Mark VI ST Control Product Overview GEH 6127

SpeedtronicTM Mark VIIndustrial Steam Turbine Control

Product Overview

GEH-6127

Speedtronic Mark VI

Industrial Steam Turbine ControlProduct Overview

GEH-6127

Issue Date: August 1998

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

These instructions do not purport to cover all details or variations in equipment, or to provide for every possible contingency to be met duringinstallation, operation, and maintenance. Should further information be desired or should particular problems arise that are not coveredsufficiently for the purchaser’s purpose, the matter should be referred to GE Industrial Systems.

© 1998 General Electric Company, USA

All rights reserved.

Printed in the United States of America.

CIMPLICITY and Genius are registered trademarks of GE Fanuc Automation North America, Inc.Field Control is a trademark of GE Fanuc Automation North America, Inc.Speedtronic is a trademark of General Electric Company, USA.GE and � are registered trademarks of General Electric Company, USA.Ethernet is a trademark of Xerox Corporation.Microsoft, Windows, and Windows NT are registered trademarks of Microsoft Corporation.Proximitor and Data Manager are registered trademarks of Bentley Nevada Corporation.Modbus is a trademark of Modicon.PI is a trademark of Oil Systems, Inc.

Speedtronic™ Mark VI Industrial Steam Turbine Control – Product Overview GEH-6127

INTRODUCTION

The GE Industrial Steam Turbine Control (ISTC) is part of the Speedtronic™ Mark VI family of turbinecontrols, which are available for all GE turbines. The ISTC is designed to provide a small core of basiccontrol functions which can be expanded in small increments for various levels of control, protection andmonitoring for the turbine, the auxiliary systems or the driven load equipment (generator / compressor /pump).

Various levels of operator interface can be provided. These include an operator interface via acommunication link from a plant Distributed Control System (DCS), a local or remote operator interfacefrom a PC / flat panel or a hardwired interface. In addition, a common operator interface can be providedfor multiple ISTCs and / or Mark V Turbine Controls, EX2000 Generator Excitation Controls, HRSGcontrols, etc.

ARCHITECTURE

The control system receives power from one, two or three power sources, which can be 115/230Vac or125Vdc. The processor card, communication card and the I/O cards are located in a single 13 slot (VMEtype) control module. I/O cards are connected to individual termination boards by computer-type cableswith 37-pin “D” type connectors.

The termination boards have pluggable, barrier type terminal blocks. Cards and termination boards can bearranged in various combinations and added in the field for future expansion. In addition, a Genius® buscan be provided to interface with Genius blocks or Field Control™ stations for remote I/O applications. Avariety of monitoring and diagnostic equipment can be integrated with the ISTC to enhance maintenance ofthe machinery.

Some of this equipment includes the following: a PC interface with a CIMPLICITY® graphics displaysystem, a Windows NT® operating system, a PC based Historian with PI™ (Plant Information) Systemssoftware for storing turbine-generator performance data on-line, and an embedded Data Manager® 2000 forWindows NT inside the Mark VI operator interface.

INPUTS and OUTPUTS

The basic system consists of a small core of inputs and outputs (I/O) for control of the speed/pressuregovernor and optional I/O that can be added for protection or monitoring options. I/O circuitry is designedfor direct interface to the sensors and actuators on the turbine to eliminate the need for interposingequipment with its resultant single point failures, maintenance and spare parts. The following diagramshows a typical I/O interface to a steam turbine with I/O for the governor and some additional protectionand monitoring.

GEH-6127 Speedtronic™ Mark VI Industrial Steam Turbine Control – Product Overview

2

Figure 1. Control system overview

Comm. CPU

VCMI UCV_ Gover. VCRC VVIB VAICVRTD VTCC VGEN VSVO

Governor

Card Rack

Gen

Actuator

Actuator

Inlet Pres.

Speed

Extraction Pressure

Exhaust Pressure

Vibration, Thrust, Eccentricity

Temperature (RTDs)

Temperature (Thermocouples)

Shaft Voltage & Current Monitor

Additional Analog I/O

Generator 3 Phase PTs & CT

Additional Servos (DAX)

Automatic Synchronizing

Trip

(24) Relays

Proxim

itors: (16) Vibration, (8) P

osition, (2) KP

(16) RT

Ds

(24) Therm

ocouples

(20) Analog Inputs / (4) A

nalog Outputs

(2) 3 Phase G

en/Line Voltage, (1) 3 P

hase Gen. C

urrent

(4) Servo C

hannels

Genius Bus

Remote I/O

(48) Contact In.

