DCS & Safety Solutions

GEs Automation
Imagination at work
Technologies
General Concepts
Imagination at work
Imagination at work
High-end
DCS Solution Overview
Mark VIe Control Platform
Performance, operability,
and reliability for todays
connected plant
Connected100% Ethernet
at all levels
FlexibleDistribute or centralize I/O
Scalabledesigned for multiple
applications
ReliableConfigure for simplex, dual, or
triple redundant operation
High PerformanceLocal process on
each module, computing power grows
as system expands
Robustcontroller rated 0 to 65C with
no fans; I/O modules rated
-30 to 65C
SecureAchilles Level 1 certification
6
Ethernet Backbone Flexibility

1 Controller
Easy, automatic redundancy
1 Operating Temp. 30 to 65C (-22 to 149 F)
Hazardous location, Class I Division 2
Achilles Level 1 certified

2 I/O Network Switch

2 Operating Temp 30 to 65C (-22 to 149 F)
8 or 16 network ports, fiber or copper
Deterministic 100 MB communications
suitable for local or remote I/O
3
Full duplex, point to point protocol

3 I/O Packs
Easy, automatic redundancy Operating Temp
30 to 65C (-22 to 149 F)
Hazardous location, Class I Division 2

If a fault occurs, controllers and I/O modules can be replaced online to maximize system
7
availability. Network diagnostics are reported in the alarm management system.
I/O flexibility
Network address is managed
through a chip on the terminal
board
Assignment of hardware is
quick and easy

Primary and Safety control can

UDH UDH
UDH UDH

co-exist on one network while

UCSB UCSB UCSB UCSB UCSB UCSB
T
IONet

Controllers

remaining independent.
R S T R S T
S
IONet

R
IONet
I/O Networks

Additionally, Primary can listen

to Safety inputs without
interference. I/O Modules
Terminal Board Terminal Board Terminal Board

Terminal Board
Terminal Board

Safety IO Excess Capacity for

BPCS use

8
Mark VIe Architecture
Plant Data Highway (TCP/IP, OPC, GSM, Modbus, PI Server, DNP 3.0) Ethernet
Operator & System 1 Historian-
Maintenance Condition OSI PI,
Stations Monitoring Cimplicity
Unit Data Highway (EGD, NTP) Ethernet

Controller(s) Controller(s)

IONet IONet

Turbine Process Fieldbus

I/O Fieldbus I/O
I/O I/O Profibus, HART,
CanOpen, FF

IONet:
1,2,or 3 networks
IEEE1588 PTP
Remote Full duplex 100MB Remote
I/O I/O
Primary Control Balance of Plant Control
 Mark Vie Architecture Guidelines
Plant Data Highway
General plant information Standard IEEE rules

Plant Data Highway Unit Data Highway

Maintenance, GE protocol devices supporting EGD
Operator, Number of devices / UDH are a function of Produced
and Gateway EGD exchanges / sec by each device
Unit Data Highway Stations 50 controllers assuming 1000 I/O pts each
provides 50,000 I/O points per UDH
Multiple UDHs are connected via Routers
Controller(s) HMIs are consumers of information, thus no physical
limit of HMI / UDH.
I/O Net
IO Net
Limited by Ethernet Octet rules
Controller limit of 199 I/O Packs
Process Process Average of 16 pts / Pack = 3184 I/O per controller max
I/O I/O
Controller loading
Function of I/O mix, scan rate, code complexity,
communications, EGD messages
Ex. 1000 I/O point, 180 PID feedback loops with alarm
monitoring, running @ 40 msec = 80% idle time

10 /
January 2014
US EAR: EAR99; NLR
Software configuration Layout

CONTROL ST Software Suite

ToolboxST
Network
System Configurator ST
Application programmer Alarm
Device Viewer
Trender
Manager
ST

WorkstationST
SCADA

11 /
January 2014
US EAR: EAR99; NLR
Integrated Safety/DCS/and Workstation Configuration
Environment

12 /
January 2014
1
US EAR: EAR99; NLR
2
Makes reusing even complicated logic easy and error-
free

13 /
13
January 2014
US EAR: EAR99; NLR
Improving operator awareness
Alarm management and visualization
Existing operator screens
Typical day
207FA daily operation (Example)

