g GE Energy Oil & Gas Nuovo Pignone

CUSTOMER TRAINING

SPEEDTRONIC Mark VIe

Operation & Maintenance
Training

© Andras Gerebitz, 2012

Nuovo Pignone
Gas Turbine Control Fundamentals
 Gas turbines in general

• Typical usage is to drive a generator or a

compressor
So called electrical or mechanical drive

• Supplied by gas or liquid, or both

• Two types: heavy duty and aeroderivative
turbines
 Main components

• Starting means
Starts to rotate the shaft. Can be:
- electric motor
- diesel motor
- steam turbine
- hydraulic starter

• Clutch
Engages the shaft and the starting motor during the start-up
 Main components

• Axial compressor
Compresses the air from the inlet filter for the combustion

• Combustion chamber
Where the combustion takes place. The spark plug and the flame
detectors can be found here. The mixage of the gas and the
compressed air flows inside.

• Turbine shaft
The combustion moves the shaft which transmits the power to the
gearbox
 Main components

• Gearbox
Handles the transmission of the power from the shaft to the utilizer

• Utilizer
The utilizer can be:
Generator – to generate electric power
Compressor – to compress gas for transportation (for pipes or tanks)
Auxiliary systems
 Lube oil system

• Gives lubrification for the system

- gas turbine bearings
- driven equipments
- auxiliary coupling
- starting means

• Also supplies oil for:

- hydraulic oil system
- control oil system
 Lube oil system

• Auxiliary lube oil pump (88QA-1), driven by an

AC motor

• Emergency lube oil pump (88QE-1), driven by a

DC motor
 Auxiliary lube oil pump

• Auxiliary pump started automatically when the

turbine is started or by a manual command

• Operates until the end of the start-up

sequence, after that point a mechanical pump
is used

• During operation, if low pressure is detected,

the pump is restarted automatically

• In this case the operator must stop it manually,

there is no automatic stop function
 Auxiliary lube oil pump

• The pump is restarted again during shutdown,

when the turbine speed goes below the
minimum operative speed

• The pump is running during the shutdown

sequence and during the cool-down as well

• It’s stopped automatically at the end of the

cool-down sequence
 Emergency lube oil pump

• Emergency pump started automatically when

LL oil header pressure is detected (TRIP)

• Also started at the beginning of the cool-down

sequence for a 15 minutes of continuous
operation – only if the auxiliary pump is not
available (AC power missing)

• After that, during the cool-down the pump is

operated based on a 30 sec ON – 3 min OFF
cycles in order to save the DC battery
 Lube oil tank heaters

• Three electric heaters (23QT-1/2/3) installed

inside the lube oil tank

• The purpose is to provide a correct viscosity

of lube oil acting on its temperature

• Switch ON/OFF logic: based the oil

temperature, there are dedicated ON and OFF
setpoints

• Manual control available for operators

 Lube oil heaters

• Cutout conditions:
- lube oil tank level low
- while flame is detected
- overtemperature of the heater is detected
 Lube oil cooling system

• Removes heat from lubricating oil by adjusting

its temperature in a range needed by the gas
turbine and other equipments

• Employs a direct oil to air heat exchanger

• The temperature control accomplished by

varying the oil flow quantity through the cooler
by a 3 way temperature regulating valve

• The air flow is realized with 3x50% fans

actuated by electric motors (main, auxiliary
and stand-by)
 Lube oil cooling system

• Fans have vibration switches, if high vibration

is detected on one fan, the fan operation is
disabled

• All three fans have also manual control

available for the operators

• The operator can also choose the auxiliary fan

when all fans are stopped

• The main / stand-by selection is made

automatically
 Lube oil cooling system

• Main fan logic:

• Started automatically during turbine start-up,

when flame is detected

• Stops automatically when the turbine is

stopped, 180 mins after flameout.
 Lube oil cooling system

• Stand-by fan logic:

• Started and stopped automatically based on

lube oil header temperature setpoint values,
only when the main fan is required to run

• Fan start is inhibited for 120 secs from its

previous stop

• Fan stop is inhibited for 240 secs from its start

 Lube oil cooling system

• Auxiliary fan logic:

• Started automatically when lube oil high

temperature alarm is detected

• In this case the operator must stop it manually,

there is no automatic stop function
 Oil vapour separator

• Removes air, water vapour and any other

moisture accumulation from the lube oil

• The extractor fans (88QV-1/2) provide the

correct moisture flow (main and auxiliary,
selectable by operator)

• Beside automatic control both fans have also

manual control available for the operators
 Oil vapour separator

• Main fan starts automatically when turbine is

started

• Stops automatically at the end of the turbine

cooldown
 Oil vapour separator

• The main extractor fan will be started

automatically also when the unit is stopped or
there’s no flame detected, if the following
conditions are both present:

• - The lube oil heaters are activated and

• - The lube oil in the tank has reached the

normal operating temperature
 Oil vapour separator

• Stand-by fan started if lube oil tank high

pressure detected

• In this case the operator must stop it manually,

there is no automatic stop function
 Hydraulic oil pump

• One hydraulic oil pump (88HQ), driven by AC

motor

• Provides pressure to hydraulic actuated

devices

• Started during startup, after lube oil system

start, when the oil header pressure is normal
 Hydraulic oil pump

• Operates until the end of the gas turbine

start-up sequence

• After this point a mechanical pump

(main pump) takes care of the oil pressure

• During turbine shutdown the pump is restarted

again

• Will be stopped when loss of flame detected

 Hydraulic oil pump

• During operation, if low hydraulic oil pressure

is detected, the pump is restarted
automatically

• In this case the operator must stop it manually,

there is no automatic stop function, after
normal pressure condition is restored

• Manual commands are available for the

operator
 Turbine starter system

• There are two subsystems:

• Hydraulic ratchet

• Starting (cranking) motor

 Hydraulic ratchet system

• DC ratchet pump (88HR) used to provide the

oil pressure for the ratchet system

• The system is used at startup:

• When the turbine shaft rotation is started, the

ratchet provides the initial breakaway of the
shaft, helping the starting system
 Hydraulic ratchet system

• The system is used also after turbine

shutdown:

• During the cooldown period slow rotation of

turbine shaft is provided by the ratchet system

• While the turbine if stopped for long-term

periods, the hydraulic ratchet can be operated
manually by software pushbutton or field
pushbutton (manual jogging) for slow
rotations
 Starting motor

• One AC motor (88CR-1)

• Used only during the turbine startup

• Started together with the hydraulic ratchet to

initiate the rotation of the turbine shaft

• Automatically stopped when the clutch is

disengaged or when the turbine shaft speed
reaches 60%

• Hydraulic torque converter provided between

the motor and the turbine shaft
 Starting motor

• Torque converter allows the selection between

two specific torque values by means of
solenoid drain valve opening/closing

• From zero speed until cranking speed higher

torque is applied

• During purge/ignition/warmup periods lower

torque is applied

• For acceleration phase high torque is used

again
 Turbine Inlet Guide Vanes (IGV)

• The IGV regulates the quantity of airflow to the

axial compressor

• Actuated by servovalve, position feedback is

provided by LVDT position sensors

• Automatic modulation is provided during the

turbine startup in order to maintain proper
combustion air flow and pressure
 Turbine Inlet Guide Vanes (IGV)

• During the beginning of the startup the IGV is

at a low opening position

• It’s modulated during the acceleration and

loading phase based on axial compressor
suction/discharge and exhaust parameters

• After loading the unit the IGV will be moved to

a high opening position
 Turbine air bleed valves

• Two valves are used to prevent turbine axial

compressor stall (antisurge) when unit is
running below operating speed

• The 11th stage extraction air is released to

atmosphere through two extraction pneumatic
valves
 Turbine air bleed valves

• The air supply to these valves is controlled by

the solenoid valve 20CB-1

• When turbine speed is below minimum

operating speed (92.5%) the bleed valves are
open

• During normal operation (above 92.5%) the

valves are automatically closed
 Fuel gas system

• Fuel gas scrubber is provided for fuel gas

conditioning

• The scrubber liquid level is Mark VIe controlled

• Based on high/low level setpoints, the drain

valve of the scrubber is automatically
opened/closed
 Fuel gas system
• In the fuel gas system we have on/off
(solenoid) valves and regulated (servo) valves

• On/off valves are fuel block and vent valves

• They are used prior the ignition to gas purge

and warm-up purposes, following and
automatic valve sequence

• The servovalves are used to regulate the fuel

supply quantity to the machine

• LVDT sensors provide position feedback to the

control system
 Fuel gas system

• Stop/speed Ratio Valve (SRV) is used to

maintain constant gas pressure before the Gas
Control Valves

• Gas Control Valve (GCV) is used to regulate to

supplied fuel quantity to the turbine
 Control oil system

• All servovalves require hydraulic oil pressure

for operation

• Without oil pressure a servovalve is fully

closed

• Control oil system provides oil for the SRV,

GCV and the nozzle operation when the
solenoid drain valves (trip valves) are closed
(energized)
 Control oil system

• There are two trip oil drain (dump) valves:

20HD-1/2 (commanded always together)

• In case of turbine trip, both drain valves are

deenergized (= they will open), the control oil
will be drained, which results fully closing both
two gas servovalves
 Inlet Air Filter

• The Inlet Air Filter is used for air filtering to

guarantee the proper clean-air level for the Gas
Turbine (combustion) and the Enclosure
Ventilation System

• The filter filters out dust, sand and other

particles from the environmental air
 Inlet Air Filter
• The filter elements used are cleaned during
normal operation of the unit by means of
compressed air injection into a selected
number of elements in reverse flow direction
without interrupting the normal flow of air
through the system

• Compressed air is injected into the filter

elements from a pulse pipe through a solenoid
valve

• The cleaning procedure is controlled by a

dedicated local panel
 Turbine Enclosure Ventilation System

• Prevents overtemperature and accumulation of

hazardous gases

• Pressurizes the turbine compartment

• Two AC motor operated fans (88BA-1/2)

