g GE Energy

GEI-100608

Mark VIe Retrofits for

Industrial Steam Turbines
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 2005 by General Electric Company, USA.

All rights reserved..
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CIMPLICITY is a registered trademark of GE Fanuc Automation North America, Inc.
CompactPCI is a registered trademark of PICMG.
Ethernet is a registered trademark of Xerox Corporation.
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 Section Page
Acronyms and Abbreviations ...................................................................................... 2
System Overview ........................................................................................................ 3
I/O Interface ................................................................................................................ 4
Control Functions ........................................................................................................ 7
Protection .................................................................................................................. 11
Accessory Subsystems............................................................................................... 13
Operator and Maintenance Tools .............................................................................. 14
Operator Interface ....................................................................................... 14
Software Maintenance Tools (ToolboxST) ................................................. 15
Diagnostics.................................................................................................. 17
Packaging .................................................................................................................. 18
Codes and Standards.................................................................................................. 19
Control Drawings ...................................................................................................... 20

Safety Symbol Legend

Indicates a procedure, practice, condition, or statement that,

if not strictly observed, could result in personal injury or
death.

Indicates a procedure or condition that, if not strictly

observed, could result in damage to or destruction of
equipment.

Note Indicates an essential or important procedure or statement.

Acronyms and Abbreviations

CT Current transformer, senses the current in a cable
DCS Distributed Control System, for the balance of plant and auxiliary equipment
DNP Distributed Network Protocol
GSM GEDS Standard Message Format
HMI Human-Machine Interface, usually a pc with CIMPLICITY software
IPL Inlet Pressure Limiter
LVDT Linear Variable Differential Transformer
OPC OLE for Process Control
PDH Plant Data Highway, links HMIs to servers and viewer
PPI Proportional Plus Integral
PT Potential Transformer, senses the voltage in a cable
RTD Resistance Temperature Device, senses temperature in the process
SOE Sequence of Events, a record of high-speed contact closures
UDH Unit Data Highway, links the controllers to the HMI servers

2 • Mark VIe Retrofits for Industrial Steam Turbines GEI-100608 Application Overview
System Overview
Mark VIe, part of the GE family of turbine controls, is applied on industrial steam
turbine generator and mechanical drives, as well as utility steam, gas turbine, and
balance of plant applications.
This flexible platform can be applied as a simple governor for straight condensing,
single-automatic, and double-automatic extraction units, can be expanded to include
protection systems, monitoring systems, and auxiliary systems. Generator controls
such as synchronizing and var/power factor control are frequently included, and
compressor drives commonly include anti-surge protection, valve sequencing and
monitoring of the compressor proximitors, and resistance temperature devices
(RTDs).
I/O can be distributed The control is particularly well-suited to retrofit applications with 100% networked
anywhere in the plant to I/O that can be distributed anywhere in the plant to integrate both unique turbine
integrate both unique turbine devices such as bi-polar servos and general-purpose sensors such as extraction
devices and general-purpose pressure transducers or even drive old annunciators or motor control center panels in
sensors. remote locations. I/O networks are 100 MB Ethernet, available as Category 5 or fiber
in any redundancy configuration (simplex, dual, or triple).
Ethernet also provides for the I/O networks, peer-to-peer communication between
GE turbine and generator controls, and distributed control system (DCS)
communications. Standard 1 ms Sequence of Events (SOE) is provided for all
contact inputs. Time synchronization is available to synchronize network controls, as
well as local controls and remote time sources.

Plant Data Highway

Ethernet
Operator &
Maintenance
Stations
Unit Data Highway
Ethernet
Controller(s)

I/O Network - 100MB Ethernet

Speed Servos Vibration Pressure RTDs TC’s Auxiliaries

& Thrust Driven Load
• Generator
• Compressor
• Pump

Remaining Process
• Balance of Plant

Control System Overview

GEI-100608 Application Overview Mark VIe Retrofits for Industrial Steam Turbines • 3
I/O Interface
A CompactPCI® based controller communicates with networked I/O over single or
multiple Ethernet networks. The controller rack consists of a main processor and
one or two power supplies. A QNX® real time, multitasking operating system is used
for the main processor and I/O. Application software is provided in a configurable
control block language and stored in non-volatile memory. It conforms to IEEE-854
32-bit floating point format.
IONet is a dedicated, full-duplex, point-to-point protocol that provides a
deterministic, high-speed 100 MB communications network suitable for local or
remote I/O with a fiber interface. It is used to communicate between the main
processor(s) and networked I/O packs.
Each I/O pack is mounted on a board with barrier or box-type terminal blocks (see
figure below). The I/O pack contains two Ethernet ports, a power supply, a local
processor, and a data acquisition card. Computation power grows as I/O packs are
added to the control system, enabling an overall control system frame rate of 10 ms
in simplex, dual, or triple. Because some process subsystems require faster
execution, the local processors in each I/O pack execute algorithms at even higher
rates.

