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g Mark V Integrated Control System
CIMPLICITY, Genius, and Series 90 are registered trademarks of GE Fanuc Automation North America, Inc.
Microsoft, Windows, Windows 95, Windows NT, and Excel are registered trademarks of Microsoft Corporation.
ARCNET is a registered trademark of Datapoint Corporation.
Ethernet is a trademark of Xerox Corporation.
Modbus is a registered trademark of Groupe Schneider, Inc.
IBM is a registered trademark of International Business Machines Corporation.
PC is a registered trademark of International Business Machines Corporation.
All other trademarks and registered trademarks are the property of their respective owners.
All specifications are subject to change without written notice.
This product description is submitted in confidence for evaluation by the Purchaser, and its
contents are proprietary to the GE Company. In taking receipt of this document, the Purchaser
agrees not to reveal its contents except to those in its own organization who must evaluate it.
Copies of this document may not be made without the prior written consent of GE.
Table of Contents
1. Introduction .................................................................... 4
1. Introduction
The GE Integrated Control System (ICS) provides power plant users with a comprehensive
solution that produces total plant control at a single level. The ICS unites the gas turbine
control, steam turbine control, generator excitation and protection, and HRSG control to form a
tightly integrated power island architecture. These unit level functions are then coupled with
compatible controls for balance of plant auxiliary functions, and visualization for all of the plant
controls is presented to the plant operators on a common Human Machine Interface (HMI).
Compared to traditional stand-alone controllers, the Integrated Control System offers several
advantages to the power plant operator, including:
By networking all of the turbine unit and balance of plant controllers together with the HMI,
operating data, alarm monitoring, and control references are implemented over the network. This
eliminates the mass of interconnecting wiring which traditional plant control systems use to pass
data and commands between the unit controllers, operator stations and plant automation
systems. The result is a lower cost installation, shorter checkout and startup effort, and
improved control system performance and reliability.
Tighter integration of plant systems improves equipment protection and control, and provides
common operator views and diagnostics for all controllers. This also reduces operator training
requirements. Increased commonality of system hardware and tool interfaces improves
maintenance expense and training, and lowers the needed complement of spares.
These advantages, coupled with the ease of ICS system expansion and GE’s Six Sigma quality
commitment, truly make the ICS the control system for the future.
2. System Description
2.1 Introduction
The Mark V ICS is intended to integrate plant control at a single level. This yields not
only improved control and equipment protection, but also provides an improved system
interface for both operation and maintenance personnel. This section describes the basic
ICS system structure and identifies component products and systems. These products
are briefly described in following sections.
A typical ICS new system configuration is shown on the following page. Ethernet and
Arcnet based data highways connect the components of the distributed control system,
which include:
• Mark V Turbine and Generator Control
ð Mark V Gas Turbine Control and I/O
ð Mark V Steam Turbine Control and I/O
ð Generator and Transformer Protection
ð EX2000 Generator Exciter
ð LCI Static Starter
PD-ics5.doc
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Mark V Integrated Control System
g Mark V Integrated Control System
ICS can easily be added to existing installations due to the modular nature of the ICS
system. The equipment can be phased in, starting with a simple HMI retrofit, and
building over time into a complete ICS system. Downtime is minimized as a result of the
system’s compatible products and software.
In the typical retrofit application, the turbine control is existing, and the ICS is connected
to an existing stage link. Existing <I> Mark V operator interfaces can coexist and
operate on the Stage Link with the new HMI based operator stations. This allows the
new equipment to be added and commissioned while the existing interface to the turbine
control is still in service, reducing risk of downtime during the installation.
System configurations for retrofit applications vary, depending on the retained mix of
existing and new ICS equipment. For instance, systems involving only HMI and higher
level plant interface functions would only need to implement the Plant Data Highway
Ethernet network. Systems involving these functions plus the addition of a Historian or
some third party systems would typically then add Modbus networks as well.
The ICS system flexibility allows users to move their existing systems into modern
operator interfaces and obtain operating information to better manage their process. GE
would be pleased to propose solutions to your process or existing equipment problems
using the ICS approach.
To Server To Server
I/O I/O
g GPP g Mark V + g GPP g Mark V +
AC DC - DC -
The complex, dynamic behavior of gas and steam turbines requires a flexible control
system that provides state-of-the-art control, monitoring, and protection functions. The
GE SPEEDTRONIC™ Mark V is a fully programmable, triple modular redundant
(TMR) turbine control system designed to meet the needs of today's power generation
industry.
