Mkvie Overview
Mkvie Overview
Presenter
18 November 2003 Introducing Networked I/O
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Application Range
9H Combined Cycle
Proprietary Design
Industrial Steam
Governors
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Flexible Architecture
Mark VI Enhanced
Processors I/O Packs Redundancy
1 Pack • Dual (Process Runs if Controller Fails)
Switches &
• Triple (Process Runs if Controller has
I/O Net
Partial or Complete Failure)
Simplex Simplex
Simplex
Distributed / Remote I/O
• Less Installation & Maintenance Cost
Dual Dual Dual • More Flexible Application
Triple
On-line Repair / I/O Packs
Triple Triple • Hot Swap in Redundant Systems
• Improved MTTR / Availability
Flexible Redundancy
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1 Control vs. Integrated Controls
Plant Data Highway
Ethernet 11Control
Operator & Controlwith
withDistributed
DistributedI/O
I/Ofor:
for:
Maintenance ••Turbine
Turbine&&Process
ProcessSensors
Sensors
Stations ••10,
Unit Data Highway 10,20,
20,40ms
40msSystem
SystemFrame
FrameRates
Rates
••Simplex,
Simplex,Dual,
Dual,Triple
TripleRedundancy
Redundancy
Ethernet
Controller(s)
Remaining Process
• Power Island
• Balance of Plant
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The Building Blocks
The Controllers The I/O
The Software
The Networks
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Mark VIe Controller Rack
Redundant Controllers
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Mark VIe I/O Packs
Features
• Dual 100MB Ethernet Ports
• Low I/O Density
• On-line Repair per I/O Block
• Operation -30C to 65C
• Accuracy -30C to 65C
• NFPA Class 1, Div 2 with Local Temp Sensor
• Infrared Transceiver for Low Level Diagnostics
- Monitor I/O Values, Set I/O Pack Host/
Function Names, Error Status
- Requires Windows Based Diagnostic Tools
on Laptop or Handheld PC
- Ethernet TSM Support
• I/O Packs Plug into Mk VI
Termination Boards z Processor 32 Bit RISC CPU 266MHz
• Barrier & Box Type TBs z Cache 32k bytes
z Ram 32M bytes @133Mhz
z Flash 16M bytes
z Communication Dual 10/100 Full Duplex Ethernet
z Power 28Vdc
z Ethernet Task Rate1.8ms
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Terminal Boards
Barrier Terminal Blocks Box Type Terminal Blocks
& 1, 2, or 3 I/O Packs 1 I/O Pack, but Dual Networks
• Barrier Type
- Derived from Mark VI
- Full Set of Functionality
- Simplex, Dual, Triple Redundant
• Box Type
- Subset of Barrier Type Functionality
- Simplex or Dual Redundant
• New I/O Types vs. Mark VI (Ex: Solid-State Relays)
- New I/O Types Backwardly Compatible to Mark VI
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Centralized I/O
Triple Redundant Cabinet – Nuclear BOP
IONet Switches
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Remote I/O
Thermocouple TB
MS5001N at GEAE Plant in Lynn, Mass.