1 ms S

OE

Ethernet

Flat Panel withTouchscreen Laptop

PC Interface

Plant DCS RS232 Modbus


3

Contact Inputs: All contact inputs are optically isolated and time stamped to within 1ms.

This built-in Sequence of Events (SOE) monitor can be observed with a level 2 operator / maintenanceinterface station. Dry contacts can be powered from either a 125Vdc or 24Vdc supply from the controlthat is fuse isolated and current limited in the turbine control.

Contact Outputs: Plug-in type magnetic relays provide a dry, form “C” contact output from each relay.

Voltage Contact Resistance Rating Contact Inductive Rating

24 Vdc 3.0 amps 3.0 amps L/R = 7 ms, no suppression3.0 amps L/R = 100 ms, with suppression

125 Vdc 0.6 amps 0.2 amps L/R = 7 ms, no suppression0.6 amps L/R = 100 ms, with suppression

120/240 Vac 3.0 amps 2.0 amps pf = 0.4

Valve Interface: Regulation of the control valve loop is provided in software with a direct interface to theservo valve actuator and the LVDT valve position feedback. Bi-polar current outputs are provided for 10,20, 40, 80, 120mA ranges. LVDT circuitry is designed for interface to LVDTs with either single or dualsecondary windings.

The inputs from the dual secondary windings can be used for either LVDTs with dual secondary windingsor a pair of redundant LVDTs with single secondary windings. A 7 Vrms, 3.2 kHz excitation signal for theLVDT is provided by the turbine control, and the LVDT feedback is 0 to 7.0 Vrms position feedback. 0 to20mA and 0 to 200mA outputs are provided for interface to I/P transducers or valve positioners.

Speed Inputs: Three (3) passive, magnetic, speed sensor inputs (2 Hz to 12 kHz) are provided. Themedian value is used for speed control and primary overspeed protection. Circuit sensitivity allowsdetection of 2-rpm speed on a sixty (60) tooth wheel to determine whether the turbine is stopped or onturning gear.

Emergency Overspeed Protection is provided by either an existing mechanical overspeed bolt or aseparate set of three (3) magnetic speed sensors which are monitored by a separate, triple redundant,overspeed module. Diagnostic tests of the emergency overspeed module can be initiated and monitoredfrom the operator interface or a plant DCS while the turbine is running or shutdown.

Proximitor® Inputs: A direct interface can be provided from the turbine control to Bently-NevadaProximitors for vibration protection, thrusts wear protection, differential expansion and eccentricitymonitoring. The 1X and unfiltered vibration levels and the 1X vibration phase angle are displayed.

A plug-in connector is available to connect the vibration and key phasor inputs to a Bently-Nevadamonitor. 3500 monitors have a matching plug on the monitor and older models require discreteterminations. BNC type connectors can be provided for remote monitoring with Bently-Nevada vibrationanalysis equipment. Inputs for seismic (velocity) type probes are available too.


4

Shaft Voltage and Current Monitor: Bearings can be damaged by the flow of electrical current throughthe bearing. This can occur due to a static voltage buildup caused by water droplets being thrown off thelast stage buckets in steam turbines or ac voltage on the shaft which is caused by ac ripple on the dcgenerator field. Voltage can build up across the oil film of bearings until a discharge occurs.

Repeated discharge and arcing can cause a pitted and roughened bearing surface that will eventually failthrough accelerated mechanical wear. The turbine control can continuously monitor the shaft to groundvoltage and current and alarm excessive levels. Test circuits are provided to check the alarm functions andthe continuity of wiring to the brush assembly that are mounted between the turbine and the generator.

Synchronizing: Automatic synchronizing is available via single phase PT inputs from the generator andline. The control matches the turbine speed to the line frequency and the generator and line voltages. Anautomatic command to close the breaker is issued when the breaker is predicted to close within the phase-slip window. A normally open contact on the breaker (not an auxiliary relay) is monitored to measure theactual breaker closure time that is used to update the database. Manual synchronizing can be providedfrom a synch scope display on a PC-based, level 2-operator interface.

Three-phase PT and CT Monitoring: The turbine control can provide a direct interface to three-phase PTsfrom the generator and line, and CTs from the generator including the neutral.

Figure 2. Circuit cards Figure 3. Termination boards


5

Temperature Monitoring: Grounded and ungrounded thermocouples and RTDs can be monitored by thecontrol with linearization for various sensor types provided in software.