460
Load
(MW)

0
12:00 AM 12:00 AM

1600 1530
1190
No. of
Alarms
175
35
0
12:00 AM 12:00 AM

Alarm statistics
Daily avg. ~3,00
0
Daily peak ~1,50
0 14 /
January 2014
US EAR: EAR99; NLR
Integration with device asset
management
Maintenance Workstation
With Device Manager Essentials

Device Asset Management

Connectivity: Control Network (UDH) - Ethernet

HART pass-through interface

to a device management Mark Vie
software or GE Device Controllers

Manager Essentials
on a workstation I/O Network

FOUNDATION Fieldbus pass- Hart

through using FF-HSE to I/O Modules

external device management

if desired Integrated Fieldbus Field Devices

15 /
January 2014
1
US EAR: EAR99; NLR
5
Built-in cyber security features

Hardened Hardened Hardened HMIs, Foundation for

controllers network switches Workstations secure architecture

The Mark VIe System features enhanced cyber security to help protect your
infrastructure against cyber attacks.
Mark VIe controllers are Achilles Level 1 certified

Additional cyber security options available

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January 2014
US EAR: EAR99; NLR
Mark VIe Distributed Control System
Integrated Control System
Integrated controls Yes Common HW/SW platform No Non-integrated controls
- unit & plant
Machine Plant Plant
Controls Controls Yes Common configuration tool No Controls
- unit & plant Machine
Controls
Yes Common operation look & No
feel - unit & plant
Yes Common maintenance, No
diagnostics, spare parts,
logistics
Hardwires
Yes Operate entire plant from No
common operator station
for all plant components
Bus Interface
Yes Common alarm, historian, No
S.O.E databases
Yes Eliminates gateways & No
hardwired interfaces
Yes Common integrated safety No
system [SIL 3]
Yes Training on single platform No 17
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Integrated control benefits

Feature Benefit
Common hardware => single spare parts inventory
Common software => training on only one system
=> improved diagnostics
Integrated FAT => reduce commissioning time
=> reduced start-up problems
Single plant database => improved fault detection & analysis
Single operator interface => improved operator awareness / plant operation
Single alarm management => improved operator awareness / plant operation
Single-point supply => no additional cost & project risk
Less checkout time => no additional cost & schedule risk
One control system => Less life-cycle cost to maintain
Low-end
DCS Solution Overview
PPS is one of GE-IPs true solution offerings
Proficy Process Systems is a Hybrid DCS solution based on our PACs hardware
platform and Proficy software products (iFIX / CIMPLICITY and Logic Developer)
as a complete process automation solution. PPS provides the control systems
engineer with the integrated tools they need to design, implement, document
and maintain a process automation system using batch and continuous process
control strategies and utilities typically associated with DCS distributed control
systems yet at a traditional HMI/PLC solution openness, flexibility, price points.

Feature Customer Benefit

Target Application Range:
Global Namespace : Enables single point Enables reduction of configuration and
configuration installation effort by ~40%

Process-oriented function blocks and ease of Deep domain knowledge to optimize

code development for process control customer operations

Choice of HMI/SCADA or controller platform Creates path for easier upgrades with
installed base

High Availability Secure operations for mission critical

 What our solution is today

Discrete products glued Highly flexible, modular Extensive Function block

together with EGD and integrated library and standard HMI
communications architecture faceplates

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Engineering Workstation
Function Block Diagram, Ladder, Structured Text
Over 140 Blocks, with over 30 for Process Control
Function Block Library - examples
PID
Feedback Control eliminate error
Feedforward Control prevent error
Function Block Library - examples

2-State and 3-State device control for valves, pumps, etc.