Signal Quality
• Processing at TB
• Processing in
Main Cabinet
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Remote I/O Panel with “S” Type Boards
Terminal Boards
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Environmental Validation
Stress Upper Highly Accelerated Life Test (HALT)
Destruct Limit Purpose: Increase Design Reliability
• Applied During Design Cycle to Identify Limiting
Upper Design Factors
Thermal Imaging
Operating Limit • Improve Design Margins
• Result: Increased Reliability U1 Q1
U2
Upper
Specification Increase Stress to:
• Discover Operating Limits R1 R23
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Turbine I/O
Unique Turbine Sensors
Types
Benefits
• Servos
• Fewer Single Point Failures • LVDT
- Big Deal in Redundant Systems
• Vibration
• Less Equipment to Maintain • Flame
• Better Diagnostics (Can Directly See the Sensor) • Shaft V/I
• Fewer Spare Parts • Synch (Auto & Backup)
• PLU / EVA
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General Purpose I/O
Redundancy
I/O Type - General Purpose Board Packs/Board
24 DI (125Vdc, group isolated) 1ms SOE TBCIH1 1 or 2 or 3
24 DI (24Vdc, group isolated) 1ms SOE TBCIH2 1 or 2 or 3
24 DI (48Vdc, group isolated) 1ms SOE TBCIH3 1 or 2 or 3
24 DI (115/230Vac, 125Vdc, point isolated) 1ms SOE on 125Vdc TICIH1 1 or 2 or 3
24 DI (24Vdc, point isolated) 1ms SOE TICIH2 1 or 2 or 3
24 DI (24Vdc, group isolated) 1ms SOE STCIH1 1
12 "C" mech. relays w/6 solenoids, coil diagn. (115/230Vac, 24/125Vdc) TRLYH1B 1 or 3
12 "C" mech. relays w/6 solenoids, voltage diagn. (115/230Vac, 125Vdc) TRLYH1C 1 or 3
12 "C" mech. relays w/6 solenoids, voltage diagn. (24Vdc) TRLYH2C
6 "A" mech. relays for solenoids, solenoid impedance diagn. (24/125Vdc) TRLYH1D 1 or 3
12 "A" solid-state relays/inputs (115/230Vac) TRLYH1E 1 or 3
12 "A" solid-state relays/inputs (125Vdc) TRLYH2E 1 or 3
12 "A" solid-state relays/inputs (24Vdc) TRLYH3E 1 or 3
36 mech. relays, 12 voted form "A" outputs Specifications TRLYH1F 3
12 fused branches •
Operation: -30 to +65CWPDFH1A
36 mech. relays, 12 voted form "B" outputs TRLYH2F 3
12 fused branches •
Accuracy: -30 to +65C WPDFH3A
10AI (V/I inputs) & 2AO (4-20/0-200ma outputs) •
I/O Filtering in Firmware
TBAIH1C 1 or 2 or 3
10AI (V/I inputs) & 2AO (4-20/0-200ma outputs) STAIH1A 1
(Not Application Software)
16 AO (4-20ma outputs) 8 per I/O Pack TBAOH1C 1 or 2
8 AO (4-20ma outputs) STAOH1A 1
12 Thermocouples TBTCH1B 1 or 2 or 3
24 Thermocouples (12 per I/O Pack) TBTCH1C 1 or 2
12 Thermocouples STTCH1A 1
16 RTDs 3 wires /RTD (8 per I/O Pack) TRTDH1C 1 or 2
8 RTDs 3 wires /RTD SRTDH1A 1
6 Serial ports for I/O drivers RS232, RS422, RS485 PSCAH1A 1
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Dual Redundant Input Options Dual Redundant Output Options
IONet TB
IONet IONet IONet
Sensor Switch Controller Controller Switch
Exchange
Process Output
Data
Switch Controller
Controller Switch
TB
IONet IONet IONet IONet
Sensor - A Switch Controller Controller Switch
Data
Sensor - B
Switch Controller Controller Switch
Two Sensors on Two TBs & Dual Controllers Dual Outputs to Three I/O Packs
IONet
IONet
Sensor Switch Controller
Exchange
Switch Controller
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Triple Redundant Input Options Triple Redundant Output Options
IONet IONet IONet IONet
Sensor - A Switch Controller Controller Switch
Outputs Driven
from Common TB
State Exchange
Controller Switch
Sensor - B
Switch Controller
Controller Switch
Sensor - C
Voting at Termination Board
Switch Controller
IONet IONet
1 of 3 Servo Coils
Fanned Inputs to Three Controllers Controller Switch
IONet IONet
Sensor - A Switch Controller
Controller Switch 1 of 3 Servo Coils
State Exchange
Sensor - B
Switch Controller
Controller Switch
1 of 3 Servo Coils
Switch Controller
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IONet
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IONet Switches
Features
• Operating Temp: -40 to 85C
• Operating Humidity: 10 to 95% Non-Condensing