• Dual 100MB
• 100 MB full-duplex ports
• Online repair per I/O pack
• Operation – 30º C (86º F) to 65º C (149º F)
• Accuracy – 30º C (86º F) to 65º C (149º F)
• I/O packs rated Class 1, Div. 2
• Ambient temperature sensor
• LEDs: power status and attention
• LEDs: Ethernet link-connected and communication-active
• LEDs: application-specific
• Processor: 32 Bit RISC CPU 266MHz
• Infrared transceiver: low-level diagnostics, monitor I/O, set
host / function names, error status
• Power: 28 V dc (typical)
• Internal solid-state circuit breaker and soft start

I/O Pack on Barrier Type Terminal Board

Valve Interface - Software regulates the control valve loop with a direct interface
to the servo valve actuator and the Linear Variable Differential Transformer (LVDT)
valve position feedback. Bi-polar current outputs are provided for 10, 20, 40, 80, and
120 mA ranges. A 7 Vrms, 3.2 kHz excitation signal for the LVDT is provided by
the turbine control, and the LVDT feedback is 0 to 7.0 Vrms position feedback. Also
provided are 0 to 20 mA and 0 to 200 mA outputs for interface to I/P transducers or
valve positioners.

4 • Mark VIe Retrofits for Industrial Steam Turbines GEI-100608 Application Overview
 Speed Control Inputs - Three passive, magnetic, speed-sensor inputs (2-14 kHz)
are provided. The median value is used for speed control and primary overspeed
protection. Circuit sensitivity allows detection of 2 rpm speed on a 60-tooth wheel to
determine whether the turbine is stopped or on turning gear.
Emergency overspeed protection is provided by either a mechanical overspeed bolt
or a separate set of magnetic speed sensors, which are monitored by a separate and
independent emergency overspeed module. Diagnostic tests of the emergency
overspeed module can be started and monitored from the operator interface or from a
plant DCS while the turbine is running or shutdown.
Synchronization - Automatic synchronizing is available through single-phase
potential transformer (PT) inputs from the generator and line. The control matches
the turbine speed to the line frequency and the generator and line voltages. An
automatic command is issued to close the breaker when it is predicted to close within
the phase-slip window. A normally open contact on the breaker (not an auxiliary
relay) is monitored to measure the actual breaker closure time used to update the
database. Manual synchronizing is provided from a synch scope display on a
Human-Machine Interface (HMI).
Shaft Voltage and Current Monitor - Electrical current flow can damage the
bearing. This is usually due to a static voltage buildup caused by water droplets
being thrown off the last stage buckets in steam turbines or to ac voltage on the shaft
caused by ac ripple on the dc generator field. Voltage can build up across the oil film
of bearings until a discharge occurs. Repeated discharge and arcing can cause a
pitted and roughened bearing surface that eventually fails through accelerated
mechanical wear. The turbine control can continuously monitor the shaft to ground
voltage and current and alarm excessive levels. Test circuits are provided to check
the alarm functions and the continuity of wiring to the brush assembly mounted
between the turbine and the generator.
Analog I/O - All inputs can monitor 4-20 mA (250 ohms) that can be configured for
self-powered, differential inputs, or as sensors that use a +24 V dc supply from the
There are10 analog inputs
turbine control. Two of the inputs are designed for 0-1 mA inputs with 5,000 ohm
and two analog outputs per
input impedance, and eight of the inputs are designed for +/-5, 10 V dc inputs. Each
I/O pack
set of two analog outputs consists of one 4-20 mA output (500 ohms maximum) and
one output that can be configured for either 4-20 mA output or 0-200 mA output (50
ohms maximum).
Contact Inputs - All contact inputs are optically isolated and time-stamped to
There are 24 contact inputs within 1 ms. This built-in SOE monitor is observed with a HMI operator /
per I/O pack, as well as maintenance leave station. Dry contacts are powered from a floating 125 V dc
standard 1 ms SOE time supply from the control, which is fuse-isolated and current-limited in the turbine
stamps per point. control. Optional 24 Vdc, 90-132Vrms, 190-264Vrms (47-63Hz) contact input
monitoring is also available.
There are 12 magnetic relays Contact Outputs - Plug-in type magnetic relays provide a dry, form C contact
with form C contacts per I/O output from each relay.
pack.

GEI-100608 Application Overview Mark VIe Retrofits for Industrial Steam Turbines • 5
 Proximitor® Inputs - A direct interface is provided from the turbine control to
Bently-Nevada proximitors for vibration protection, thrust wear protection,
differential expansion, and eccentricity monitoring. The 1X and unfiltered vibration
levels and the 1X vibration phase angle display, with -24 V dc supplied from the
ISTC to each Proximitor. The composite and 1X vibration levels also display, as well
as the 1X phase angle. An active isolation amplifier is provided on each terminal
board to buffer the sensor signal from the BNC connectors. These connectors can be
used to access real-time data by remote vibration analysis equipment.
Thermocouple Inputs - Each I/O pack contains 12 thermocouples that can be
grounded or ungrounded. Software linearization is provided for type E, J, K, or T
thermocouples.
RTD Inputs - The eight RTD inputs in each pack can be grounded or ungrounded,
and software linearization is provided for 10 ohm copper, 100/200 ohm platinum, or
120 ohm nickel RTDs.
Three-phase PT and CT monitoring - The turbine control provides a direct
interface to optional, three-phase potential transformers (PT) from the generator and
line, and current transformers (CT) from the generator, including the neutral.
Megawatts, VARs, and power-factor values can be calculated from the PT and CT
inputs, then used as feedback for control functions.