Thermocouple Table

Type "E" (-)60 to +1100 ºF (-)51 to +593 ºC

Type "J" (-)60 to +1400 ºF (-)51 to +798 ºC

Type "K" (-)60 to +2000 ºF (-)51 to +1093 ºC

Type "T" (-)60 to +750 ºF (-)51 to +399 ºC

RTD Table

SAMA or GE 10 ohm copper (-)60 to +500 ºF (-)51 to +260 ºC

SAMA 100 ohm platinum (-)60 to +1100 ºF (-)51 to +593 ºC

DIN 43760 100 ohm platinum (-)60 to +1292 ºF (-)51 to +700 ºC

MINCO (PA) 100 ohm platinum (-)60 to +1292 ºF (-)51 to +700 ºC

MINCO (PB) 100 ohm platinum (-)60 to +1292 ºF (-)51 to +700 ºC

Rosemont 104 100 ohm platinum (-)60 to +1292 ºF (-)51 to +700 ºC

MINCO (NA) 120 ohm nickel (-)60 to +480 ºF (-)51 to +249 ºC

US Industrial 200 ohm platinum (-)60 to +400 ºF (-)51 to +204 ºC

Analog I/O: Each analog I/O termination board contains ten (10) analog input circuits and two (2) analogoutput circuits. All inputs can monitor 4-20mA (250 ohms) which can be configured for self-powered,differential inputs or as sensors which use a +24Vdc supply from the turbine control.

Two (2) of the inputs are designed for 0-1mA inputs with 5,000 ohm input impedance, and eight (8) of theinputs are designed for +/-5, 10Vdc inputs. Each set of two (2) analog outputs consists of one (1) 4-20mAoutput (500 ohms max.) and one (1) output which can be configured for either 4-20mA output or 0-200mAoutput (50 ohms max.).

Remote I/O: Genius is a family of proven I/O instrumentation for local or remote control applications. Itconsists of I/O blocks that communicate to the host controller over a serial communication link(153.6kbaud).

Each block has a specific I/O function such as reading thermocouple inputs. Field Control is a newaddition to the Genius family that consists of a rack, called the Field Control station, with the FieldProcessor and up to eight (8) different types of I/O modules in the rack.


6

Genius blocks and Field Control stations can coexist on the same serial bus with each block or rackcounting as one (1) node with a maximum of 32 nodes. An assortment of I/O blocks and cards areavailable.

A typical application for remote I/O in retrofit applications is to mount Genius blocks or Field Controlstations inside an old operator console consisting of: analog meters, switches, annunciators, etc. Thiswiring can be localized within the console between the instrumentation and a few remote I/O blocks andcommunicated with the steam turbine control via a Genius bus link.

Figure 4. Field Control station - remote I/O

PACKAGING

The standard turbine control enclosure consists of a NEMA 1, convection cooled cabinet with front accessand top or bottom cable entrances. It is rated for continuous operation in a 0 to 45 ºC ambient andoperation up to 50 ºC during maintenance periods; however, it is recommended that this microprocessorbased product be located in an air-conditioned environment. Other types of enclosures are available withbuilt-in cooling systems and purification systems as required for the application.

Field Processor

I/O Module: up to 8 per rack

Terminal Blocks- Barrier Type- Box Type


7

The I/O cards are located in a 13 slot (VME type) control module. The front of an I/O card has three (3)LEDs.

- Green = RUN or OK

- Red = Error or power-up failure

- Yellow = Card specific

Each I/O card plugs into a slot that has P1 and P2 connectors on the backplane, and J3 and J4 connectors(37 pins) located directly beneath the card. These connectors are used to connect each I/O card to itscorresponding field termination board.

“D” type connector cables are used with latching fasteners. One wire in the cable is dedicated totransmitting an identification message from the termination board to the I/O card containing a bar-codeserial number, board type, hardware revision, and a connection location.

The termination boards are arranged in vertical columns with separate wire channels for high level andlow-level wires. Each termination board contains passive noise filters and two (2) pluggable, 24 point,barrier type terminal blocks. Each screw can terminate two (2) #12 AWG 300 volt insulated wires.Provision is made on each termination block for shield terminations, which are connected, to the chassisground.

English Units Metric Units

Dimensions 35.4”W x 86.6”H x 35.4”D 900mmWx 2,200mmH x 900mmD

Weight 800 lbs. (typical) 362.9 kgs. (typical)

Temp. – Operate +32 to +113 ºF 0 to +45 ºC

– Storage -40 to +158 ºF -40 to +70 ºC

Heat 700 Watts (typical) 700 Watts (typical)

Humidity 5 to 95% non-condensing 5 to 95% non-condensing

POWER

The turbine control can be powered from either 115/230Vac or 125Vdc sources. Provision for a floating125Vdc source is always available. One or two redundant 115/230Vac sources can be provided in additionto the 125Vdc source.


