Products and Services

Email: Info @ turbineservices.asia

OVERVIEW
Older control systems, for example the Speedtronic Mark I or II, cannot fulfil the demands of a modern gas turbine control such as complicated control functions like DLN (Dry Low NOx) The MACH7 is a flexible and scalable programmable control processor that can monitor, control, and regulate all the gas turbine processes including all the existing peripherals. Due to its flexibility, it is possible to easily add at anytime very complicated control tasks and algorithms, that result from new developments or environmental regulation laws and etc, or inputs from other systems.

Technical Design Parameters

Our control concept is based on the efficient modular expandable SPS platform for complex automation solutions, specifically designed for use in the power generating industry. Based on open and flexible programmable system, that is easily expandable in regard to adding extra control functions. The control can have a maximum of 131,072 digital signals and 8,182 analogue signals All control components are under continuous self-diagnosis that can determine a problem before it has any impact to the process. The processor can be repaired while in operation or even replaced. After a repair or replacement, the processor will be automatically put in the HOT STANDBY MODE. The control is only composed of 4 to 5 different standard components. This implies economical solution to a complete spare part inventory is possible.

PANEL CONFIGURATION

The Mach 7 panel is as big as a Mark IV panel Optional panel mount operator interface.

LAYOUT of REDUNDANCY
Mach 7 employs the principle of active redundancy (HOT STANDBY) which has been thoroughly tested and used in the state of the art process control worldwide

PROCESSOR ACTIVE REDUNDANCY

Critical control sequences and turbine protection are run in separate Tasks. Both processors <P1> and <P2> are continuously active during operation. The lead processor is assumed by the first processor booted-up. The second one will automatically be set in the Hot Standby mode. In the event of a fault there is a bump less transfer to the still functioning backup device for control of the process.

<P1> and <P2> are configured in two completely separated standard built cores with their own separate power supplies. The redundant communication between the single processors is accomplished through double runs of fibre optic cable.

COMM ACTIVE REDUNDANCY

The communicator processors <C1> and <C2> are located in each of the cores of the processors <P1> and <P2>. The <C> processors are responsible for the data transfer to the Turbine Monitoring System They too follow the Hot Standby principle so the lead <C> processor handles the communication to the operator terminals thereby relieving the lead <P> processor from the memory intensive communication work. In the case of a fault, there is a bump less transfer of work to the still functioning backup device.

All components of the controls can be changed during operation. When the CPU is changed, it will automatically be configured and reload all the actual programs and data.
Adding or removal of different cores, DP-Slaves and memory chips as well as making configuration changes are all possible during operation.

HARDWARE DESIGN
CPU
In the Mach7 turbine control, the processor 417-4H is exclusively used, which at this being the best available suited for this type of process control application.

HARDWARE DESIGN
IO and Functions Cores
The selection of the input, output or function core hardware is dependent upon the turbine as well as the functions required. Depending on the importance of the signal, the input and output signals will be distributed to the different modules. The used cores are the standard cores from SIMATIC S7. With a decentralized control structure, the gas turbine signals as well as any additional local skids, are processed in the required standard built type (ET200M) and the data is then transmitted to the processor through double redundant bus cables (fibre optic). Short and clearly laid out cable connections between the field devices and the I/O modules facilitates a condition for safe and problem free data exchange between the I/O modules

HARDWARE DESIGN
IO and Functions Cores
The amount of input and output signals in the MACH7 is dependent on the type of turbine plus 20% planned spares. This way there is enough reserve capacity that can be used for future added turbine functions or including a variety of diverse related devices without the need to add new modules. After the 20% reserves are used, the capacity of I/O is almost unlimited through additional cores. The theoretical upper limit is 131,072 digital input/output signals as well as 8,192 analog input/output signals.

