Nexus

User-Oriented Integrated Solutions

www.bhge .com
CONTENTS
System Overview 3

System Architecture 4

System Network 5

Nexus Hardware 6

OptimumC Software 12

Integrated Monitoring of Nexus and Mark VIe Systems 21

High Fidelity Simulation Technology 22

IntelliMax Energy Saving Navigation 23

ST600 Small Turbine Control Module 24

Automatic Plant Start-up and Shutdown System (APS) 26

DCS Comprehensive Diagnostic Services 28

System Platform Upgrade and Expansion Services 29

Maintenance/Yearly Package Services 31

System Overview

In today's competitive market environment, process Nexus Control System Features

industries demand a totally integrated control and
optimization solution that can increase productivity,
reliability, and quality while minimizing cost. The Performance
automation users are constantly searching for solutions Full redundancy of system
to improve their competitive edge and to enhance their architecture is designed to enhance
return on investment. reliability of control applications and
The Nexus control system is designed to meet these availability of the system
customers' needs by delivering operating efficiency
improvement, productivity gain, and unit reliability and Flexibility
availability enhancement, while providing overall cost
Simplified and standardized hardware
reduction during the lifecycle of the plant.
design provides ease of system
The distributed architecture of the Nexus Control System expansion
provides users with flexible system configuration,
meeting the requirements for system layout in different
applications while ensuring system reliability. The
component design and network redundancy guarantees Reliability
the operability of critical systems and control functions Wide applications and superior
in response to single or even multiple points of failure. performance have proven the reliability
of Nexus as a mature technology
in terms of structure, system and
software

Maintainability
Plug-and-play and hot swapping of I/O
modules and communication bus are
convenient for system maintenance

Installation
Bus architecture and modular design
facilitates ease of installation and
reduction of installation space

3
System Architecture
Control system failures can result in personal injury, loss
of production and equipment damage. This makes system
reliability an extremely important consideration when
choosing a control system. Nexus has been optimized and
engineered with special attention to system diagnostic and
redundancy features, which have proven to increase system
availability. In addition, Nexus can provide users with remote
diagnostic service. The Unit Data Highway (UDH) allows
control data, process information, operator and engineering
stations, and gateway functions to be fully shared on
a common network. The UDH network is a redundant
industrial Ethernet, and uses a separate, high speed serial
iLink IO network to collect plant information. Each controller
in the system is dual redundant and normally segregated
by process function, but closely integrated with its peers in
terms of data sharing.
The architecture distributes risk so the failure of any single
component does not affect the rest of the system. For
example, if a single controller fails, operation in other areas of
the plant will not be impacted. The distributed architecture
also gives users greater flexibility in system installation and
space utilization. Having the flexibility to distribute control,
I/O, and HMI functions to different areas of the plant allows
users to reduce the length of cable runs, minimize the
footprint of electronics rooms and cut down capital cost.

Large screen display

CAL OPU OPU OPU

Unit DCS network

Fieldbus (Profibus, FF, Hart)

Remote I/O
Xducer Detecter DAQ Valve Analizer

Industrial ST/Boiler/BOP
process Remote controller

4
System Network
The Nexus Control System backbone network is designed
with 100/1000Mbps high-speed industrial Ethernet switches
with redundant fault tolerance and standard GE EGD
protocol. The communication network of Nexus is provided
with a single-layered, peer-to-peer redundant network
structure that minimizes communication failure and
network congestion while enhancing network performance
and reliability. Plant Data Highway integrates Nexus Control
Systems from all units across the plant, and provides plant-
level unit load dispatching and performance optimization
using optimization software.
The Unit Data Highway provides superior reliability and
availability between the operator and control layers through
its double-ring high-speed Ethernet architecture, allowing
uninterrupted access to real-time process information,
alarms, and events.
The redundant Process I/O Link establishes a high-speed
data transmission between Local DCS and Remote I/O
stations and supports Precision Time Protocol system-wide
time synchronization. The transmission media is normally
Common systems that are shared between multiple units
can be placed on separate networks to allow individual unit
network without impacting common systems. The common
network connects to and communicates with the network
of individual units via a network bridge. Monitoring of the
common system by the operator can be accomplished on
operator stations on any network. Operation interlocking can
be established between two units for the common system,
with a designated unit being allowed to operate the common
system at one time. Each unit or the common system has its
own power system and separate network structure. Such
structure provides full isolation between the units and the
common system, providing extreme convenience for users
during blackout and maintenance.
Engineer Station/
Operator Station Historian Station Large Screen Display

twisted pair cable or fiber link for longer transmission

distance (up to two kilometers).

