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Control Systems

Turbine Control System Upgrade


Speedtronic Mark* VIe







Increased production
Higher efficiency
Compliance with environmental regulations
Availability and Reliability
Life extension

Customer benefits include:


Reliability & Availability
Having two independent protection systems decreases
the possibility of damage occurring to the turbine or
generator due to overspeed conditions
Direct sensor connections with no intermediate
instrumentation reduce single point failures
Triple Modular Redundancy (TMR) offers the highest
operating availability. All critical hardware and software
are triple redundant to eliminate single-point failures
Dual systems to support all small gas turbine
applications are available as an option for higher
availability compared to the SIMPLEX architecture
I/O module replacement time minimized: hot
replacement, one-line repair and auto-configuration
fully supported
Controller rated 0 to 65C (fan not required) and I/O
modules rated at 30 to 65C with on-board
temperature sensor to increase reliability even in
extreme environments
Redundant network ports on each I/O module provide
improved communication reliability

* Trademark of General Electric Company

Flexible Architecture & Performance


Expandable, modular design of control and I/O modules simplifies custom
site configuration
Based on QNX real-time multi-tasking operating system
100% networked I/O allows remote I/O solutions and requires less field
wiring, reducing maintenance and improving I/O signal quality
Flexible, modular selection of power sources: electronics and field power
segregation increases reliability
Capable of future enhancements: each component can be upgraded
independently without loss of compatibility
SIL capable design: Mark* VIeS TMR SIL rated I/O pack certified by TUV
for applications up to SIL3 in accordance with IEC 61508
Retrofittable - control system upgrade occupies same footprint as prior
generation controls (Mark series).
Upgradeable control processor and I/O extends product life
10 ms scan time supported in all configurations (Simplex, Dual, TMR)
Improved alarm and trip log capabilities
High speed trending capability with data import/export support
Industry standard historian (GE PROFICY & OSIsoft and PI)
Remote Monitoring & Diagnostics (RM&D) connectivity enabled
Field I/O industry standard protocols: Profibus DP, CANopen, and HART
Improved DCS communication capabilities:
Industry standards: Modbus TCP/IP, Modbus RTU, OPC DA and AE
Proprietary protocols: EGD and GSM
User-friendly design includes:
Windows-based common Human Machine Interfaces (HMI)
Control screens (CIMPLICITY)
Maintenance tools (ToolboxST)
Password protected access to operator/maintenance tools
Dual language operator screens fully supported
Metric/imperial measurement systems fully supported

TMR SIL rated I/O pack & terminal board

What it is
The Speedtronic Mark* VIe represents
the state-of-the-art in technology of
the GE Turbine Control product line.
The control panel is the brain of the
turbocompressor/turbogenerator train.
It is a key component of turbomachinery
units, imparting superior availability,
reliability, maintainability, safety, and
compliance with environmental
regulations.

When considering potential


improvements to industrial plants, the
Control Panel should be included in the
assessment, and if the control panel
can help to improve plant performance,
it should be included as part of the
overall plant upgrade plan. In those
cases where a control panel upgrade is
indicated, we recommend the state-ofthe-art Speedtronic Mark* VIe.

Proficy is a registered trademark of GE Intelligent Platforms.


OSIsoft and PI Server are registered trademarks of OSIsoft, Inc.
PROFIBUS is a registered trademark of PROFIBUS International.
CANopen is a registered trademark of CAN in Automation (CiA).
HART is a registered trademark of HART Communication Foundation.
Modbus is a registered trademark of Schneider Automation.
OPC is a registered trademark of The OPC Foundation.
CIMPLICITY is a registered trademark of of GE Intelligent Platforms.
ToolboxST ia s registered trademark of General Electric Company.
QNX is a registered trademark of QNX Software Systems, Ltd. (QSSL).

SIMPLEX I/O pack & terminal board

How it works
The control system is composed of
one, two, or three controllers that
each consist of simply a main
processor board, power supply and
networked I/O interface.
A triple redundant backup protection
system is included for all turbine
controls regardless of the redundancy
of the primary controllers. This
includes backup overspeed
protection, backup synch check
protection, manual trip, cross-tripping
between the backup and primary
controllers, all backup diagnostics
available on the network, and
watchdogs that monitor the health of
the controllers. Many of these
features are not available in standalone overspeed trip systems since
there is no high speed, redundant
communication between the backup
and primary systems.
The backup protection is completely
independent of the controllers, and
has its own processor and I/O, plus
capability for on-line repair. Separate
sets of relays are used for contact
voting of the outputs from the
primary and backup protection
system for the hydraulic trip relays.
In addition, the status of each relay
and the solenoid voltage are
monitored and assessed/diagnosed.