TECHNICAL SPECIFICATIONS
STANDARD CONTROL PANEL HARDWARE
Control Panel RITTAL HxWxD 2000x1200x500 Siemens S7400H (2x CPU 417-4, 2x CP443-1, separate power supplies) Active Redundant Processors connected with fiber optic ET200M Module for redundant IO with 2x IM153-2 DC-DC Converter redundant (125VDC / 24VDC) Redundant Power Supplies for all Modules Galvanic Isolation for I/O Signals No Ventilator Required Fiber Optic Switch Module for Fiber Optic Ring Vibration Measurement Signal conditioning Flame Detector Signal conditioning for Honeywell UV Flame Detector SIMATIC Panel PC 670 15" TFT 1024x768 touch pad Keyboard, Mouse Internal Wiring (I/O Terminals, Power Supplies, Modules) Internal Bus Wiring (Profibus, Ind. Ethernet, OSM, Video Server) Internal Panel I/Os (Door open / closed, Temperature, Lighting) 1 1 X 6 3 X X X 2 12 8 1 X X X

TECHNICAL SPECIFICATIONS
EXAMPLE OF PROCESS SEQUENCE SOFTWARE
Standard Software for GE Gas Turbines 2 out of 3 Voting with generating middle value for 3 redundant Field I/Os Exhaust Temperature Control Speed (Frequency) Control for Island Operating Mode Double Electronic Overspeed Protection Circuits Software for Steam Injection Software for Water Injection Software for DLN1 Control 17th Stage Compressor Protection (MS 6001) Software for Inlet Air Heating Software for Anti Icing Flame Monitoring Exhaust Temperature Monitoring Wheelspace Temperature Monitoring Bearing Oil Drain Temperature Monitoring Bearing Metal Temperature Monitoring Generator Temperature Monitoring Vibration Monitoring Inlet Guide Vane Control On-Line / Off-Line Compressor Water Wash Numerous Turbine Protection Functions Variable Fast Start Calculations with Self Adjustment TMOS Turbine Monitoring System for Operator Turbine Control X X X X X X X X X X X X X X X X X X X X X X X

TECHNICAL SPECIFICATIONS
Standard Inputs / Outputs of the MACH7

MACH 7 IO NETWORKs
The networking uses a PROFIBUS DP Optical Link with a bus speed capable of 12 Mbit/s. Advantages of Fiber Optic Technology:
Unaffected by electromagnetic interference No influence from outside disturbances No grounding problems Galvanically isolated Easy cable routing Limited weight

417-4H CPU TECHICAL SPECIFICATIONS

MACH 7 HARDWARE RELIABILITY

Reliability can be reflected with average time of Failure-free operation during a mission or Mean Time Between Failure Statistical MTBF can be used to judge the reliability of a system and/or component MTBF of MACH 7 (or S7) components are calculated based IEC 61709 standard

Components
CPU 417-4H IM 153-2 FM 350-2

Function
CPU Comm. Module of ET200M Pulse Counter

MTBF (years)
34.5 47.6 35.7

SM 321 PS 407

Digital Inputs Power Supply

30.6 60

Reference: Siemens website https://support.automation.siemens.com/WW/llisapi.dll?func=cslib.csinfo&lang=en&objid=168184 90&caller=view

TYPES OF TURBINES SUPPORTED

TYPICAL MACH 7 PANEL ORGANIZATION

ET200M 2oO3 VOTING RACK ARRANGEMENT EXAMPLE

FUNCTIONAL DIAGRAM (2oO3 reading, 1 to 3 writing)

ET200M INPUT and/or OUTPUT MODULE ARRANGEMENT EXAMPLE

NON-REDUNDANT IO FUNCTIONAL DIAGRAM

EXAMPLE of MACH 7 IMPLEMENTAION

INSTALLED BASES
Installed Systems Installed Power Peak Load Power Characteristics : 21 : About 667 MW at ISO : About 667 MW at ISO : Approved and used for black start and net reconstruction

TMOS Visualizing, Archiving & Diagnosis System

TMOS Turbine MOnitoring System has all the characteristics that a future oriented digital system must possess. TMOS was designed especially for the maintenance, display, and monitoring of gas turbine data. The use of TMOS is not limited to only the turbine operation, but can also be applied to other processes (such as boilers, generators, compressors, balance of plant, etc.). Integration with plant Local Area Network enable data sharing with network users Components based on Server and Client models Windows based and dual LCD displays with multiple windows support

TMOS CAPABILITY OVERVIEW

DCS

TMOS COMMUNICATION CAPABILITY

TMOS can communicate and control the following systems:
GE Speedtronic Mark IV GE Speedtronic Mark V / Mark V LM GE Speedtronic Mark VI ITS MACH 7