• Shock: 200g @ 10ms
• Vibration / Seismic: 50g, 5-200Hz, Tri-axial
• MTBF: > 2M hours
• Auto-sensing 10/100 Base TX, Duplex, and MDIX
• Up to 2.6Gb/s, High Speed Backplane
Switch Types • Steel Enclosure, Prevents EFI and RFI
• N-TRON 500 Series • DIN-Rail or Rack Mounted
• 508TX – 8 10/100 BaseTX RJ-45 Ports • Redundant Power Inputs 10-30Vdc,
• 516TX – 16 10/100 BaseTX RJ-45 Ports - 200ma (w/o fiber) 400ma (w fiber) at 24Vdc
• 509FX – 8 10/100 BaseTX RJ-45 Ports • Bi-color LED’s for Link, Speed, Activity, and Duplex Status
1 100 BaseFX Fiber Port
• 517FX – 16 10/100 BaseTX RJ-45 Ports Emissions and Safety Approvals
1 100 BaseFX Fiber Port • FCC Part 15 Class A
• UL Listed (US & Canada)
• Class 1, Div 2, Groups A, B, C, D, T4A
• CE: EN55011, EN61000-6-2 and –6-4
• EN61000-4-2,3,4,5,6,11, EN61010-1 Class III,
Pollution Degree 2
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IONet Specifications
Controller Local I/O TB
Pack Field
U Switch Device
C IONet - Cat. 5 IONet - Cat. 5 Field Wire
C 100m / 328' 100m / 328' 300m / 984'
A
100Base TX 100Base FX
IEEE Specification 802.3u 802.3u
Wire Speed 100Mbps 100Mbps
Cable Type UTP Cat. 5 Fiber (multi-mode)
Connector Type RJ-45 SC
Max I/O Packs / Network 199 199
Topology Star Star
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ToolboxSTTM
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I/O Configuration& Diagnostic Tools (ToolboxSTTM)
Toolbar
Select Category z View I/O Data
z I/O Calibration
z Diagnostic Messages
Select
Device
Active Pictorial of Equipment
z Terminal Board
z I/O Packs w/Diagnostic LEDs
z I/O Network Status
Overview of I/O Network
Hardware ID
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Field Programming Tools (ToolboxSTTM)
Features
Features
Field
FieldProgrammable
z
z Programmable
Floating
FloatingPoint
z
z Point
Dynamic
Dynamic DataDisplay
z Data
z Display
z Drag & Drop Points
z Drag & Drop Points
Math
MathBlocks
z
z Blocks
Macros
Macros(User
(UserBlocks)
z
z Blocks)
Function
Function & LadderBlocks
z & Ladder
z Blocks
z Multiple Block Libraries
z Multiple Block Libraries
Editors
EditorsFor:
z
z For:
- -Application
ApplicationSoftware
Software
- -I/O Assignments
I/O Assignments
- -Tuning
TuningConstants
Constants
Password
PasswordProtection
z
z Protection
Boolean
Boolean & AnalogForcing
z & Analog
z Forcing
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Trending Tools (ToolboxSTTM)
Features
Features
Automatic
AutomaticUpload
UploadofofCapture
CaptureBlocks
z
z Blocks
z Micro-second Resolution
z Micro-second Resolution
Drag
Drag&&Drop
DropofofVariables
VariablestotoTrender
z
z Trender
z Browser for Variables Selection
z Browser for Variables Selection
100’s
100’sofofSignals
Signalsper
perTrend
z
z Trend
- -Mask
Mask & Unmask of SelectedVariables
& Unmask of Selected Variables
z Video Type Forward-Reverse
z Video Type Forward-Reverse
Left-Right
Left-RightDrag
DragofofTime
TimeAxis
z
z Axis
Dual
Dual Cursor (Delta, Min, Max,Average)
z Cursor (Delta, Min, Max,
z Average)
z Stacked Traces
z Stacked Traces
Alarm
AlarmMessages
Messageson onTrip
TripTrend
z
z Trend
z Events Log Linked to Trend
z Events Log Linked to Trend
Export
Exporttoto.CSV
z
z .CSV
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Power
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Power Sources, Converters, Supplies
Internal Power Converters
Create 28Vdc for:
• Compact PCI® Controller(s)
• IONet Switches
• I/O Packs Power for Electronics
Field Power Sources 24Vdc Controllers
• 1 Source 125Vdc Switches
• 2 Sources 28Vdc
• 3 Sources 115/230Vac I/O Packs
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Power Sources and Supplies
Incoming Power Sources Termination Boards
z 24Vdc
z Power requirements vary according
z 125Vdc
to the application needs. Example:
z 115/230Vac
125Vdc field solenoids
z Any Redundant Combination
z Most power for transducers comes
Controller Power Supplies “through” the I/O Packs, is current
I/O
limited per point, and fed to the
Controller Pack transducers.