 Turbine Enclosure Ventilation System

• Main and Auxiliary selection by operator

• Changeover sequence permits changing fan

selection while the system is running

• Ventilation cutout if fire detected in any

compartment, CO2 discharged or gas detected
at inlet filter

• Both fans can be also manually controlled by

operator
 Turbine Enclosure Ventilation System

• Main fan logic:

• Starts automatically when turbine starting

sequence is initiated

• Stops automatically when the turbine is shut

down, 120 minutes after flame out detected
 Turbine Enclosure Ventilation System

• Automatic changeover is carried out (stopping

Main and starting Auxiliary fan) in the
following condition :

• - Enclosure differential pressure low-low alarm

detected
 Turbine Enclosure Ventilation System

• After 30 sec, if enclosure differential pressure

low-low alarm is still active, unit will be tripped

• Automatic changeover and unit trip can be

bypassed by manually activating the „Loss of
ventilation disabled” functionality

• Bypass remains active for a maximum of 8

hours
 Water-wash system

• To minimize gas turbine damage due to

compressor fouling

• Helps to maintain the turbine’s efficiency

• Removes possible accumulated deposits from

the turbine axial compressor

• Takes water and detergent from a tank

 Water-wash system

• Injects the water into the axial compressor inlet

through solenoid valves

• Only these valves are controlled by the Mark VIe

• The water-wash trolley must be connected

manually

• There is a dedicated local panel for water-wash

control
 Water-wash system

• Can be online and offline mode

• Online mode is done during operation, while

the turbine is running

• Offline mode done at cranking speed, while

turbine is driven by the starter system
 Water-wash system

• Can be started and stopped by the operator

(no automatic start)

• Both modes have permissive conditions which

are verified before starting the wash

• The required permissive conditions can be

checked on the graphic pages
 Water-wash system

• During online wash the turbine is running on

gas fuel

• Only clean water is used

• The water will be vaporized (high temps.) and

will leave through the exhaust section
 Water-wash system
• During offline wash the fuel supply is closed

• Mixture of water and detergent is used

• The water drained through manually open

drain valves, where the we can check if water
runs clear and clean

• If drained water is dirty, the cleaning cycle

(5-10 mins) shall be repeated after refilling the
storage tank

• The offline wash is more effective than the

online wash
 Process compressors antisurge system

• The CCC antisurge system monitors process

compressor suction/discharge parameters

• The output of the surge controller regulates

the antisurge valve to prevent compressor
surge

• The antisurge system will trip the gas turbine

when surge is detected and the antisurge
valves will be fully open
 Introduction to the
Speedtronic Mark VIe Control Panel
 Speedtronic Mark VIe Control Panel

PLC (Programmable Logic Controller) system

based, engineered and developed to control
the entire Gas Turbine Plant
 Speedtronic Mark VIe Control Panel

• Complete system based on the latest product

of the Speedtronic controller family
• Strong integration with Gas Turbine Control,
Safety Controllers, Fire Fighting Controllers,
DCS, HMIs
• Distributed from year 2009
• Ethernet based networking
• Distributed I/O
 Speedtronic Mark VIe Control Panel

Reasons of Mark VIe Development

• Need of dual redundancy beside simple the

triple systems
• Need of distributed (remote) I/O
• Need of increased computing power and I/O
network speed
• Need of support for additional I/O types and
communications methodes
The Unit Control Panels (UCP)
Advantages of Remote I/O
 Speedtronic Mark VIe Control Panel
Mark VIe provided in three different configurations:

• Triple Modular Redundant (TMR)

Employs three identical control processors (<R>, <S> and <T>) and
each performs identical operations for redundancy. Very stable and
reliable.
• Dual Redundant System
Employs two identical control processors (<R> and <S>). Process
runs if one controller fails.
• Simplex
Similar like TMR, but employs only a single control processor <R>,
without redundancy
 Speedtronic Mark VIe Control Panel
Special tasks of the MarkVIeS safety controller:

• Overspeed protection
• Combustion chambers flame detectors
monitoring
• Trip solenoid valves control
• Manual ESD trip pushbuttons monitoring
 Speedtronic Mark VIe Control Panel
Special tasks of the MarkVIeS safety controller:

• GT enclosure ΔP sensor monitoring

• Enclosure ventilation cut-out to MCC directly
• Receives HW cumulative trip signals from
Bently Nevada and Fire&Gas systems
• Receives external customer ESD signal
• Off skid fuel gas valves control
Speedtronic Mark VIe Control Panel

Flexible architecture
General overview of the control system
Gas Turbine and
Generator

field cables

Unit Control Panel (UCP)

Mark VIe + MarkVIeS

communication cable

HMI
 The Unit Control Panels (UCP)

• The controlling systems can be found here

• Connected to all the instrumentations with
field cabling
• Controlling the field instruments based on its
internal software, the signals received from the
field sensors and the operator commands
 The Operator Interface (HMI)

• Connected to the Mark VIe in the UCP

• Can be rack mounted or desktop installed
• Windows XP operating system
• The internal software of the Mark VIe can be
modified from the HMI
• The operator can monitor the most important
field processes on the HMI
• The operator can give commands to the
Mark VIe through the HMI (e.g. startup the
turbine, change the speed)
The UCP and the HMI
The UCP and the HMI
 The Unit Control Panels (UCP)