8

The AC Power Converters include an isolation transformer and a full wave rectifier to produce a 125Vdcoutput, which is “high-selected” with the 125Vdc outputs from the other power converters. Thisredundant, internal 125Vdc bus is isolated and fed to the various module power supplies via the PowerDistribution Module. Separate 125Vdc feeders are used to distribute the power to each contact inputtermination module for external contact power and to each relay termination module to power external125Vdc solenoids.

Each solenoid circuit has additional fuses on the positive and negative sides. 24Vdc power sources for thecontact inputs and solenoid outputs are available too. Diagnostics monitor each voltage source and eachfeeder including the fuses in each solenoid circuit on the relay termination board.

Control Cabinet Power

Steady-State Voltage Frequency. Load Comments

120Vac (108 to 132Vac) 47 - 53Hz57 - 63Hz

6 A rms Harmonic distortion < 7%

240Vac (216 to 264Vac) 47 - 53Hz57 - 63 Hz

3 A rms Harmonic distortion < 7 %

125Vdc (100 to 145Vdc) 6 A dc Ripple <= 5%

Power source load estimate does not include the load of external solenoids.

OPERATOR and MAINTENANCE INTERFACE

The operator and maintenance interface for the control system can be provided in several arrangements.

Operator interface from the plant DCS

- Communication link between ISTC and the plant DCS

- Hardwired interface between the ISTC and the plant DCS

Operator and Maintenance interface from the ISTC human machine interface (HMI)

- Maintenance and Backup Operator Interface: Laptop or PC

- Level 1 HMI: Operator interface only: Flat Panel with touchscreen, no editors

- Level 2 HMI: Operator and / or Maintenance interface, full capability

A communication link can be provided from the turbine control to the plant - Distributed Control System(DCS). This link will enable the DCS to issue all operator commands, monitor any turbine parameters andmonitor any process or diagnostic alarm data. A hardwired interface between the ISTC and the DCS isavailable too. However, this can be I/O and wiring intensive depending on the complexity of the controlsystem and the degree of remote monitoring.


9

An RS232 link with Modbus™ protocol is available from the processor card in the Control Module. This isa Modbus slave device that can be run in either RTU (binary) or ASCII mode at 9,600 or 19,200 baud,none, even, or odd parity and 7 and 8 data bits.

The Level 2 HMI can provide either a RS232 - Modbus link, an Ethernet™ Modbus link, or an EthernetTCP-IP link directly from the HMI. Plants with PLC based controls can use this operator interface tointegrate communications to both the turbine-generator controls and the PLC controls via a wide variety ofnetworks.

The Level 1 operator interface is a NEMA 4 flat panel. It can be mounted on the turbine control cabinetdoor or as a rackmount insert. The flat panel communicates directly with the processor card in the ISTCcontrol module via a Genius bus with a 153.6k baud communication rate.

A 640x480 TFT, 10” color display, is provided with a resistive touchscreen. Pop-ups allow operators toadjust process setpoints while monitoring turbine and generator data on the primary display. Alarms,which are logged on the display, are available for logging on an optional printer.

Note: A software maintenance toolset is provided which contains an editor for the application software,logic forcing, analog forcing, access to the extensive ISTC diagnostics, adjustment capability for systemtuning constants, real time trending, etc. This software can be run on a PC with Windows® 95 andWindows NT 3.51 and 4.0. It is embedded in the level 2 HMI.

The Level 2 HMI is an operator and / or maintenance interface with software tools for editors. It isavailable as a PC or laptop. It includes CIMPLICITY graphics display system for Windows NT.CIMPLICITY offers true client / server capability and HMIs can be applied as stand-alone units ornetworked together. Host redundancy is available for servers to provide automatic switch over from theprimary server to the secondary server in the event of a computer failure.

Various languages are available for displays, alarm messages and user “help” windows. Convenient pop-up faceplates can be opened to adjust process variables or to initiate trends while continuing to monitor theprocess graphics. Trend charts can be embedded into displays, and there is no restriction on the number ofpen lines in the chart. Maintenance personnel can use familiar Windows type toolbars locatedconveniently around the screen of the drag and drop type graphics editor.