Automatic
Manual
Maintenance
Alarm
Global Namespace
Points are created once referenced throughout the system
Common system communications
Reduce development times by 40%

Global
Namespace
Historian
Choice of visualization

Your choice of Visualization Technology

CIMPLICITY or iFIX

CIMPLICITY

iFIX
 Easy and Rapid Development
Environment
Drag and Drop objects
Faceplates and tags instantiated (created) from Function Blocks

Global
Namespace
Historian
Weighing the risks
Probability of occurrence vs. cost of disaster

28
Imagination at work.
Critical Control
Two types of Critical Control
Availability type of applications
Goal: Eliminate Downtime
Prevents a system from not functioning
Application: A system defect should never make the difference
between uptime and downtime
Safety type of applications
Goal: Eliminate Dangerous Situations
Prevents a system from malfunctioning
Application: A system defect should never make the difference
between a safe and a dangerous situation
Critical Control

Typical High Safety System Typical High Availability System

Does not rely on 1 component Does not rely on 1 component
Always has a second component Always has a second component
that also processes (check) ready to operate, when the
Multiple primary component fails
Inputs collected Single
Processes of the inputs
Input
Outputs generated by the processes
Processing of the input
Depending on the type of process an
action will be taken Output

31
GE Title or job number
7/22/2016
High-end
Process Safety Solution
Overview
Mark VIeS - A proven and safe solution

EXPERIENCE
Over 45 years of expertise in the most risk-averse
industries in the world

APPLICATION DIVERSITY
Critical infrastructure is what we do best

WORLDWIDE PRESENCE
Installations and support networks in every corner of
the globe

CERTIFICATIONS
Exida certified, SIL3 capable

BUILT-IN CYBERSECURITY
Controller certified as Achilles Level 1.
Mark* VIeS flexible controller redundancy

1 Triple Modular Redundant (TMR)

TMR (2oo3) SIL3 high / low demand
for de-energize to trip
TMR (2oo3) SIL2 low demand for
energize to trip
TMR degraded (1oo2) SIL3 high / low
demand for de-energize to trip
TMR degradation sequence (2oo3) to
(1oo2) to Fail Safe
2 Dual Redundant
Dual (1oo2) SIL3 high / low demand for
TMR Dual Simplex de-energize to trip
Dual (2oo2) SIL2 low demand for energize
1 2 3 / de-energize to trip
3 Simplex
Simplex (1oo1) SIL2 low demand for
de-energize to trip
Ethernet Backbone Flexibility

1 Safety Controller
1 Easy, automatic redundancy up to TMR
Operating Temp. 30 to 65C (-22 to 149 F)
Hazardous location, Class I Division 2
Achilles Level 1 certified
2
2 Safety I/O Network Switch
Operating Temp 30 to 65C (-22 to 149 F)
8 or 16 network ports, fiber or copper
3
Deterministic 100 MB communications
suitable for local or remote I/O
Full duplex, point to point protocol

3 Safety I/O Packs

Easy, automatic redundancy up to TMR
Operating Temp 30 to 65C (-22 to 149 F)
Hazardous location, Class I Division 2
I/O flexibility
Single or TMR I/O
Network address is managed
through a chip on the
terminal board
Assignment of hardware is
quick and easy
UDH UDH
UDH UDH

Primary and Safety control

UCSB UCSB UCSB UCSB UCSB UCSB
T

IONet

Controllers

can co-exist on one network

R S T R S T
S
IONet

I/O Networks
R
IONet while remaining independent.
Additionally, Primary can
Terminal Board Terminal Board Terminal Board
listen to Safety inputs without
I/O Modules

Terminal Board
interference.
Terminal Board

Safety IO Excess Capacity for

BPCS use

36
Hardened environments of the Mark VIeS

The Mark VIeS can operate in

temperatures ranging from
-30 to +65C without fans or
other external cooling.
The processors, network
switches, and I/O blocks are
approved for hazardous location,
Class 1, Division 2.

37
Mark*VIeS Architecture
Plant Data Highway
Plant Data
Highway General plant information standard IEEE
Maintenance,
Unit Data Operator, and Unit Data Highway
Highway Gateway Station
GE protocol devices supporting EGD
Number of devices/UDH are a function of
produced EGD exchanges/sec/device
Controller(s) Gateway Multiple UDHs connected via routers
Controller
No physical limit of HMI/UDH.
IO Net
I/O Net Limited by Ethernet Octet rule
Controller limit of 199 I/O packs
Average of 16 pts / Pack = 3184 I/O per
controller max
Controller loading
Process I/O
Function of I/O mix, scan rate, code
complexity, communications, EGD messages
Example of a burner management system
Low-end
Process Safety Solution
Overview
 SafetyNet and Process Control Architecture
Operator Consoles
Engineering Workstations