Human- Machine Interface (HMI)

System Architecture
The Mark* VIe has a very flexible
architecture, consisting of:
1-3 main processors with power
supplies,
1-3 network switches, and
1-3 sets of I/O Packs mounted
on terminal boards.
These components can be mixed and
matched in virtually any combination.
Dual redundant systems are designed
to continue to run if one main
processor, power supply, or switch
fails. Triple redundant systems run on
the voted value of logical data and
the median value of analog data.
Therefore, they override a failed
component in any mode, and
diagnostics identify differences
between the three sections.
Redundant control systems support
on-line repair of failed devices with
hot-swap capability. This feature
improves the mean-time-to-repair
(MTTR) and the system availability.
The flexible I/O can be situated
locally, remotely, or a combination of
the two. Remote applications are
supported with cat. 5 or fiber and
have the advantage of digitizing the
signal at the sensor to reduce system

System Architecture

noise, eliminating ground faults,


reducing susceptibility to lightning,
and reducing installation and longterm maintenance costs. The I/O
can also be placed in adjacent
cabinets to seamlessly integrate
the I/O from peripheral generator,
compressor, or BOP equipment.
The I/O Packs contain the active
electronics and are mounted on the
terminal boards that contain the
barrier or box type terminal blocks
and the passive R-C noise filters.
Each I/O Pack contains an I/O
processor board that is common to
all Packs and an application-specific
data acquisition board. A key
differentiator is the accuracy of the
I/O over its entire operating range
from -30 to +65C, which is critical
in remote I/O applications where
the system is typically running at
elevated temperatures. The Packs
also dissipate little heat (approximately
6W) so they are very conducive to
remote applications.
Each Pack has two Ethernet ports
for the IONet and can be replaced
on-line (assuming control redundancy).
They may be hot-swapped by simply
unplugging the 28Vdc connector and
inserting a new Pack.

How
Whatititworks
is
Reduced Operating Costs
Comprehensive diagnostics reduce
system repair time through rapid
troubleshooting
On-line repair for TMR/DUAL
controllers minimizes the number of
forced outages
Direct sensor interfaces reduce
spare parts requirements
Common operator interfaces and
tools improve operator efficiency
and reduce training needs
Remote access to the control
system via OSM RM&D reduces
troubleshooting time and cost
Barrier-type terminal boards are
designed for easy access and
maintenance
Integrated Turbine & Compressor
Controls (ITCC)
The Mark* VIe provides an integrated
solution for turbine and compressor
controls that delivers the following
benefits:
Common spares for both turbine
and compressor control systems
reduces overall spare inventory
requirements
Common software and diagnostic
tools for maintenance of turbine
and compressor controls
Common tools also reduce startup
time and cost
A common HMI delivers better
data quality and correlations for
debugging and diagnostics
Compressor Graphic pages on the
unit HMI facilitate understanding and
management of the unit operation

Upgrade
GE Oil & Gas has developed a specific
plug & play solutions to replace
the Mark II, Mark IV and Mark V with
the new Mark* VIe maintaining the
same foot print and field devices, using
the same terminal block arrangements
and multi-cables and automatic
porting software for Mark V.

Testing
Advanced dry rig dynamic simulation
testing is performed to reduce
installation time, achieving a significant
reduction of 50% in installation and
start up time, and allowing upgrades
to occur without extending planned
maintenance downtime.

Toolbox example ... Configuring controllers

Advanced Simulation Test Bed: hydraulic skid


for hardware in the loop testing

Toolbox example ... Configuring logics

Advanced Simulation Test Bed: UV & vibration


simulation

Training time and costs, both initial


and ongoing, are reduced with a
single control system used for both
turbine and compressor controls.
Integrated Turbocompressor control

g
GE Oil & Gas

via Felice Matteucci, 2


50127 Florence - Italy
T +39 055 4272500
F +39 055 4232800
Nuovo Pignone S.p.A.

GE imagination at work
Advanced Simulation test bed: DryRig simulator

E customer.service.center@ge.com
www.ge.com/oilandgas

COMK/MARK 839/II - Designed by: Studio Tre Fasi


Printed by: Sagraf - 01-2010
2010 Nuovo Pignone S.p.A. All Rights Reserved

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