6 • Mark VIe Retrofits for Industrial Steam Turbines GEI-100608 Application Overview
Control Functions
Each retrofit is reviewed for Turning Gear Control - The Mark VIe can interface with the turning gear system
auto-turning gear control or in either a manual or an automatic mode. In manual mode, the operator interface
manual engage from the engages the turning gear. In automatic mode, the turning gear is automatically
control room. engaged when the turbine speed is below a safe engaging speed.
Speed Control - The speed control system controls the turbine’s speed and load by
operating in response to its actual speed signal and called-for speed reference.
Passive magnetic-type probes are used in conjunction with a multi-toothed wheel on
the steam turbine shaft to sense rotational speed. Speed control prior to generator
synchronization is Proportional Plus Integral (PPI). After synchronization, the
control is proportional only.
Isochronous Control - In some applications, a unit is required to either operate
under isolated conditions continuously or to occasionally maintain plant frequency.
Minor variations in desired Once placed in service (usually from a tie-line status contact), the isochronous speed
plant frequency can be control function resets speed to its setpoint following load variations by
obtained by adjusting the automatically manipulating the load setpoint. It maintains a constant steady-state
speed setpoint. speed, which eliminates the need to continuously change the load setpoint to match
the load being carried.
Speed Wobulator - A wobulator in the speed control slowly varies turbine speed
above and below the speed setpoint. This prevents the turbine from running at a
constant speed near critical bucket resonances.
Speed /Frequency Matching - The speed-matching function sets the steam
turbine at synchronous speed at the completion of the start-up routine.
Synchronization - Automatic and manual synchronization, as well as
synchronization check protection, are available.
• Automatic Synchronization is performed with phase-slip windows in the
control modules. The control system matches speed and voltage, and issues a
command to close the breaker based on a calculated breaker closure time.
Diagnostics monitor the actual breaker closure time and self-correct each time
the breaker closes. A monitor mode allows automatic speed and voltage
matching, but inhibits closing the breaker for the operator’s inspection.
• Manual Synchronization can be initiated by operating a RAISE/LOWER load
setpoint command either on the generator control panel or from the turbine
control synchronization screen located on the operator interface.
• Synchronization Check Protection, performed in the protection <P> module,
provides backup to the automatic and manual synchronization systems.
When the unit is synchronizing, Load Control - The load setpoint is an open-loop command for the control valves.
the load setpoint also functions The name implies that it is load control; however, it can only contribute to the
as a fine-speed adjustment. demand for steam flow.

GEI-100608 Application Overview Mark VIe Retrofits for Industrial Steam Turbines • 7
Software regulates the valve
Valve Control - Valve interface is implemented with LVDT/R and servo loops or a
reference and the position 4-20 mA valve interface. Each interface includes an auto-calibrate display for the
feedback. valves and hardware diagnostics.

• Main Stop Valve(s), which are solenoid-operated, allow the turbine control
valve(s) to be isolated from the high-pressure steam. They also provide, in
conjunction with the control valve(s), redundant protection against overspeed
through two independent lines of defense.
• Inlet Control Valve(s) regulate the high-pressure steam flow into the turbine
and respond to speed/load control commands.
• Extraction Control Valve(s) regulate the steam flow into or out of the turbine
down stream of the inlet control valve by responding to pressure and speed/load
control commands.
Automatic Extraction - The extraction control algorithm balances the turbine
under various conditions. Mark VIe provides a bumpless transfer between operating
modes by calculating the inlet pressure setpoint required to maintain the current inlet
valve position. For example, to transfer from speed/load and extraction to inlet
pressure and extraction control, the operator selects the desired mode.
Single automatic extraction units are normally used to control speed/load and one
process pressure simultaneously. Both the inlet and the extraction control valves
respond to commands to change the steam flow equally to each section to control
speed/load without affecting extraction flow, such as pressure. The inlet and
extraction control valves manage extraction pressure without affecting speed/load.
This is accomplished by moving the valves in opposite directions in such proportions
that the load change in the inlet section is balanced by an opposite load change in the
exhaust section. The difference between the inlet and exhaust steam flow is the
extraction steam.
• Extraction Flow control. Under certain plant conditions, it is desirable to
operate the turbine extraction at a fixed flow rather than controlling the
extraction pressure. In this mode of operation, the extraction pressure setpoint is
changed to a level higher than the stage pressure, and the flow control setpoint is
reduced to fix the extraction flow reference signal. Extraction flow remains
constant in this operating mode if extraction header pressure is maintained by
another plant control system. This method allows the control valves to reduce
flow if the stage pressure goes above the turbine maximum design.
• Double Automatic Extraction. Speed/load and two extraction process
pressures are controlled simultaneously. In some cases, such units are used to
control three process pressures, two extractions, and either inlet or exhaust
pressure (example: non-condensing).
Inlet Pressure Control - This mode allows the steam turbine to control inlet
header pressure. The standard controller is a proportional + lag with a 5% regulation.
The inlet pressure controller can be placed in service at any time after the generator
breaker is closed and when there is approximately 20% load on the unit. The
controller calculates a pressure setpoint that allows a bumpless transfer from load to
inlet pressure control. Most applications allow a pressure control setpoint to be
adjustable from 40% to 105% of design. The controller has a lower control valve
position limit equal to approximately 3% load to ensure that the control action does
not allow the turbine to come offline due to reverse power.