Second Power Supply
I/O Packs
Power Supply 175W z Single 16-32Vdc from Local Supply
Typically: 24Vdc or z Exception: Servo I/O Pack is 26-32Vdc
115/230Vac z Local Supply(s): 24Vdc, 115/230Vac, 125Vdc
z Hot-swap with Solid-state Breaker & Soft-start
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Mark VI vs. Mark VIe
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Mark VI VME Control Module
Mark VI e
I/O Processing Moved
to Termination Boards • Passive Termination Boards
• Latching “D” Type Connectors
• ID Chip on Each Board
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Mark VI vs. Mark VIe Architectures
Plant Data Highway (PDH) - Ethernet
Operator Stations
Maintenance Stations
Historian
Peer-to-Peer Communications
Unit Data Highway (UDH) - Ethernet with GE Controls
Mark VI Mark VI e
Control Module Control Module
Main Main
Processor Processor
Compact PCI
Cat 5 / Fiber
Switch
37 Pin
Cable
Termination Termination
IONet - 10MB Ethernet Board Board
"Internal" IO Bus IONet - 100MB Ethernet
"Internal" IO Bus I/O Pack
Processor &
Conditioning
Local or
Remote
Mounting
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Mark VI & Mark VIe Comparison
Mark VI Mark VI Enhanced Benefit
z VME Architecture z Compact PCI® Architecture z Change from Backplane to Network Based I/O
z No Remote I/O z Remote I/O z Lower Installed Cost & Long Term Maintenance
z Speed - Electronics z Speed - Electronics z Speed - Electronics
- 20MHz Backplane, Rated - 160MHz Backplane, Rated - Improved Performance
- 300MHz CPU, 16MB Flash - 650MHz CPU, 32MB Flash - Improved Performance
- 50Mhz I/O Card Processor - 266Mhz I/O Pack Processor - Improved I/O Performance (10ms to 1.8ms)
- 10MB Ethernet I/O - 100MB Ethernet I/O - Improved I/O Performance
z Speed – System z Speed – System z Speed – System
10ms Simpl, 20ms some TMR 10ms Any Configuration - Improved Performance in Redundant Applica.