10

Figure 5. CIMPLICITY graphics display


11

Feature HMI Level 1 HMI Level 2Platform NEMA 4 - Door mounted

NEMA 4 - Insert

PC

Laptop

Graphics Text and bar charts CIMPLICITY drag and drop editor

Commands Full operator capability Full operator capability

Full maintenance capability

Alarm/Events Alarm management (1-sec resol.) Alarm management (frame rate)

Sequence of events (1 ms)

Oper. System DOS running under a scheduler Windows NT

Networks Genius® bus: ISTC to HMI

RS232 Modbus to DCS

(from ISTC Control Module)

Ethernet EGD to GE Fanuc PLCs

(from ISTC Control Module)

Ethernet EGD: ISTC to HMI

RS232 Modbus to DCS

Ethernet Modbus to DCS

Ethernet TCP-IP to DCS

Ethernet EGD to GE Fanuc PLCs

Arcnet to GE Mark V controls

Others available

Trending None Real time and short term

Printers Alarm (logging) printer Alarm (logging) printer

Laser (document) printer

Color printer

Maintenance Run applicable turbine tests

* See Note

Run applicable turbine tests

Full diagnostic access to ISTC

Adjust tuning constants

Logic and analog forcing

Edit application software

Edit displays

APPLICATION SOFTWARE

The ISTC is a fully programmable control system, which can be applied to any industrial steam turbine.Application software is created from in-house software automation tools, which select proven GE controland protection algorithms and integrate them with the I/O sequencing and displays for the each application.


12

Floating point data (IEEE-854) is typically run at a frame rate of 40ms. The frame rate is the elapsed timewhich it takes to read control inputs, condition the inputs, execute the application software, and sendoutput commands to the control valves. Changes to the application software can be made with passwordprotection and downloaded to the control module while the turbine is running. All application software isstored in the control module in non-volatile memory.

Figure 6. Maintenance software tools

Application software is executed sequentially and represented in a ladder diagram format. A library ofsoftware building blocks allows maintenance personnel to add or change analog loops, sequencing logic,etc. Math blocks are also available. Application software documentation is created directly from thesource code, and it can be printed at the site. This includes the primary elementary diagram, I/Oassignments, the settings of tuning constants, etc.

CODES and STANDARDS

• ISO 9001:1994 in accordance with Tick IT by Lloyd’s Register Quality Assurance Limited.

• ISO 9000-3:1997 Quality Management and Quality Assurance Standards.

• Part 3: Guidelines for the Application of ISO 9001:1994 to Development Supply and Maintenance ofSoftware.

Safety Standards- UL 508A Safety Standard Industrial Control Equipment

- CSA 22.2 No. 14 Industrial Control Equipment


13

Printed Wire Board Assemblies- UL 796 Printed Circuit Boards

- UL recognized PWB manufacturer, UL file number E110691

- ANSI IPC guidelines

- ANSI IPC/EIA guidelines

Electromagnetic Compatibility (EMC) Directive 89/336/EEC- EN 6100-4-2 Electrostatic Discharge Susceptibility

- ENV 50140:1993 Radiated RF Immunity

- EN 50082-2:1994 Generic Immunity Industrial Environment

- EN 6100-4-4 Electrical Fast Transient Susceptibility

- EN 6100-4-5 Surge Immunity

- EN 50141 Conducted RF Immunity

- EN 50081-2 Generic Emissions Standards

- EN 55011:1991 ISM Equipment Emissions (CISPR-11)

Low Voltage Directive 72/23/EEC- EN 50178 Safety of Electrical Equipment, Industrial Machines

- IEC 529 Intrusion Protection Codes / NEMA 1 / IP 20

Vibration- Seismic: UBC - Seismic Code Section 2312 Zone 4

- Shipping: 72 hours at 0.3G rms between frequencies of 4 to 16 Hz

3 shocks of 15G, 2 ms impulse each repeated for all three (3) axes

- Operating / Installed at Site: 1.0G horizontal, 0.5G Vertical at 15 to 120 Hz

For < 15 Hz see Seismic Standard

Enclosures- NEMA 1 (similar to IP-20) - Standard

- NEMA 12 (similar to IP-51) - Option

- NEMA 4 (similar to IP-67) - Option

- NEMA 4X (similar to IP-68) – Option


14

SERVICE and TRAINING

GE - Power Generation Services (PGS) is a worldwide organization of field service engineers who arededicated to the installation and maintenance of GE turbines and generators. Engineers are trained on themachinery and the associated controls as an integral system. Standard and custom training classes areavailable at the site and at the GE factory for operators and maintenance personnel on the ISTC and theturbine.

�*(�,QGXVWULDO�6\VWHPV

*HQHUDO�(OHFWULF�&RPSDQ\�� 5RDQRNH�%OYG�ZZZ�JH�FRP 6DOHP��9$��86$

Documents

Mark VI ST Control Product Overview GEH 6127