ERP Historian
Change
Management
Batch
PAC8000 SafetyNet
Applications
Controllers

PAC8000 Controllers
Fieldbus and I/O

Remote
8000 Process I/O

Field Devices
SafetyNet Logic Controller

8851-LC-MT SafetyNet Logic Controller

Logic control applications in a SIL2 environment

Subset of IEC 61131-3 languages (LD, ST, FBD)
Redundancy with bumpless transfer for higher availability
Dual-redundant high-speed Ethernet connections
Peer to peer communications between controllers
On-line configuration
Modules and controllers are hot swappable
Same environmental specifications as standard controllers
Diagnostic scan (1oo1D architecture)
Can handle 64 modules (safety and/or standard) as local IO
Workbench Walk Through
Create Project and Controller
A project contains the hardware (controllers and IO)
as well as the logic required for shutdowns and control.
SIL 2 Logic Solver
Certification

Provide the ability to state with confidence that the hardware

and software meet all the criteria of the IEC 61508 specification

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 Critical Control
Typical High Safety System
Does not rely on 1 component
Always has a second component
that also processes (check)
Multiple
Inputs collected
Processes of the inputs
Outputs generated by the processes
Depending on the type of process an
action will be taken
Typical High Availability System
Does not rely on 1 component
Always has a second component
ready to operate, when the
primary component fails
Single
Input
Processing of the input
Output
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7/22/2016
Almost Done GEs high
availability solution

7/22/2016 46
Every second of downtime counts
$20 billion or 5% of annual production
lost to unscheduled downtime and poor quality in global process industry*

Whats high availability?

A system implementation that prevents a system
from not functioning (fault tolerant).
It is more than redundancy. It is the ability to change,
edit, troubleshoot and fix the system without
stopping it.
= A system defect should never make the
difference between uptime and downtime.

Whats a mission critical application?

An essential industry, business or government
function that must run 24x7x365.
Failure of a mission critical application can lead to
significant financial, safety and reputational costs

*ARC Advisory Group estimates

Industry & application overview
High Availability with PACSystems PROFINET System Redundancy

Backup Power &

Mining Water/
Critical Cooling Wastewater
Transportation Oil & Gas
Backup power Applications Upstream Extraction Water Treatment
Paralleling throughout Separation Shovel-electric Plants
metro/transit
switchgear & power EOR Shovel-hydraulic Sewage pumping
systems Artificial Lift some
distribution Dragline Advanced sewage
Generator sets Tunnel ventilation redundancy treatment
Microgrid, fuel cells, systems Handling Disinfection/chemic
microturbines Midstream
Environmental Conveyance belts al management
Compression stations
control systems Pumping stations and systems Backup power
Critical cooling (lighting, cooling) Process
HVAC Building Equipment/Skids Communition Pumping Stations &
Building systems automation CNG Crushing waste/sewage
systems NGL pumping
OEMs, System LNG Refining Distribution network
Integrators, Motor control Vessels (FPSO)
centers Kilns Pump management
Engineering firms (pump size
OEM equipment determines HA)
Mission critical End users, EPCs/Sis
Pump optimization
facilities: Data focusing on midstream
applications and pressure control
centers, hospitals,
airports, financial Water Transfer Stations
services operations Desalination Plants

48
PACSystems PROFINET System Redundancy
Summary

A high availability architecture from GE

Intelligent Platforms ensures maximum
uptime with a flexible, intelligent system
that can be customized to your mission
critical needs.
The PROFINET-based system
significantly reduces the total cost of
ownership of a high availability system
by delivering a solution that is easier to
install, operate, and maintain.

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7/22/2016
PACSystems PROFINET System Redundancy
Lower TCO for a high availability control solution

Keep your process running with

uninterrupted control through defects,
maintenance, or system updates Ethernet

Reflective Memory

Ensure a high-speed connection to

remote I/O with PROFINET, a leading
open Ethernet standard

Design from a single point with name-

based configuration for simple, fast,
and easy setup and maintenance

Eliminate devices and cost with

integrated network switches and media
converters

Reduced cost & complexity for up to 30% lower TCO

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2013, General Electric Company. Proprietary information. All rights reserved.