z Simplex & TMR Redundancy z Simplex, Dual, and TMR z Flexible Redundancy & Cost Competitiveness
z Separate Main/Comm. Cards z Common Main/Comm Card z Improved Control Performance & Reliability
z On-line Repair per Card Rack z On-line Repair per I/O Pack z Better Maintainability, MTTR, Reliability
z 1 Link to Each I/O Card z 2 Links to Each I/O Pack z Improved Communications Reliability
z 12 bit Analog Outputs z 14 bit Analog Outputs z Improved Accuracy
z No LEDs at TBs for DI & DO z LEDs on I/O Packs for DI&DO z Better Maintainability
z No Temp Sensor at TBs z Temp Sensor on I/O Packs z Better Maintainability
z 125Vdc Electronics Power z 28/24Vdc Electronics Power z Improved Conformance to Industry Standards
z LAN Based Diagnostics z LAN & Wireless Diagnostics z Remote Access for Ease of Maintainability
z Limited Third Party Interfaces z Expanded Third Party Interf. z Better Systems Integration & More Versatile I/O
z NTP Time Synch 1-10ms z PTP Time Synch 1 micro-sec. z NTSB-Class Root Cause Analysis & Global SOE
Coordination
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Third Party Interfaces
& Time Synch
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Third Party Interfaces
Plant Data Highway HMI Interfaces
Ethernet TCP/IP z Modbus Serial/Ethernet Client/Server
HMI z GSM Ethernet TCP-IP Server
z OPC Ethernet Client / Server
z DNP 3.0 Serial/Ethernet Server
z PI Server Interface
Controller(s)
Dual Triple
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Third Party Interfaces
Feature Modbus GSM OPC DNP 3.0
Physical Layer Serial / Ethernet Ethernet Ethernet Serial / Ethernet
Client / Server Client / Server Server Client / Server Server
Time Tags
Alarm Queue & Commands
Alarm / Event Excep. Reports
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Time Synch Between Controllers
Wall Clock
Time Reference
Master
Clock
Plant Data Highway (PDH) - Ethernet
IRIG-B HMI
Server +/-1ms Time Accuracy & Time
Coherence to Time Reference
Time
Card
Mark VI e
"R" "S" "T"
Mark VI e Mark VI e Controller Controller Controller
U U U
C C C
Controller Coordination C C C
- UDH Communicator A A A
- Generates Process Alarms
- Designated Controller IONet IONet
- Supplies Initialization Data
- Keeps Master Clock
- Master for Control Data
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Backup
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Architecture
Plant Data Highway
Ethernet TCP/IP
HMI
I/O Pack General Purpose I/O
Discrete I/O
ToolboxSTTM I/O CPU Analog I/O
Supply Thermocouples
RTDs
Operator & Processor Communications
Maint. Station 2 Ethernet
Turbine-Specific I/O
100MB Ethernet
Data Speed & Overspeed
Unit Data Highway Acquisition
Servo Control
GE Control Systems Vibration & Position
Card Synchronizing
Controller Controller Controller Combustion Monitor
PLU and EVA
PS
Processor
Opt.
Term. Board
Dual Triple
Option Option
PS Terminal
Block
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Mark VIe Product Introduction Plan
SYSTEM
SYSTEMAPPLIACTION
APPLIACTION - -(First
(FirstCustomer/Article)
Customer/Article) ATQ
ATQ Ready
ReadytotoShip
Ship Std.
Std.Reqn.
Reqn.Cycle
Cycletime
time
____ __(define / code / test)
__(define / code / test)
• Balance of Plant - TMR control, New or CM&U (Lungmen) Sept’03 Apr ‘04 24 to 36 wks
• Balance of Plant - TMR control, New or CM&U (Lungmen) Sept’03 Apr ‘04 24 to 36 wks