The Mark V couples GE's extensive turbine control application and design experience
with modern electronic hardware and software. Users have access to all major control
functions, extensive monitoring capabilities, and many built-in features that automatically
protect the turbine-generator against a host of abnormal operating conditions such as
overspeed, loss of oil, and overheating.
The Mark V control is easily integrated with GE's Windows NT based HMI and SCADA
systems, as well as the remainder of the plant control systems. With a heritage of over
40 years of successful turbine control and automation, the SPEEDTRONIC Mark V
control leads the industry in system performance, reliability, and availability. Please see
the Mark V Product Description document for further detail.
The EX2000 is GE's second generation digital excitation system. Some of the benefits
that this excitation system provides are:
l Improved performance from faster response, better regulation, and no thermal drift
l Better diagnostics with self-test on power up, fault display, and extensive bridge
monitoring
l Greater reliability
l Reduced maintenance through extensive use of digital design
l Improved protective features
The EX2000 can provide control of brushless exciters as well as direct excitation in both
single and multiple bridge designs to support a range of generator sizes. The system
supports a number of redundancy strategies, and can be supplied in simplex design, as
required to meet the needs of the application. Please see the EX2000 Product
Description document for further detail.
Protection and metering for the driven generator is provided by a Generator Protection
Panel (GPP). The heart of the panel is the DGP2 (Digital Generator Protection) relay.
Some of the benefits of this system are:
• Improved performance from faster response, better fault detection, and lack of
thermal drift
• Easily programmed Alarm and Trip pick-up points through a laptop PC via RS-
232 serial port
The GE LCI Static Start System works with the EX2000 exciter to convert the generator
to a starting motor for the turbine set. This eliminates the need for a separate electric
starting motor, torque converter, and associated electrical hardware while freeing up
critical space around the turbine base.
The static start system is fully integrated with the GE Mark V SPEEDTRONIC system
and EX2000 digital excitation system. The Mark V control supplies the run, torque, and
speed setpoint signals to the LCI, which operates in a closed loop control mode to supply
variable frequency power to the generator stator. The EX2000 is controlled by the LCI
to regulate field current during startup. By controlling field and stator current, the LCI
will accelerate or decelerate the generator to the synchronizing speed.
Genius Genius
Bus Bus
Genius I/O Genius I/O Genius I/O Genius I/O Genius I/O Genius I/O
GE Fanuc 90-70 series PLC equipment is typically used to provide control for the HRSG (Heat
Recovery Steam Generator) and balance of plant functions. Either two or four PLCs are used
for the HRSG, turbine auxiliary functions, remaining balance of plant auxiliaries and the
electrical distribution, depending on the size of the controlled plant.
The PLCs are typically configured in a hot backup arrangement, although simplex arrangements
are also available. Plant signals connect to both PLC controllers in a hot backup configuration
through GE Fanuc field or Genius I/O equipment, which can be either local or remote. In the
hot backup arrangement, only one PLC is sending outputs, but both controllers monitor all I/O
and are maintained in a synchronized state. If the primary unit fails, the hot backup unit already
has the I/O information, and will take over active control.
The PLCs communicate with the HMI through the Ethernet-based Plant Data Highway. Please
see the HRSG and BOP Product Description documents for further detail.
Dot Matrix
The Mark V CIMPLICITY HMI is a milestone for the turbine control marketplace. In one
powerful, flexible and user-friendly operator interface, it brings together all of the displays and
functions needed for real-time control and monitoring of turbine-generator processes, auxiliary
equipment, driven devices and diagnostic alarms associated with power plant control. As the
operator interface for the power plant Integrated Control System (ICS), the Mark V HMI serves
a variety of plant configurations. These systems can include heavy-duty gas turbines, steam
turbines, single-shaft STAG combined-cycle units, generator excitation systems, static starters,
heat recovery steam generators (HRSGs), and balance of plant (BOP) auxiliaries.
The Mark V HMI system is designed with an open system concept, and uses standard open
hardware and operating system software. The HMI’s software system is based on the Windows
NT client-server architecture from Microsoft. Windows NT provides built-in multi-tasking,
networking and security features. The ability to run the system on conventional PC-based
platforms minimizes cost, promotes open interfaces, permits system scalability, and ensures
longevity of investment and future performance enhancement.