8 • Mark VIe Retrofits for Industrial Steam Turbines GEI-100608 Application Overview
Sliding pressure control is not Sliding Pressure - Sliding pressure control manipulates the pressure setpoint to
generally implemented on maintain the control valve position between 89 and 95%. This provides the least
industrial units with power amount of pressure drop across the control valves. At minimum roll off inlet
boilers. pressure, the control valves slowly open and eventually maintain a fully open
position as the pressure and setpoint increases to rated conditions.
Inlet pressure limiting is Inlet Pressure Limiting - This can be performed as a function of a fixed level or a
independent from inlet decreasing rate. Both provide closed loop control on inlet pressure, reducing inlet
pressure control. flow for abnormal decreases in inlet pressure.
• Fixed Limiting control is implemented only with a proportional plus lag (droop
control) algorithm. The inlet pressure limiter setpoint is subtracted from the inlet
pressure signal, then the net error is multiplied by the appropriate gain (a
function of regulation, normally 10%, and the pressure control range) to produce
the control signal. The setpoint, usually adjusted below the header pressure, is
always in a standby mode ready to control pressure if the header pressure decays
to that level. The newer design of Inlet Pressure Control with a bumpless
transfer is sometimes more desirable to use inlet pressure control with logic to
place it in service when the header pressure drops a certain amount below
header pressure.
• Rate Limiting is recommended to protect the turbine against mechanical
damage from water induction caused by carryover on turbines operating from
unit boilers, or on header systems where rapid decay of inlet pressure is
possible. This subsystem also decreases the rate at which the inlet pressure
decreases and increases the chance of recovering before a boiler/turbine trip is
necessary.
The rate-sensitive inlet pressure limiter (IPL) is a control subsystem set up to remain
in standby (even during a startup), responding when the rate of decrease in the inlet
pressure exceeds a preset value. It operates by placing an upper limit on the inlet
control valve position, or speed/load signal. This limiting action increases, and the
control valves eventually close to the floor limit if the rate of decrease in inlet
pressure exceeds the preset value. The time required for this to occur depends on the
amount that the rate exceeds the preset value. The floor limit prevents closing of the
inlet control valves below the position necessary to pass minimum flow. The main
requirement needed is the rate of decay in pressure (psig/min) the boiler can
withstand without causing a high-water level.
Exhaust Pressure Control - This is a closed loop proportional control function
with adjustable regulation. For extraction units, it acts on a set of extraction or
admission valves to maintain the pressure near the setpoint. If there is no extraction
requirement, it will act on the inlet control. The required interaction between the
extraction or admission valve and the inlet valve is included. Exhaust pressure
control must be enabled by the operator. The standard regulation is 5%. Placing the
control function in service does not require the operator to adjust the setpoint prior to
the exhaust pressure control selection. The control system calculates the correct
setpoint based on maintaining the control valve position at the time of transfer.
Megawatt Control - A megawatt setpoint is compared against a megawatt
feedback value. The output of the deadband controller block produces adjustments to
the load setpoint (raise/lower), depending on the error. The Mark VIe can directly
control generator MW or net MW if the MW input is from the tieline. A second
controller block can be added to select control for either one. In single/double auto
applications, one of the selected modes must be power. Bumpless transfer into MW
control is accomplished by presetting the megawatt setpoint to the present running
MW level. This preset is done as single shot upon selecting MW control.

GEI-100608 Application Overview Mark VIe Retrofits for Industrial Steam Turbines • 9
 Power Factor Control - A power factor setpoint is compared against a feedback
from a transducer or the watts/VARs calculation. The error is used to energize
raise/lower relays feeding the exciter regulator. Pulsing is provided for slow, fine
correction of small errors. This relay interface is the same as required for the voltage
matching option. In addition, power factor is calculated from watts and VARs.
VAR Control - A VAR setpoint is compared against a scaled 4-20 mA VAR
feedback from a transducer. The error is used to energize raise/lower relays feeding
the exciter regulator.
Auxiliary Systems - The Mark VIe can control some auxiliary systems, in
addition to its primary function of controlling and protecting the steam turbine.
These include condenser level control, lube oil temperature control, steam seal
pressure control, water spray valve, and turbine auxiliary motors.