 High performance
Quick response, always in sync
Smart synchronization simple, fast and seamless
Unique reflective memory technology supporting multi gigabit speed in PACSystems keep CPUs synchronized with
simple configuration, minimal impact to application performance, and bumpless switchover if a failure occurs.

Reflective Memory

Running through issues

Ring redundancy minimizes the likelihood and impact of network failures while
not bogging down the network traffic

Up to 1Gb speed, 1ms updates

Process I/O data over a wider, faster
pipeline
System Flexibility
Scalability without the complexity
Smart availability
With built in media redundancy protocol (MRP), adding a single wire to
make a ring keeps a system running thru a failure anywhere along the
network with no harm to bandwidth.

Fast setup or maintenance

Add or replace a node on a network using a standard SD card to quickly
assign a name to a node. For redundancy, configure one system, mirror,
then download.

Ultimate simplicity
4 ports (2 RJ45, 2 for copper or fiber SFPs) and built-in switch. Eliminate
external connections reducing space required, cost, network traffic, possible
noise on line, and setup time.

Large system capacity

Support for up to 255 nodes per CPU, with the ability to integrate 3rd party
devices. Use Auto Discovery tool to browse and configure new nodes.

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Maximum Uptime
An architecture with answers

PROFINET System Redundancy keeps

you up and running through:
Ethernet
Fail & recovery of either CPU
Redundant IP
Fail & recovery of I/O nodes Redundancy
Links
Cable break & recovery of ring
Cable break & recovery while an I/O
node is in maintenance mode
Cable break & recovery in either or
both CPU redundancy links
PROFINET IO Ring
Starting the system with a stand
alone CPU in RUN mode
Changing the hardware
configuration or logic

Dont let problems become downtime 53

22/07/2016
How does the data synchronization work?
Reflective Memory (RMX) data synchronization provides:
Large data transfer - configurable up to 2Mbytes
Fast data transfer - 2.12 Gbaud fiber optic network
Automatic data transfers - no application program logic required
Fully redundant data synchronization
Two modules for Multimode fiber up to 300m (RMX128) or Single-
mode fiber up to 10km (RMX228)
Results:
Full mirror image of process data
No single point of failure
Bumpless switchover
Fiber optic direct connection. CPUs can be up to 10 kilometres apart.

Reflective Memory

7/22/2016 54
How do EGD and PROFINET compare?

Fewer Network Components to Purchase, Install, & Maintain

Less Network Cable to Install
Single Point of Connect7/22/2016
for Configuration 55
Run-mode Updates of Program AND Hardware Configurations
And Finally EBoP
Electrical Balance of Plant
Title or Job Number | XX Month 201X See tutorial regarding 57
confidentiality disclosures.
 MARAFIQ IWPP Saudi Arabia
Worlds largest Water Desalination facility
Four 307FA/D11 Combine Cycle Plant
27 (in three groups) desalination plants
2750 megawatts 800,000m3/day
10% country power 20% country water
Reduce risk and operating costs
Single plant control for your most expensive asset

Single Control System

Steam Turbine Generator Gas Turbine HRSG BOP Safety

Simplicity of a single plant wide control system

59
 61
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Complete and integrated Control Solution for EBoP

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Modernization
Migration to todays technologies

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7/22/2016
With aging automation comes

Lack of availability Diminished productivity

Electronics age and technology Dont fall behind your competitors who
advances. Diminishing demand for old deploy mobility, remote monitoring, and
product makes the supply chain fragile. workflow solutions.

More downtime Workforce stagnation

As components age, the risk of failure Are you able to hire the right talent? The
increases. Have you considered best young engineers and techs want
modern redundancy options? contemporary technology.

Lost knowledge Increased cyber risk

Sometimes we lose the know-how that Does your equipment have
makes the old product work. Are your cyberhardening advances? Does it
expert technicians thinking of retiring? protect you from employee mal intent?

7/22/2016 64
Driving migration
Our target platforms are:
MarkVIe(S) and RX3i
Supporting this movement we will:
Mature RX7i -> RX3i
Mature 9030 -> RX3i

Migration kits available now:

9070/RX7i to RX3i
9030 to RX3i
9030 Maxon to RX3i
GMR to MarkVIeS

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7/22/2016
GRACIAS !!!