic Mark VI

– ITS MACH 7

• The communication protocols that it supports: – ARCNET DLAN as well as DLAN+

– GE DDUMP (Serial as well as Ethernet TCPIP)

– GE MSP (Serial as well as Ethernet TCPIP)

– GE GSM

– Modbus RTU (Serial as well as Ethernet TCPIP)

– S7 Communication (over TCPIP)

– OPC DA 3.0 and EA 1.0 Server



TMOS AS OPERATOR INTERFACE

• Animated color screens

• Multiple screens open at once

• Signal Information

• Start realtime trending with only 2 clicks

• Movable alarms panels

• Customizable Display Styles: TMOS, HMI,

IDOS, P&ID and etc



TMOS DISPLAY OPTIONS

•

TMOS STYLE




•

HMI STYLE




•

P&ID STYLE



SIGNAL INFO

•

One Click leads to many roles



TMOS AS HISTORIAN

• Archive Analogue signals, Alarms, Diagnostics, Events and

Digital IOs events for future retrieval

• Trend realtime or historical signal

• Data stored as RAW = no compression loss

• Timestamp up to 0.001s resolution

• Up to 1s sampling rate for analogue signals

• Export Alarms, Events, Diagnostics and Digital IO events to

other formats: xls, jpg, xml and so on.



TMOS as ANALYZER - TRENDVIEWER

• Powerful but user friendly tool to trend realtime as well as

historical data

• Drag and drop signals to start trending

• Able to select signal from particular processor (Speedtronic TMR)

• Zooming and panning functions with auto-configured trend

resolution

•

3 movable slide bars to pinpoint signals behaviours



TMOS as ANALYZER - TRENDVIEWER



D.E.A Viewer

• Organizer and viewer of both current and historicalDiagnostics, Digital, Events and Alarms

• Things you can do - Find, sort, filter, print and export



TMOS HIGH SPEED DATA LOGGING

• Under certain circumstances, a high speed data

logger to capture fast changing signals in order to

pinpoint root cause of the problem, such as powerswing.

• This tool can capture signal up to 32 sample/sec

• Able to specify sampling trigger condition and source

target



TMOS HIGH SPEED DATA LOGGING



USER DEFINED SIGNALS

• Not only can TMOS display, archive, trend and print signals

from various data sources (like Speedtronic, Mach 7, GC

Analyzer, BN 3500 and etc), user can also define formulas to

derive calculated signals for more meaningful analysis

• The formula can consist of common mathematical operator

like sin, cos, tan, log and so on, contained in a maximum of 8

layers of parantheses.

• Calculated values can also be used in the next formula



USER DEFINED SIGNALS



TMOS FAULT TRACING MADE EASY

• No more alarm drop number, please!

• Direct link from alarm windows to the particular sequencingrung that triggers it



TMOS DYNAMIC RUNG DISPLAY

• Intuitive and features packed.

•

Fast coil tracing• IO connection details displayed

• Direct Logic Forcing from display



TMOS DYNAMIC RUNG DISPLAY



Mark V Diagnostics

• Especially useful for Mark V users, this tool enable detailed

diagnosis into Mark V systems as well as ARCNet

• May print or save as text file



Mark V Diagnostics



TMOS ENGINEERING TOOLS

As a completely re-engineered HMI solution, TMOS has all the

necessary engineering tools:

• Pre-vote viewer for Speedtronic TMR

• LVDT & SERVO calibrator

• EEPROM Programmer for Speedtronic Mark V

• IO Configurator for Speedtronic Mark V

• STEP 7 Manager for Mach 7

•

Constants adjust and Logic Forcing



TMOS ADMINISTRATION

• Block nuisance events

• 10 users assignable and user rights customizable

• Time synchronization options



TMOS PLATFORM & HARDWARE

• Windows Server 2003R2 and 2008

• TMOS recommends HP Proliant Server

• compatible to all modern Intel processors and

chipsets• DVD Writer

• RAID 5 storage array

•

Minimum 4Gb RDIMM RAM• PCIe ARCNet Card (8 x 2kb buffer and fast bus

speed)



TMOS ADVANTAGE

• Redundant Server Configuration

• License free remote Display, Trender and

Historian Clients ( theoretically supports over

50 network users)

• Optional Remote dial-in support

• Continuous improvements



TMOS REFERENCES

Documents

ITS Products and Services