10 • Mark VIe Retrofits for Industrial Steam Turbines GEI-100608 Application Overview
Protection
The protection system detects undesirable or dangerous operating conditions with the
turbine generator, takes appropriate trip actions, then reports back to the operator.
The complete protective system consists of sensors, input modules, signal
processing, software logic, output modules, relay outputs, and redundant electronic
trip devices (ETDs) in the hydraulic system. Certain parts of this system can be
tested online or offline.
A trip action is initiated by
• An analog signal having exceeded a predetermined limit (such as an axial
position probe)
• A sensor detecting an out-of-limits condition (such as a low lube oil pressure
switch).
The trip action is accomplished by interrupting the current to the ETDs, which will
port oil from the stop valve actuators, causing them to close. In addition, action is
taken by the controller to close the control valves. The trip action is completed by
displaying the cause of the trip at the operator interface.
Under normal operation, the Overspeed Protection - The overspeed protection system protects the steam
speed/load loop controls the
turbine against possible damage caused by overspeeding the turbine shaft. The
shaft’s speed. This overspeed trip
system is activated only if that primary electronic overspeed system is part of the normal speed control system and
control loop failed. uses magnetic pickups to sense turbine speed, speed-detection software, and
associated logic circuits. The overspeed trip level is set by adjusting constants.
The backup overspeed protection system (emergency overspeed – EOS) is a triple
redundant system consisting of three separate and independent I/O Packs on separate
terminal boards. Three magnetic speed sensors, separate from the primary sensors,
are compared with the EOS setpoints. When the turbine speed exceeds these settings,
the ETDs are tripped directly with relays independent from the primary protection
system.
Vibration Protection - The control system monitors the turbine and driven-load
vibration levels. High vibration levels can indicate rotor imbalance, long-term
degradation, or imminent catastrophic failure. Vibration protection is activated if
vibration amplitude reaches a preset level. The control system monitors the levels,
issues alarms, and takes responsive action up to and including an emergency trip of
the turbine.
Axial Position - The axial position channel measures the axial position of the
turbine shaft at the thrust-bearing casing. A mounted probe observes the motion of a
Each probe can cause a wear collar on the turbine rotor. This system uses two or three non-contacting probes, as
alarm. well as Proximitors. Two alarm levels for each axial direction (active and inactive)
and probe failure circuitry are provided. The levels are adjusted to provide a wear
alarm at one level and a turbine trip plus alarm at a higher level. The probes are used
in a voting logic where two probes must indicate a trip condition before the unit will
trip.
Differential Expansion - Turbine rotors usually respond to steam-to-metal
temperature mismatches and temperature changes faster than the turbine shells. This
is caused by the rotor’s smaller mass, the higher heat transfer coefficients, and their
almost total immersion in the steam path. Because the axial clearances between the
rotating and stationary parts are necessarily small, the changes in metal temperatures
that occur while loading and unloading the unit result in expansion differences that
could be large enough to cause internal rubbing.

GEI-100608 Application Overview Mark VIe Retrofits for Industrial Steam Turbines • 11
 The turbine shell is free to axially expand away from where it is keyed to the
foundation, and the turbine rotor is free to axially expand away from its thrust
bearing. This system uses a non-contacting probe(s) and proximitor(s), resulting in
alarm, trip, and fault detection for excessive expansion in either direction.
Eccentricity - The eccentricity measurement is an indicator of the rotor’s bow. A
non-contacting detector is generally mounted in the front standard, at least 18 inches
away from the bearing centerline. The calculation of peak-to-peak eccentricity is
made while the turbine is on turning gear, and calculated once per revolution as
determined by a reference probe. The system provides alarm and fault indications.
Reference (Keyphasor) Probe - The Keyphasor signal provides a once-per-turn
shaft reference mark for speed and phase angle measurements. The reference signal
is often used for speed, reference for eccentricity, turning gear engagement, and
balancing.
Functional Tests - Functional tests verify the condition of critical protective
devices, elements, and circuits in the control system. Each test must be performed
If the control system fails to pass
a test, the probable source of
successfully at the intervals outlined. Failure to test at the suggested intervals or
trouble displays. failure to correct a problem following a failed test compromises the level of turbine
protection provided by the control system. Each test is accessed and run through its
own display on the operator interface.
Offline tests:
Offline tests include the following:
• Electrical Trip Devices ETD-1 and ETD-2
ETD-1 and ETD-2 are available on medium steam units shipped after 1981. On units
prior to 1981, Mark I and Mark II logic can be provided if there is an existing
exercisor at the turbine from standard. The ability to test the ETD will be discussed
during the controls finalization meeting.
• Primary overspeed trip subsystem
• Emergency overspeed trip subsystem. This is set slightly higher than the
Mechanical bolt setpoint. When tested, the actuation point is reduced by 8%
below the setpoint.
• Mechanical overspeed test (on units with mechanical bolts)
Online tests:
Online tests include the following:
• Main stop valve(s) (solenoid-operated)
• Primary overspeed trip subsystem
• Emergency overspeed trip subsystem
• Shaft voltage monitor