UCP main sections:

• TCP – turbine control panel + HMI

• MP – marshalling panel
• SIS – safety system control panel
• PDP – power distribution panel
• ACP – auxiliary control panel
The UCP / TCP and ACP sections doors
The UCP / TCP and SIS sections
The UCP / TCP and SIS section
The UCP / PDP section
The UCP / PDP section
The UCP / MP section
Barriers, surge arrestors
Terminal strips for field connections
Mark VIe Hardware description
 Mark VIe Hardware description

Main parts of the Mark VIe:

• Power distribution
• Internal network communication devices
• Main CPU processors
• I/O packs
• Terminal Boards
 Power distribution

The components are:

• JPDC power distribution board

• PPDA power diagnostic pack
• JPDH power distribution board
• JPDE power distribution board
• JPDD power distribution board
• JPDM power distribution board
• JPDB power distribution board
• JPDF power distribution board
 JPDC power distribution board

• 28 V dc main control power output board

• receives 110 V dc input power from
redundant external source
• powers triple reduntant external dc/dc
power converters and receives back 28 V dc
• distributes 28V dc power to the system
components
• seats the PPDA I/O pack for power
diagnostic purposes
• contains three independent 28 V dc power
buses
 PPDA power diagnostic pack

• installed on the JPDC board

• passes power feedback diagnostics to
the main CPUs through network
communication
• diagnostics include dc bus voltage,
power supply status contact feedback,
and auxiliary circuit status
• does not take direct protective actions. It
only reports information to the system
controllers where corrective action can
be programmed
PPDA power diagnostic pack
 JPDP power distribution board

• supplied by the JPDC board with 28V dc

• provides the power supply to certain
MkVIe terminal boards and I/O packs and
also for internal network ethernet
switches as well
• actually used only for servovalve board
supply
JPDP power distribution board
 JPDH power distribution board

• the High Density Power Distribution

board
• provides 28 V dc power to 24 Mark VIe
terminal boards, I/O packs and 3
Ethernet switches from a 28 V dc supply
• receives 28 V dc input power directly
from the JPDC board
 JPDH power distribution board

• additional JPDHs are connected in a

daisy-chain arrangement to provide
power to more I/O packs as required
• the circuit for each I/O pack connector is
protected with a positive temperature
coefficient fuse device
JPDH power distribution board
JPDH power distribution board
 JPDE power distribution board

• 24 V dc main power distribution board

• receives 24 V dc input power from
redundant, external ac/dc power supplies
• distributes power to all the JPDD the
distribution boards
• supports a diagnostic link to the main
JPDC board which seats the PPDA I/O
pack for power diagnostic purposes
JPDE power distribution board
JPDE power distribution board
 JPDD power distribution board

• 24 V dc power distribution board

• receives 24 V dc input power from the
JPDE board
• distributes power to digital input and
output terminal boards
• usage for digital inputs: excitation
voltage for line continuity check
• usage for digital outputs: solenoid power
supply for solenoid valves control
 JPDD power distribution board

• one JPDD board has 6 power channels

• each channel includes:
• fuses for circuit protection
• switch for power isolation
• a green LED to display presence of
power on the channel
JPDD power distribution board
JPDD power distribution board
 JPDM power distribution board

• 28 V dc main control power output board

• receives 28 V dc input power from
redundant, external dc/dc power
supplies and distributes power to the
control system
• seats the PPDA I/O pack for power
diagnostic purposes
• contains three independent 28 V dc
power buses
JPDM power distribution board
JPDM power distribution board
JPDM power distribution board
 JPDB power distribution board

• 240 V ac power distribution board

• receives 240 V ac input power from two
separate external sources
• distributes power to the JPDF board
• provides power diagnostics information
through the JPDM board
• includes power line filters for both input
lines
 JPDF power distribution board

• 110 V dc power distribution board

• receives redundant 240 V ac input power
directly from the JPDB board
• powers dual reduntant external ac/dc power
converters and receives back 110 V dc
• distributes 110 V dc power to the system
components
 Mark VIe networking

• Three different types of networks

• IONET used for communication between the
main CPUs and the Mark VIe I/O packs
• Unit Data Highway (UDH) for data exchange
between the MarkVIe, MarkVIeS, Bently Nevada
and the HMI
• Plant Data Highway (PDH) for data exchange
between the HMI and any other thirdparty
system (e.g. Fire Fighting controller)
• All the three networks are separate ethernet
networks
 IONET internal network

• Allows the communication between the main

controllers and the I/O packs (reading input
states and writing output states)
• 100 MBit/s Ethernet network
• RJ45 connectors used with twisted pair cable
• For longer distances (for distributed I/O) fiber
optic connection can be used if required
• EGD protocol is used for the communication
• Available in single, dual, and triple
configurations
IONET internal network color codes
 IONET internal network

• for interconnecting the IONET devices

N-TRON switches are used
• N-TRONs are Industrial Ethernet Switches
with increased performance and reliability
• model N-TRON 517FX switches are used
• they provide two types of physical
connections:
• twisted pair cables for devices inside the
same cabinet
• fiber optic connection for longer distance
interconnections (if required)
IONET internal network
IONET internal network
IONET internal network