The Mark V HMI system is firmly based on GE Industrial Systems (Salem, Virginia) and GE
Fanuc Automation (Charlottesville, Virginia) products, which are in wide use on a variety of
power generation and industrial applications. GE Fanuc’s widely used CIMPLICITY HMI
serves as the foundation system. GE Industrial Systems configures and integrates the base
CIMPLICITY product to create the Mark V HMI, making the system well-suited for the critical
tasks of power island and power plant control.
This combination of a state-of-the-art, open architecture HMI system from GE Fanuc, along
with the power plant control experience and capability of GE Industrial Systems, provides an
HMI product which is unique in the industry. The HMI System has the flexibility and capability
to span a wide range of power island and balance of plant situations through a variety of
interface mechanisms. Although the interfaces vary, the plant operators are still provided with a
common visualization of plant operation and conditions. Please see the HMI Product
Description document for further detail.
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6.1 Historian
Historical data for system analysis are collected by the Historian. Based on the same
Windows NT hardware as the CIMPLICITY HMI system, the Historian uses PI and
PI-Process Book application software from OSI Software for data collection and
retrieval.
The GE Historian provides a fully automated package, designed to collect, store, and
present plant data. Convenient and fast data access can significantly reduce the time
required to make critical business decisions to stay competitive. Rapid access to plant
data also makes it easier to run a power plant for optimum performance and
troubleshooting.
Data accuracy is not compromised as it is with some process historians, which cope with
tremendous amounts of data by averaging the data over a time period. The GE Historian
uses “exception reporting” data collection techniques and data compression algorithms to
reduce the amount of data to be manipulated and stored. This also ensures a fast
response time when users retrieve the data for display.
The Historian accesses turbine control data directly through its connection to the Stage
Link. Data from GE Fanuc PLCs is accessed through Modbus. Historical data for about
500 different points [per unit] are stored in a typical turbine control application, exclusive
of alarm and event data.
Alarms and events are time-tagged locally in the Mark V control. Alarms and events are
sampled every 62 ms, while contact inputs are time-tagged at 1 ms. Analog data is
collected at 1 Hz rates. HRSG and balance-of-plant alarms and events collected by the
PLCs are time-tagged by the Historian computer, which is synchronized with the Mark V
control.
The Historian is connected to the Plant Data Highway (Ethernet) for data retrieval.
Historical data can be viewed or analyzed by authorized users at the Historian or through
any HMI operator interface in the control system.
Two methods are used to access and analyze data. The first— a native PI product called
PI-Process Book— gathers and displays data from the system. In addition to generating
trends and plots, Process Book can be used to make displays similar to those of the HMI.
The second method for viewing data is through ODBC (Open DataBase Connectivity).
Data can be written to an output file and imported into a variety of commercially
available spreadsheets and relational database management software packages such as
Access, Excel, or Microsoft SQL. Any of these products can be used to produce
standard reports. Please see the Historian Product Description document for further
detail.
The Engineering Workstation provides tool access to the ICS system equipment for
programming, configuration changes, HMI screen modification and generation, and for
system program documentation. Application software and configuration tools reside on
this computer, which also serves as the source for all system documentation. The tool
workstation uses Windows NT based computers, similar to those used for other
functions in the system. The tool software packages will run on any of the Windows
NT computers in the system, if you should decide that a dedicated workstation is not
needed.
The Mark V ICS uses Stage Link (Arcnet) as its mechanism for communication with the GE
turbine control and turbine auxiliary equipment. Communication with the HRSG, balance of
plant and external systems occurs over an Ethernet data highway, which can be optionally be
supplied as a redundant network. Please see system configuration drawing in Section 2.2.
The Stage Link provides communication within the GE turbine island equipment. The HMI
servers host this network, transmitting and receiving control and supervisory data. Due to the
importance of the control signals on the Stage Link, and the need for quick communication, the
Stage Link is restricted to GE system equipment. A proprietary GE protocol is used for
communication on this network.
The Plant Data Highway (PDH) serves to integrate the unit turbine control systems with the
overall total plant and external communication requirements. The HMI Viewer stations connect
to the PDH, and receive their data from the Servers over this network. Auxiliary control
systems, such as the HRSG and BOP PLCs, tool workstations, Historians and other system level
devices also interface here. Since this network is intended to provide external interface, it uses
open and widely used communication interfaces, such as TCP/IP.