12 • Mark VIe Retrofits for Industrial Steam Turbines GEI-100608 Application Overview
Accessory Subsystems
Gland Exhausters - This feature allows the control system to monitor the blower
status, as well as provide remote start/stop capability.
As an option, the control AC Lube Oil Pump Interface - The AC motor-drive lube oil bearing pumps are
system can provide remote identical. They serve as the main and primary backup pumps that supply oil to the
start/stop and monitoring turbine generator shaft bearings (may supply seal oil on an hydrogen generator).
capability, depending on the These pumps operate during turbine startup, shutdown, normal operation, and on
existing equipment. turning gear.
Hydraulic Fluid Pump Motor Control - The standard is for the control system to
only monitor pump status. An option is for the control system to provide remote
start/stop and monitoring.
Steam Seal Pressure Control - The shaft sealing system is required to seal the
steam turbine casing so air does not leak into the subatmospheric sections of the
turbine. Units with local pneumatic controls can be modified to be controlled by the
Mark VIe. This option is not available on units with the mechanical steam seal
pressure control.
Steam Seal Temperature Alarm - This feature monitors steam seal temperature
to prevent differential thermal expansion, thermal fatigue, and possible wet steam. A
thermocouple is used for monitoring the steam seal temperature. The Mark VIe
compares the steam seal temperature against limits and when those limits are
exceeded, an alarm is generated to inform the operator.
Vapor Extraction Blower Motor Control - This design standard defines how the
vapor extraction blower motor(s) should be operated. The standard feature is for the
control system to only monitor blower status. An optional offering is for the control
system to provide remote start/stop.

GEI-100608 Application Overview Mark VIe Retrofits for Industrial Steam Turbines • 13
Operator and Maintenance Tools

Operator Interface
The HMI includes a pc with a Microsoft® Windows®-based operating system,
client/server capability, a CIMPLICITY® graphics display system, and software
maintenance tools (ToolboxST™). It can be applied as:
• Primary operator station for one unit or the entire plant
• Maintenance station gateway
• Engineer(s) station
• Gateway for communications: Modbus, GSM, OPC, DNP 3.0, PI
All local and remote data in the The HMI can be re-initialized or replaced with the process running without
Mark VIe is accessible for
impacting the control system. It communicates with the main processor board in the
screens with high-resolution time
tags for alarms and events. Mark VIe controller(s) through the Unit Data Highway (UDH), and to third-party
control and monitoring systems via the Plant Data Highway (PDH).

Operator Interface Graphics

14 • Mark VIe Retrofits for Industrial Steam Turbines GEI-100608 Application Overview
 System (process) alarms for fault conditions are time-tagged at frame rate in the
controller(s), then transmitted to the HMI alarm management system. System events
are time-tagged at frame rate, and SOE for contact inputs are time-tagged at 1ms in
the I/O packs. Alarms can be sorted according to ID, Resource, Device, Time, and
Priority. Operators can add comments to alarm messages or link specific alarm
messages to supporting graphics.
A standard alarm/event log stores data for 30 days and can be sorted in chronological
order or according to the frequency of occurrence. In addition, a trip history is
provided that stores the key control parameters and alarms / events for the last 30
trips. This includes up to 200 alarms, 200 events, 200 SOE messages, and analog
data before and after the trip.
Data is displayed in English or Metric engineering units with a one-second update
rate and one second to repaint a typical display graphic. Operator commands can be
issued to increment/decrement a setpoint; a numerical value can be entered for a new
setpoint.
Security for HMI users is important to restrict access to certain maintenance
functions, such as editors and tuning capability, and to limit certain operations. A
system called User Accounts limits access to or use of particular HMI features.

Software Maintenance Tools (ToolboxST™)

The Mark VIe is fully programmable. Application software is maintained by factory-
supplied automation tools that select proven GE control and protection algorithms
and integrate them with the I/O, sequencing, and displays for each application.
Multiple block libraries contain general-purpose blocks, math blocks, macros (user
blocks), and application-specific blocks.
Changes to the application software can be made with multi-level password
protection, then downloaded to the controller(s) while the system is running without
Application software is stored in
non-volatile memory.
rebooting the main processors. In redundant control systems, the application
software in each controller is identical, and is represented as a single program to
maintenance personnel. Changes are downloaded to redundant controllers;
diagnostics monitor any discrepancies between the controllers.
Application software is started sequentially, with dynamic data shown in function
block and ladder diagram formats. Maintenance personnel can add, delete, or change
analog loops, sequencing, I/O assignments, and tuning constants. To simplify
editing, drag-and-drop data points from one block to another. You can also drag-and-
drop data points from the software diagrams onto trends. Other features include
Boolean (digital) forcing, analog forcing, and trending at the frame rate of the
software execution.
Documentation, created directly from source code, can be compiled and printed at
the site. This includes the application software diagram, I/O assignments, the settings
of tuning constants, and such. The software maintenance tools are available for use
in the HMI or as a separate software package on a Windows-based pc.