The communication protocols that it supports:

ARCNET DLAN as well as DLAN+ GE DDUMP (Serial as well as Ethernet TCPIP) GE MSP (Serial as well as Ethernet TCPIP) GE GSM Modbus RTU (Serial as well as Ethernet TCPIP) S7 Communication (over TCPIP) OPC DA 3.0 and EA 1.0 Server

TMOS AS OPERATOR INTERFACE

Animated color screens Multiple screens open at once Signal Information Start realtime trending with only 2 clicks Movable alarms panels Customizable Display Styles: TMOS, HMI, IDOS, P&ID and etc

TMOS DISPLAY OPTIONS

TMOS STYLE

TMOS DISPLAY OPTIONS

HMI STYLE

TMOS DISPLAY OPTIONS

P&ID STYLE

SIGNAL INFO

One Click leads to many roles

TMOS AS HISTORIAN
Archive Analogue signals, Alarms, Diagnostics, Events and Digital IOs events for future retrieval Trend realtime or historical signal Data stored as RAW = no compression loss Timestamp up to 0.001s resolution Up to 1s sampling rate for analogue signals

Export Alarms, Events, Diagnostics and Digital IO events to other formats: xls, jpg, xml and so on.

TMOS as ANALYZER - TRENDVIEWER

Powerful but user friendly tool to trend realtime as well as historical data Drag and drop signals to start trending Able to select signal from particular processor (Speedtronic TMR) Zooming and panning functions with auto-configured trend resolution 3 movable slide bars to pinpoint signals behaviours

TMOS as ANALYZER - TRENDVIEWER

D.E.A Viewer
Organizer and viewer of both current and historical Diagnostics, Digital, Events and Alarms Things you can do - Find, sort, filter, print and export

TMOS HIGH SPEED DATA LOGGING

Under certain circumstances, a high speed data logger to capture fast changing signals in order to pinpoint root cause of the problem, such as power swing. This tool can capture signal up to 32 sample/sec Able to specify sampling trigger condition and source target

TMOS HIGH SPEED DATA LOGGING

USER DEFINED SIGNALS

Not only can TMOS display, archive, trend and print signals from various data sources (like Speedtronic, Mach 7, GC Analyzer, BN 3500 and etc), user can also define formulas to derive calculated signals for more meaningful analysis The formula can consist of common mathematical operator like sin, cos, tan, log and so on, contained in a maximum of 8 layers of parantheses. Calculated values can also be used in the next formula

USER DEFINED SIGNALS

TMOS FAULT TRACING MADE EASY

No more alarm drop number, please! Direct link from alarm windows to the particular sequencing rung that triggers it

TMOS DYNAMIC RUNG DISPLAY

Intuitive and features packed. Fast coil tracing IO connection details displayed Direct Logic Forcing from display

TMOS DYNAMIC RUNG DISPLAY

Mark V Diagnostics
Especially useful for Mark V users, this tool enable detailed diagnosis into Mark V systems as well as ARCNet May print or save as text file

Mark V Diagnostics

TMOS ENGINEERING TOOLS

As a completely re-engineered HMI solution, TMOS has all the necessary engineering tools: Pre-vote viewer for Speedtronic TMR LVDT & SERVO calibrator EEPROM Programmer for Speedtronic Mark V IO Configurator for Speedtronic Mark V STEP 7 Manager for Mach 7 Constants adjust and Logic Forcing

TMOS ADMINISTRATION
Block nuisance events 10 users assignable and user rights customizable Time synchronization options

TMOS PLATFORM & HARDWARE

Windows Server 2003R2 and 2008 TMOS recommends HP Proliant Server compatible to all modern Intel processors and chipsets DVD Writer RAID 5 storage array Minimum 4Gb RDIMM RAM PCIe ARCNet Card (8 x 2kb buffer and fast bus speed)

TMOS ADVANTAGE
Redundant Server Configuration License free remote Display, Trender and Historian Clients ( theoretically supports over 50 network users) Optional Remote dial-in support Continuous improvements

TMOS REFERENCES