•40 msec TMR Cont. (Compact PCI Controller CPU) (Lungmen has extended test in Salem into 1H’04)
•40 msec TMR Cont. (Compact PCI Controller CPU) (Lungmen has extended test in Salem into 1H’04)
•CI, RO, AI, AO, RTD, TC I/O
•CI, RO, AI, AO, RTD, TC I/O
•QNX6 runtime & ToolboxST
•QNX6 runtime & ToolboxST
• Balance of Plant - Dual control, New or CM&U Dec ‘03 Apr ’04 16 to 24 wks
• Balance of Plant - Dual control, New or CM&U Dec ‘03 Apr ’04 16 to 24 wks
• Aero Derivative Turbine - Dual control (AEP LM6000PC) Dec ’03 Mar ‘04 6 to 8 wks Kits only
• Aero Derivative Turbine - Dual control (AEP LM6000PC) Dec ’03 Mar ‘04 6 to 8 wks Kits only
• 10 msec Dual Cont. (first engine test on Houston test line Jan ’04)
• 10 msec Dual Cont. (first engine test on Houston test line Jan ’04)
• DIN Rail Terminal Boards
• DIN Rail Terminal Boards
• Servos, PTUR; (w/o PVIB and PPRO)
• Servos, PTUR; (w/o PVIB and PPRO)
• QNX6 runtime & ToolboxST
• QNX6 runtime & ToolboxST
• with PVIB and PPRO Jan ‘04 Jul ‘04
• with PVIB and PPRO Jan ‘04 Jul ‘04
• (LM6000PD) Jan ‘04 Aug ‘04
• (LM6000PD) Jan ‘04 Aug ‘04
• (LMS100) Sep ‘04 Dec ‘04
• (LMS100) Sep ‘04 Dec ‘04
• Aero Derivative Turbine / Compressor - TMR control (O&G Darwin ) Nov’ 03 Mar ’04 20 to 24 wks, skid
• Aero Derivative Turbine / Compressor - TMR control (O&G Darwin ) Nov’ 03 Mar ’04 20 to 24 wks, skid
• 10 msec TMR Cont., LM2500+ DLE Compressor Drive, integrated control skid
• 10 msec TMR Cont., LM2500+ DLE Compressor Drive, integrated control skid
• Second CPU for auxiliaries
• Second CPU for auxiliaries
• w/o PVIB and PPRO
• w/o PVIB and PPRO
• QNX6 runtime & ToolboxST
• QNX6 runtime & ToolboxST
• with PVIB and PPRO Jan ‘04 Jul ‘04
• with PVIB and PPRO Jan ‘04 Jul ‘04
• HD Turbine - TMR control, CM&U GT / ST (Lynn GT) Dec ‘03 Jul ‘04 14 to 20 wks
• HD Turbine - TMR control, CM&U GT / ST (Lynn GT) Dec ‘03 Jul ‘04 14 to 20 wks
• 40 msec TMR Control (Lynn site test Feb ’04 w/ MK6 VVIB & VPRO)
• 40 msec TMR Control (Lynn site test Feb ’04 w/ MK6 VVIB & VPRO)
• Uses Mark VI controller for VPRO and VVIB interface
• Uses Mark VI controller for VPRO and VVIB interface
• QNX6 runtime & ToolboxST
• QNX6 runtime & ToolboxST
• with PVIB and PPRO
• with PVIB and PPRO
• HD Turbine - Dual control, CM&U GT / ST Dec ‘03 Aug ‘04 12 to 24 wks
• HD Turbine - Dual control, CM&U GT / ST Dec ‘03 Aug ‘04 12 to 24 wks
• with PVIB and PPRO
• with PVIB and PPRO
• Simplex Turbine control, CM&U GT / ST Jun ’04 Dec ‘04 12 to 24 wks
• Simplex Turbine control, CM&U GT / ST Jun ’04 Dec ‘04 12 to 24 wks
• with PVIB and PPRO
• with PVIB and PPRO
• HD Turbine - TMR control, New Unit GT / ST Jun ’04 Dec ‘04 12 to 24 wks
• HD Turbine - TMR control, New Unit GT / ST Jun ’04 Dec ‘04 12 to 24 wks
• 3 ph. PT/CT - PLU (PGEN)
• 3 ph. PT/CT - PLU (PGEN)
• with PVIB and PPRO
• with PVIB and PPRO
• w/o Advanced I/O PAMB (acoustic monitor / lean blowout)
• w/o Advanced I/O PAMB (acoustic monitor / lean blowout)
• with ToolboxST for EX2100 & LS2100
• with ToolboxST for EX2100 & LS2100
• with Advanced I/O PAMB (acoustic monitor / lean blowout) TBD ~’05 TBD ~’05
• with Advanced I/O PAMB (acoustic monitor / lean blowout) TBD ~’05 TBD ~’05
•Next Gen HMI Dec ’04 Dec ’04
•Next Gen HMI Dec ’04 Dec ’04
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