GEI-100608 Application Overview Mark VIe Retrofits for Industrial Steam Turbines • 15
 Features
- Field-programmable
- Floating Point
- Dynamic Data Display
- Drag & Drop Points
- Math Blocks
- Macros (User Blocks)
- Function & Ladder Blocks
- Multiple Block Libraries
- Editors for:
- Application Software
- I/O Assignments
- Tuning Constants
- Password Protection
- Boolean & Analog Forcing

Editing Tools (ToolboxST TM)

Features
- Automatic Upload of Capture Blocks
- Micro-second Resolution
- Drag & Drop of Variables to Trender
- Browser for Variables Selection
- 100s of Signals per Trend
- Mask-Unmask of Selected Variables
- Video Type Forward-Reverse
- Left-Right Drag of Time Axis
- Dual Cursor
- Delta, Min, Max, Average
- Stacked Traces
- Alarm Messages on Trip Trend
- Events Log Linked to Trend
- Export to .CSV

Trending Tools (ToolboxST TM)

16 • Mark VIe Retrofits for Industrial Steam Turbines GEI-100608 Application Overview
 Diagnostics
High/low (hardware) limit checking is provided for each analog input. These non-
configurable limits are selected to be outside the normal operating range but inside
the linear hardware operational range (before the hardware reaches saturation).
Diagnostic messages for hardware limit checks and all other hardware diagnostics
for the board are accessed with the software maintenance tools. A composite
diagnostic alarm state is provided in the database for each I/O pack, and a separate
logic state is provided to indicate a high/low (hardware) limit fault of any analog
input or the associated communications for that signal.
Diagnostic and system (process) alarms are time-stamped in the controller(s) and
transmitted to operator and maintenance stations. Communication links to a plant
DCS can contain both the software (system) diagnostics and composite hardware
diagnostics.
Diagnostic LEDs are provided on I/O packs as previously shown for the Analog I/O
pack. Standard LEDs indicate: power status, attention (abnormality detected),
An electronic ID on each board
provides board name, revision,
Ethernet link-connected, and Ethernet link-communicating. LEDs on discrete I/O
and a unique serial number. packs also indicate the status of each point. When power is applied to the I/O
processor, it reads the terminal board ID, the application card, and itself. It then uses
this information for a start permissive, diagnostics, and system asset management.
Since the terminal boards can be mounted remotely, local temperature sensors
monitor the temperature at each I/O pack. Excessive temperature causes an alarm
message. The alarm state and current temperature value are available for display and
for use in the application software.

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

Activity / Status Log

I/O Pack Diagnostics

GEI-100608 Application Overview Mark VIe Retrofits for Industrial Steam Turbines • 17
Packaging
Cabinet access Front-door access only
Cabinet NEMA 1 convection cooled, similar to IP-20
Cable entrance Top and/or bottom
Dimensions Simplex & Dual: 35.4” W x 91.5” H x 35.4” D – TBs on side walls
(900 mmW x 2324mm H x 900mm D)
63.0” W x 91.5” H x 23.6” D – TBs on back base only
(1600mmW x 2324mm H x 600mm D)
Triple Redundant: 53.3” W x 91.5” H x 35.4” D – TBs on side walls
(1350mm W x 2324mm H x 900mm D)
102.4” W x 91.5” H x 23.6” D – TBs on back base only
(2600mm W x 2324mm H x 600mm D)
E-coat primed, pebble gray – RAL 7032
Door, rear wall, roof: powder painted
Locks Lockable door
Material Sheet steel
Terminal blocks (24) point, barrier type terminal blocks that can be unplugged for maintenance. Each screw
2
can terminate (2) #12 AWG (3.0mm ), 300 v insulated wires.
Weight Simplex & Dual: 1200 lbs. (544 kg) Triple Redundant: 2500 lbs. (1134 kg)
Temperature Operating: 32 to 113° F 0 to 45° C
Storage: -40 to 158° F -40 to 70° C
Heat loss Simplex & Dual: 700 W Triple Redundant: 1000 W
Humidity 5 – 95% non-condensing

18 • Mark VIe Retrofits for Industrial Steam Turbines GEI-100608 Application Overview
Codes and Standards

Safety Standards EN 61010-1 Safety Requirements for Electrical Equipment for

Measurement, Control, and Laboratory Use, Part 1: General
Requirements
CAN/CSA 22.2 No. 1010.1-92 Safety Requirements for
Electrical Equipment for Measurement, Control, and
Laboratory Use, Part 1: General Requirements
ANSI/ISA S82.02.01 1999 Safety Standard for Electrical and
Electronic Test, Measuring, Controlling, and Related
Equipment – General Requirements