Use of TCP/IP on Ethernet minimizes impact on the systems being interfaced. A standard open
GE messaging protocol (GSM) is normally used for external communication, but the system
additionally allows Modbus interfaces with other systems. These open interfaces allow the
system to collect and display data from a variety of plant-wide sources.
Some systems also include other optional GE or third-party equipment that has been pre-
structured for integration into the ICS control and operator interface systems. These include
The OSM is provided by GE Power Systems as part of its optional remote Monitoring
and Diagnostics service. The OSM is installed at the plant site, and receives data from
the plant systems through its full integration on the system networks. The data is then
processed to analyze the equipment performance and compared to baseline information.
The OSM provides first-level problem detection and notification, which alerts the on-site
personnel and the GE M&D center to developing problems or potential failures. The
M&D center diagnostic engineers can then gather any necessary data, and make
recommendations to the customer to maximize uptime of the GE equipment.
GE and Bently Nevada Corporation have combined forces to integrate Bently Nevada’s
industry-leading vibration monitoring technology with GE’s turbine control and ICS
systems. Vibration monitoring and analysis systems provide critical information
necessary to assess the mechanical condition of rotating and reciprocating machinery, and
provide protection for such machinery. The optional Bently Nevada systems
continuously measure and monitor a variety of supervisory parameters, providing crucial
information for early identification of machinery problems. Plant availability and
operating costs are improved by timely knowledge of machine conditions that could
impact operations. Data from the system can be displayed on the ICS HMI operator
stations, giving the plant operators a better understanding of machinery condition.
GE Harris Energy Systems, a joint venture between GE Power Systems and Harris
Corporation, provides digitally-based, intelligent energy management systems and
services to electric utilities and industrial users that automate and integrate power
systems for optimal efficiency. These state-of-the-art, information technology systems
also enable electrical producers and users to better capitalize on opportunities to buy, sell
and manage power in a deregulated market.
GE Harris designs, manufactures and markets computer control centers and other
electronics that help utilities identify the most cost-effective methods to dispatch power,
track power quality, simulate outages and recommend timely actions to optimize
operations. This is supported by GE Harris’world-leading distribution automation
product line that allows the remote measuring of voltages, currents, power flows and
temperatures while providing a data link to the central energy management system.
The GE ICS system will integrate with the GE Harris EMS system, providing UCA
based generation objects and universal relay objects to the higher level enterprise system.
From these data, the overall utility control system receives accurate information on the
condition of the ICS controlled plant, which helps in planning, maintaining and
optimizing the operation of the system.
Many levels of testing are done to insure the quality of the system. The major areas are
hardware, software, system testing, and system simulation.
Purpose: The Stage Link is the system network used by the Mark V turbine
controllers and their auxiliaries. The Stage Link ties the turbine
controllers of a integrated control system together, and provides a
data path to the operator stations and higher level plant functions
on the Plant Data Highway (PDH).
Redundancy: The Stage Link is normally a single network, with the HMI servers
terminating both ends. This allows either server to access all
nodes on the network. The turbine controller hardware will also
support completely redundant networks.
Network Media: Coaxial cable for network backbone between server and controller
device connections. Optional optical fiber for network backbone,
depending on distances and system configuration needs.
Protocol: GE proprietary
Purpose: The Plant Data Highway (PDH) is the plant level system network.
The PDH provides connectivity for the operator stations, any plant
level or auxiliary controllers, such as the HRSG and BOP
controllers, plant level functions such as the Historian, Engineering
and Tool workstations, and any external interfaces.
External Interfaces: Various third party interfaces are available. Ethernet using GSM
or Modbus RTU are the most common.
Network Hubs: PDH Network Hubs (2), Cabletron SEHI (1) and SEH (1), or
equivalent
Fiber Cable: Cable, optical fiber Ethernet 10Base-FL type, 6 fiber (3 pair),
62.5/125 micron, dual window, graded index profile, multimode
glass-on-glass construction, thermoplastic jacket, including ST
connectors
UTP Cable: UTP (Unshielded Twisted Pair) cable, 4 pair, Category 5 or better,
including RJ-45 connectors
Fiber Cable: Cable, optical fiber, 4 fiber, 62.5/125 micron, multimode, Optical
Cable Corp. part RK920929-A or equivalent, with ST connectors