Local / Distributed I/O

 Mark VIe main processors – the UCSA

• stand-alone computer that runs the

application code
• communicates with the I/O packs through
on-board I/O network interfaces
• the operating system is QNX Neutrino, a
real time, multitasking OS for high reliability
industrial applications
 Mark VIe main processors – the UCSA

• 256 MB DDR SDRAM memory

• CPU speed is 667 MHz
• there are three UCSA processors installed in
TMR configuration
• logic execution time is 40 ms
 Mark VIe main processors – the UCSA

• 3 ethernet ports for internal IONET

communication (R/S/T)
• 2 ethernet ports for external communication
with HMI (UDH, Unit Data Highway)
• one RS-232 serial port (COM) for
configuration
• removable Compact Flash card used for
storing configuration, network settings and
the logic sequence
• the Compact Flash card is reprogrammable
using the HMI
Mark VIe main processors – the UCSA
Mark VIe main processors – the UCSA
Mark VIe main processors – the UCSA
Mark VIeS CPCI controller rack
Mark VIeS CPCI controller rack
 Mark VIeS CPCI controller rack

• CompactPCI (CPCI) enclosure with PCI form

factor
• for a TMR system 3 CPCI racks are
provided for the R/S/T processors
• hosts the MarkVIeS main processor cards
• one main processor card and 3 additional
extension cards can be seated
 Mark VIeS CPCI controller rack

• built-in power supplies provides ±12 V dc,

5 V dc and 3.3 V dc voltages using the
28 V dc inlet supply
• switch above the power supply provides
individual power isolation for each controller
or optionally a second, redundant power
supply can be installed
• green LED shows the energized status
• built-in cooling fan provided
Mark VIeS CPCI controller rack
 Mark VIeS main processor – UCCC

• stand-alone computer that runs the

application code
• communicates with the I/O packs through
on-board I/O network interfaces
• the operating system is QNX Neutrino, a
real time, multitasking OS for high reliability
industrial applications
• Intel Pentium M CPU, at 1.6 GHz speed
• 256 MB DDR SDRAM memory
• logic sequence frame period: 40 ms
 Mark VIeS main processor – UCCC

• 3 ethernet ports for internal IONET

communication (R/S/T)
• 2 ethernet ports for external communication
with HMI (UDH, Unit Data Highway)
• one RS-232 serial port (COM) for
configuration
• removable Compact Flash card used for
storing configuration, network settings and
the logic sequence
• the Compact Flash card is reprogrammable
using the HMI
Mark VIeS main processor –UCCC
Mark VIeS main processor –UCCC
 Mark VIe I/O packs

• processing the input signals from the terminal

boards
• operating temperatures range is
- 30 °C to +65 °C
• directly installed on the terminal boards
• connected to the IONET network by two 100
MB/s ethernet ports
• infrared transceiver for low level diagnostics
• hot swappable in case of pack failure
 Mark VIe I/O packs

• provide the detected input/output values for

the CPUs through the internal IONET network
• for a specific signals type a specific type of I/O
pack is reqired
• front LEDs are showing the card status
• diagnostic information available through HMI
Mark VIe I/O packs
 Mark VIe I/O packs

• Front status LEDs are showing the diagnostic

status of the pack:
 Mark VIe I/O packs

• A green LED labeled PWR shows the presence

of control power
• A red LED labeled ATTN shows pack status.
This LED indicates four different conditions as
follows:
- LED out, there are no detectable problems with the pack
- LED solid on, a critical fault is present that prevents the
pack from operating
- LED flashing quickly (¼ second cycle), an alarm condition
is present in the pack
- LED flashing slowly (¾ second cycle), the pack is not
online yet
 Mark VIe I/O packs

• A green LINK LED is provided for each

ethernet port to indicate that a valid ethernet
connection is present
• A yellow TxRx LED is provided for each
ethernet port to indicate when the pack is
transmitting or receiving data over the port
Mark VIe I/O packs
Mark VIe I/O packs IONET connections
 Mark VIe terminal boards

• field input/output signals (coming through the

Marshalling Panel) are connected to the
terminal boards
• for a specific signals type and I/O pack type a
specific type of terminal board is required
• S type terminal board (simplex): only one I/O
pack is mounted
• T type terminal board (triple): three I/O packs
are mounted, used for critical signals
• screw connections provide the hardware
inputs/outputs
Terminal boards screw connections
S type terminal board
T type terminal board
Mark VIe I/O packs and terminal boards
 Mark VIe I/O packs and terminal boards:

• PTUR I/O pack – Primary turbine protection:

TRPG: flame detectors and redundant
controlled TRIP digital output (not used on
this MarkVIe)
TTUR: turbine regular speed detection
• The TTUR board seats the PTUR I/O packs
and provides connection to the TRPG board
Mark VIe I/O packs and terminal boards:
 Mark VIe I/O packs and terminal boards:

• PCAA I/O pack – Core Analog Module:

TCAS: core analog input/output signals
- thermocouple temperature inputs
- servovalve command output
- 4..20mA analog inputs
- 4..20mA analog outputs
TCAT: core analog input/output signals
- servovalve position feedback (LVDT) input
- 4..20mA analog inputs
- 4..20mA analog outputs
Mark VIe I/O packs and terminal boards:
 Mark VIe I/O packs and terminal boards:

• PDIO I/O pack – Discrete input / output:

TDBT: digital input/output signals
WROB: optional card for solenoid outputs

• Solenoid outputs require hardware jumper

configuration.
 Mark VIe I/O packs and terminal boards:

Digital input signals:

• Powered by 24 Vdc voltage to detect circuit

continuity (excitation or wetting voltage)
• Inversion mask can be applied to each
contact inputs on the I/O pack, to normalize
the data value and simplify the understanding
of the control logic
 Mark VIe I/O packs and terminal boards:

Digital output signals:

• Dedicated magnetic relay for each output

• Can be NO or NC depending on the terminals
used
• For solenoid signals 24 Vdc or 110 Vdc
voltage is switched according to the output
logic status
• For solenoid usage jumper must be inserted
to each output channel
Mark VIe I/O packs and terminal boards:
Mark VIe I/O packs and terminal boards:
 Mark VIe I/O packs and terminal boards:

• PAIC I/O pack – Analog Input/Output Module:

TBAI or STAI: analog input/output signals
- 4..20mA / ±5/10V dc analog inputs
- 4..20mA analog outputs

• Analog inputs require hardware jumper

configuration.
Mark VIe I/O packs and terminal boards:
Mark VIe I/O packs and terminal boards:

Analog inputs can

monitor 4..20 mA loops,
which can be configured
as self-powered or can
be powered from the
Mark VIe.
 Mark VIe I/O packs and terminal boards:

JA: Selected
inputs can be
configured as
4..20 mA input
or as ±5, 10 V
dc input.

JB: Selected
internal/external powered
transmitter wiring
Mark VIeS I/O packs and terminal boards
 Mark VIeS I/O packs and terminal boards:

• YTUR I/O pack – Primary turbine protection:

TRPG: flame detectors and redundant
controlled TRIP digital outputs
TTUR: turbine regular speed detection for the
safety logic sequence
• The TTUR board seats the YTUR I/O packs
and provides connection to the TRPG board
 Mark VIeS I/O packs and terminal boards:

• YPRO I/O pack – Emergency protection:

SPRO: turbine speed pickup sensors input for
overspeed detection
TREG: manual TRIP pushbutton inputs and
redundant controlled TRIP digital output
• The SPRO board seats the YPRO I/O pack
and provides connection to the TREG board
Mark VIeS I/O packs and terminal boards:
 Mark VIeS I/O packs and terminal boards:

• YAIC I/O pack – Analog Input/Output Module:

TBAI or STAI: analog input/output signals
- 4..20mA / ±5/10V dc analog inputs
- 4..20mA analog outputs

• Same configuration as the PAIC pack

 Mark VIeS I/O packs and terminal boards:

• YDIA I/O pack – Discrete input:

TBCI: digital input signals
 Mark VIeS I/O packs and terminal boards:

Digital input signals:

• Powered by 24 Vdc voltage to detect circuit

continuity (excitation or wetting voltage)
• Inversion mask can be applied to each
contact inputs on the I/O pack, to normalize
the data value and simplify the understanding
of the control logic
 Mark VIeS I/O packs and terminal boards:

• YDOA I/O pack – Discrete output:

TRLY: digital output signals
 Mark VIeS I/O packs and terminal boards:

Digital output signals:

• Dedicated magnetic relay for each output

• Can be NO or NC depending on the terminals
used
• For solenoid signals 24Vdc or 110 Vdc
voltage is switched according to the output
logic status
• For solenoid usage jumper must be inserted
to each output channel
TMR voting system
Triple redundant input connection
Triple redundant output connection
Logical input voting examples
Analog (median) input voting examples
Logic output voting
Panel documentation
 Piping and Instrument Diagram (P&ID)

• Displays all the intruments and sensors

present on the field and the connection
between them and the Mark VIe control system

• One page of the P&ID describes one coherent

part of the instrumentation (e.g. Lube oil
system)

• Usually each P&ID page have a graphic page

ordered to it in the HMI

• This allows the operator to understand and

monitor/control all the instrumentation
 The Instrument List

Lists all the input and output signals of the UCP

including:
• Signal name
• Customer tag
• Signal description
• Transmitter type
• Calibration range
• Analog setpoints
 The Functional description

Describes the Mark VIe internal software

explaining each procedure of the control
processes, for example:
• Startup process
• Shutdown process
• Water-wash process
• Different motors, heaters, valves sequences
 The Control system schematic

Describes the interconnection between the

standalone devices:
• Unit Control Panel
• Operator Interface (HMI)
• CMS
• Fire&Gas controller
• Vibration monitor
 Signal identification

• All a panel documentations are using standard

naming for the signals.
• For example we can find a device name 88HQ:

Motor 88 HQ
Hydraulic Oil
 Signal identification
According the standard naming, the number in the
signal name shows the device type:
-88 motor -28 flame trasmitter
-52 feedback motor is running -39 vibration
-4 command start/stop motor -77 speed
-33 limit switch -45 Fire and gas trasmitter
-20 command for electrovalve -90 cmd to servovalve
-96 general trasmitter -65 LVDT
-26 temperature signal -49 overload
-63 pressure signal -27 undervoltage
-71 level signal -86 fault
-60 flow transmitter -3 permissive
 Signal identification
According the standard naming, the letters in the
signal name shows the signal type:
-E emergency -F fuel
-G gas
-R ratchet
-Q oil
Mark VI software tagname prefixes:
-H hydraulic
-L Logic (digital signal 0-1)
-A auxiliary
-A Analog signal
Examples:
-L52QA Æ lube oil auxiliary pump running
-A63HQ Æ hydraulic oil pressure
-L33HR Æ hydraulic ratchet limit switch
Software description
 Human Machine Interface (HMI)

• main interface for the MarkVIe

• monitoring the unit
• customizing Mark VIe (I/O, sequence)
• not critical, doesn’t do sequencing
 Human Machine Interface (HMI)

• Intel Pentium processor

• Windows XP operating system
• monitor
• keyboard, pointing device (mouse or trackball)
• alarm printer
• Ethernet interface cards
 Software structure

• Main software package: GE ControlST

• ST = System Technology
 Software structure

• WorkstationST
configuration and communication management for:
- EGD (signal exchange with MarkVIe)
- OPC (signal exchange with Cimplicity)
- Alarms management
• ToolboxST
Mark VIe development interface, allows I/O
assignment and logic sequence development
• Cimplicity
visualization software, displays the animated
graphic pages, and handles instructions from the
operator
 Directory structure

• E:\MASTER
configuration files for the Mark VIe/MarkVIeS
(sequences, I/O configuration)
• E:\SITE\CIMPROJ
Cimplicity project files (graphic pages, project
specific configuration)
 Software structure

• Importance of software backups (E:\SITE and

E:\MASTER) after modifications
• Must have individual licence for each computer
 WorkstationST

Always running
hidden in the
background, taking
care of the
communication
managenent.
 ToolboxST

• ToolboxST is used to configure and

troubleshoot the MarkVIe controller
• ToolboxST deals with all MarkVIe components
for a site as one application
• Provides diagnostic information about the
system
ToolboxST – System Editor
ToolboxST – Component Editor
Servovalve calibration
LVDT- Linear variable differential transformer
LVDT- Linear variable differential transformer
 Calibration procedure

• Unit must be stopped

and lube/hydraulic oil
systems started
• Open the component
editor for the MarkVIe
device which is
required to perform the
Servo LVDT calibration.
• In the component editor
select the Hardware Tab
 Calibration procedure

• Select the appropriate

PCAA I/O pack from the
tree view area.
• Select the Regulators
tab in the summary
view area
 Calibration procedure

• In the summary view select the appropriate

regulator from the drop down dialog box
• The Enable check box should be selected for
this regulator to be enabled
• Select the Calibrate Valve button
 Calibration procedure

• Select the Calibration

Mode button
• A trender window will
open automatically and
plot the servo current
and valve position
 Calibration procedure

• Select the minimum end

button
• Observe the change in
current (blue) and
change in valve
position (red).
Physically verify that
the valve is closed
 Calibration procedure

• Select the Fix Minimum

End button. This
records the LVDT
voltages is the full
closed position
• Select the maximum
End button
 Calibration procedure

• Observe the change in

current (blue) and
change in valve
position (red).
Physically verify that
the valve is open
• Select the Fix Maximum
End Button. This
records the LVDT
voltages at the full open
position
 Calibration procedure
• Select the calibrate button. This
calculates the equation for each
LVDT
• Select the save button then
select Yes. This updates the
calibration from the PCAA
I/O pack into ToolboxST
 Calibration procedure

• In the calibration window

select off
• Select Manual
• Enter 0 into the setpoint field
• Select send
• Repeat for 25, 50 75 and 100
• Verify that the commanded
position is close to being
equal to the feedback
position
 Current and Position Verification

• Select the current button in the calibration

window

• This should sweep the current to open and

then close the valve. Ensure that the position
moves smoothly (no flat spots)

• Select the position button in the calibration

window

• This should sweep the demanded position

from 0 to 100 and back to 0. Ensure that the
position moves smoothly (no flat spots)
 Closing the calibration window

• In the calibration window

select the off button
• A close regulator dialog
window will appear. If it is
desired to save the trender
file from the calibration
session select yes
• In the component editor
select the save button
Control software philosophy
 Control software philosophy

• Gas turbine control

For example if the exhaust temperature exceeds the allowed limit, the
fuel supplied to the turbine will be reduced

• The operating conditions are changing based

on the sensor detected values
• The control is realized by the use of different
control loops
Control software philosophy
 Control software philosophy

• Major control loops:

startup, speed, temperature

• Secondary control loops:

acceleration, manual, shutdown

• Fuel Stroke Reference (FSR) is the output

command signal to the fuel flow
 Control software philosophy

• Minimum selector receives the output of the

control loops

• The lowest FSR value will be always active and

controlling the fuel flow

• Correct speed detection is very important

 Startup control loop

Speed relays detect the current speed of the

shaft:

• L14HR – Zero speed(below 0.3% of max.speed)

- turbine shaft started to rotate

• L14HM – Minimum firing speed (above 20%)

- turbine reached minimum firing speed

• L14HA – Accelerating speed (above 41%)

- acceleration phase, turbine startup is in progress

• L14HS – Min. operation speed (above 92.5%)

- the turbine has reached the operational speed
 Startup control loop

The startup control loop operates using different

preset levels of FSR stored as Mark VIe
constants:
• ZERO FSR
• FIRE FSR
• WARM-UP FSR
• ACCELERATE FSR
• MAX FSR
 Startup control loop

• During the startup process the different FSR

values are applied by the startup control loop
to the fuel flow, based on the current speed of
the shaft.
 Speed control loop

• The LP shaft speed is detected by 3 magnetic

pickup sensors
• The current speed - TNL is calculated from the
sensors’ signals
• The reference speed – TNR is the desired
speed
 Speed control loop

• Proportional regulator calculates FSR based

on the TNL and the TNR
• TNL typically changes between 70-105% of
speed
• Under manual control the operator may
change the TNR within the range above
 Acceleration control loop

• The acceleration control loop monitors the

increasing rate of the turbine speed
• If during the startup process a predefined
acceleration limit is reached, the acceleration
control loop takes over the FSR control from
the startup control loop to limit the
acceleration and protect the machine
 Temperature control loop

• Maintains allowed operating temperatures by

limiting fuel flow to the turbine
• Uses 13 exhaust thermocouples as input
temperature values
• A regulator is used to calculate the FSR based
on the current values and predefined values.
 Temperature control loop

• If the calculated FSR is lower than the current

FSR, the temperature control loop will take
over the FSR control according the minimum
selector
Protection systems
 Protection systems

• If the control system is not able to protect the

machine in dangerous cases, the protection
system helps to prevent damages

• When a predefined limit is reached, alarm is

generated to notify the operator about the
malfunction

• In serious cases the turbine is tripped

 Overtemperature protection

• In normal operating conditions the

temperature control loop regulates the fuel
flow in the case of overtemperature

• If this control loop fails, the temperature can

dangerously exceed the allowed limits
 Overtemperature protection

• The overtemperature protection system

compares the exhaust temperatures with
dynamically calculated alarm and trip
setpoints

• If the temperature is too high, alarm is

generated or the machine is tripped
 Overspeed protection

• Protects turbine against damage caused by

overspeeding

• Useful if the speed control loop can not avoid

overspeeding

• If TNH or TNL becames higher than the

overspeed setpoint, the turbine is tripped
 Vibration protection

• Vibration sensors are used to prevent

dangerous vibration levels

• Detectors are located on different parts of the

machine (bearings, housing)

• Alarm or trip is generated in the case of

dangerous vibration level is detected

• Vibration detectors are usually installed in

pairs to avoid trip by single detector failure
 Flame detection protection

• Flame detectors installed in the combustion

chambers

• Their input is used for logic sequencing (start-

up process) and for protection as well

• Flame loss detection during turbine operation

generates an emergency shutdown (TRIP)

• Turbine will keep running if at least 2oo4

detectors detect flame
Mark VIe Troubleshooting
 UDH network communication problems:

• Check if the ethernet switch is powered on and

working

• Check the flashing Tx/Rx LEDs close to the

ethernet connectors on the CPU card, on the
switch and on the HMI network card

• Use the “ping controller-IP” command to all

the four controllers to verify link presence
 UDH network communication problems:

• Check the ethernet cables and the connections

for failure

• For just replaced CPU cards make sure that

the Compact Flash card has been inserted and
reprogrammed if required
 Line voltage problems:

• Check that the MkVIe main power supply

voltage is correct (should be 28Vdc)

• Make sure that on the supply line there are no

disturbances, noise, spikes

• Verify the power LED’s on status on the

controllers and on the I/O packs

• Verify the diagnostic alarms on the PPDA

power monitoring pack
 Mark VIe I/O packs problems

• Check I/O packs front ATTN red LED status, if

it’s on or flashing, check the Diagnostics tab
in the ToolboxST for more details on the
problem
 Mark VIe internal IONET problems

• Check if the N-TRON IONET switch is powered

on and working

• Check the flashing Tx/Rx LEDs close to the

ethernet connectors on the CPU cards, on the
N-TRON switch and on the I/O packs

• Make sure all the black, red and blue IONET

network cables are properly connected, there
is no cable damage
 Unable to obtain ‘Ready to Start’

• Check if the Mark VIe is in the proper operate

mode for startup (for example Auto)

• Verify the permissive check graphic pages in

the Cimplicity for failure of required permissive
signals

• Use the ToolboxST logic sequence display to

investigate the reason of the failure
 Other erratic failures

• Tighten all network and power connection

cables on the Mark VIe controllers / I/O packs

• Reboot the Mark VIe and the HMI

• Re-build and re-download the software than

reboot the Mark VIe and also the HMI

• Contact GE for support

 g GE Energy Oil & Gas Nuovo Pignone
CUSTOMER TRAINING

The end

© Andras Gerebitz, 2012

Nuovo Pignone