Printed wire board assemblies UL 796 Printed Circuit Boards

ANSI IPC Guidelines
ANSI IPC/EIA Guidelines

Electromagnetic Compatibility (EMC) EN 55081-2 General Emission Standard

EMC Directive 89/336/EEC as amended EN 50082-2 Generic Immunity Industrial Environment
by 92/31/EEC and 93/68/EEC EN 55011 Radiated and Conducted Emissions
IEC 61000-4-2 Electrostatic Discharge Susceptibility
IEC 61000-4-3 Radiated RF Immunity
IEC 61000-4-4 Electrical Fast Transit Susceptibility
IEC 61000-4-5 Surge Immunity
IEC 61000-4-6 Conducted RF Immunity
IEC61000-4-11Voltage Variation, Dips & Interruptions
ANSI/IEEE C37.90.1 Surge

Low-Voltage Directive 72/23/EEC EN 61010-1 Safety Requirements for Electrical Equipment for
Measurement, Control, and Laboratory Use, Part 1: General
Requirements

ATEX Directive 94/9/EC EN 50021 Electrical Apparatus for Potentially Explosive

Atmospheres

GEI-100608 Application Overview Mark VIe Retrofits for Industrial Steam Turbines • 19
Control Drawings
For multiple transducer applications IPCR
IP1 Median
Select IP
IP2

IP3

Manual Setpoint
KIPCR_H Max
Proportional + Lag IPCR_CMD
Signal Command
IP_P Ma Control
Scaling KIPC_H x KIPCR_L Min
KIP_D Out_RQ IPCR Preset Value
L69IPCR CHG L69IPCR Preset

Ref IPC
FB P+I Clamp
KIPC_L

IPC_L Min
KIPC_H

L43IPC_CMD

SPEED/LOAD
SPEED TPWR SELECT
CONTROL Valve
Linearizatio
Valve Ouput
n
Min TN_LD V1_STROKE V1_OUT
Select

LOAD LIMITER LLR

Valve Ouput
IP
IPL
LIMITER V1L_OUT

EXHAUST
PRESSURE EPC* For units with offchest valves
CONTROLLER

*Non-Condensing Units Only

Straight Condensing/Non-condensing Control

20 • Mark VIe Retrofits for Industrial Steam Turbines GEI-100608 Application Overview
 For multiple transducer applications
IP1 Median
Select IP IPCR
IP2

IP3
Manual Setpoint
KIPCR_H Max

Proportional + Lag IPCR_CMD Command

Signal Ma Control
Scaling IP_P KIPCR_L
KIPC_H x Min
IPCR Preset Value
KIP_D Out_RQ
Preset
L69IPCR CHG
Ref IPC

FB P+I Clamp

KIPC_L Min

SPEED TPWR SINGLE L69IPCR

CONTROL AUTO EXTRACTION
IPC_RQ
Valve
SAX_CMD SAX_STAT Linearizatio Valve Ouput
n V1_STROKE V1_OUT
V1_FLO_R
LOAD LIMITER LLR

Valve Ouput
V1L_OU
T
HP EXTRACTION HPXPC
CONTROL

For units with offchest valves

EXHAUST V2_FLO_R Valve

PRESSURE EPC*
Linearizatio Valve Ouput
CONTROLLER n V2_STROKE V2_OUT

*Non-Condensing Units Only

Single Automatic Extraction Control

GEI-100608 Application Overview Mark VIe Retrofits for Industrial Steam Turbines • 21
 For multiple transducer applications
IP1 Median
Select IP IPCR
IP2

IP3
Manual Setpoint
KIPCR_H Max

Proportional + Lag IPCR_CMD Command

Signal
IP_P Control
Scaling KIPC_H Max KIPCR_L
Min
IPCR Preset Value
KIP_D Out_RQ
Preset
L69IPCR CHG
Ref IPC

FB P+I Clamp

KIPC_L Min

SPEED TPWR DOUBLE L69IPCR

CONTROL AUTO EXTRACTION
IPC_RQ
DAX_CMD DAX_STAT Valve
Valve Ouput
Linearization
V1_STROKE V1_OUT
V1_FLO_R

LOAD LIMITER LLR

Valve Ouput

V1L_OUT
HP EXTRACTION HPXPC
CONTROL

For units with offchest valves

V2_FLO_R
LP EXTRACTION LPXPC Valve
CONTROL Linearization Valve Ouput
V3_FLO_R V2_STROKE V2_OUT

EXHAUST
PRESSURE EPC*
CONTROLLER
Valve
Linearization Valve Ouput
*Non-Condensing Units Only V3_STROKE V3_OUT

Double Automatic Extraction Control

g GE Energy General Electric Company

1502 Roanoke Blvd.
Salem, VA 24153-6492 USA
GEI-100608
050211

1 540 387 7000

www.geenergy.com