Optic Fiber Optic Fiber

Single-layered, peer-to-peer
redundant network structure

GTW1 GTW3
UDH
PDH

Redundant Common System Redundant

UDH PDH #1 Unit Network #2 Unit Network PDH UDH
Network

GTW2 GTW4

5
Nexus Hardware
Low Power Consumption Hardware
The hardware of Nexus provides greater reliability with a variety of
internationally renowned certifications. The entire system is a low power
consumption system.
The controller is < 10W and most of the I/O modules are < 3W in terms of
power consumption. Due to low power consumption, the Nexus cabinet
requires no forced cooling system, and all types of cabinet feature fanless
design providing a level of protection up to IP56. Reduced heat generation by
the Nexus Control System hardware not only improves system stability and
lifecycle, but also lowers maintenance workload for users significantly.

HMI Station
The Nexus Human Machine Interface (HMI) is used to view and control
information collected by the control system. Trending, alarm management,
and reporting functions are all available to plant operations using an HMI.
Nexus operator stations support operation, engineering configuration, and
maintenance functions from a single workstation. During failure of an operator
station, many control systems often impact operational capacity. Multiple
functions can be enabled on one Nexus workstation. Therefore, the loss of any
operator station will not impair proper operation and maintenance of entire
system.

6
Nexus Controller
The Nexus iDPU controller is an embedded computing
platform for the process control application software. The
controller is a standalone device which is directly secured to
the mounting plate of control cabinet without any backplane
bus or chassis. The iDPU controller provides real-time
two-way communications with Nexus I/O modules via the
intelligent I/O bus interface (iLink) beneath the module. The
controller is embedded with the QNX® Neutrino® real-time
multiple task operating system that enables high speed, high
reliability industrial process applications.
Features of iDPU Controller
• No backup battery required for memory retention
• Enhanced EMC capability with real board-level
electromagnetic compatibility
• Redundant 24 VDC power supply
• Redundant real-time industrial Ethernet interface
supporting 1000Mbps traffic rate
• 1ms time precision between system nodes; 0.1ms time
precision on I/O network
• Low power design with no need for fans
• QNX real-time operating system
• Multispeed processing, configurable processing cycle
20ms-60s
• Support of up to 56 field I/O modules
• Industrial enhanced casing with better dust protection
and corrosion resistance
• Integrated slim body design with small footprint; modular
structure for ease of use and maintenance
• Power indication, diagnostics and fault alarm
• Jumper-free configuration
Operating Environment
• Operating temperature: 0℃ ~ +60℃
• Storage temperature: -40℃ ~ +85℃
• Relative humidity: 5 ~ 95% (non-condensing)
• Greater computing power
• Precise and predictable real-time performance, with all
control applications completed within one processing
cycle
• 2000 algorithm configuration pages, with 512 modules
supported on each page
• Data scanning cycle for process I/O module: 20ms as a
minimum
• 1ms log resolution for high-speed event sequence,
with availability significantly enhanced by greater fault
tolerance
• Redundant high-speed serial network deployed
between controller and I/O module, with 2Mbps traffic
rate, precision timing protocol support, and hundred-
microsecond synchronization precision; shielded twisted
pair used as transmission media
• 1+1 fault tolerant design on controller, with dual
controllers online simultaneously, enabling zero
disturbance and “zero” delay handover between
master and slave controls
7
Features of Nexus Control Nexus I/O Module
System I/O Bus: Nexus I/O provides an economical, total process interface solution, with all the
• Direct communication between subsystems providing extreme reliability and flexibility
controller and I/O module
• Redundant communication for All types of industrial I/O
all I/O modules Most requirements are met using general-purpose I/O modules (AI, AO, DI, DO,
• Redundant power supply for all TC/RTD), dedicated DEH modules (MVP, MSP) and dedicated ETS modules (MLP),
I/O modules simplifying I/O design and implementation and minimizing the cost for spare
parts. This modular design can accommodate any size application and is easily
• High-precision time
expandable.
synchronization of +/-0.1ms for
I/O modules
Distributed I/O with enhanced design and flexibility of
• Traffic rate up to 2Mbps assembly
• Overall communication The modules can be distributed on demand at multiple locations, indoor or
unaffected by single point of outdoor, which may be separately installed or combined into small or large
failure groups. Remote I/O modules can be located directly in the field close to operating
• Hot-swap capability for online devices, which reduces field wiring runs and saves system installation expenses
maintenance significantly. All the modules are produced with surface mount technology that
prevents against shaking and vibration. Flexible panel mount installation offers
• No shared bus components
options for wall mounting and floor mounting. The industrial enhanced casing
provides greater dust protection and corrosion resistance for the modules.

Availability significantly enhanced by greater fault tolerance

A redundant high-speed serial network is deployed between controller and I/O
module, with 2Mbps traffic rate, precision timing protocol support, and hundred-
microsecond level synchronization precision. Shielded twisted pair is used as
transmission media. The controllers are designed with 1+1 fault tolerance, with
dual controllers online simultaneously, enabling zero disturbance and “zero”
delay switchover between master and slave controls. The power supplies can be
implemented with 1:1 redundancy, with every I/O module featuring internal and
external power isolation.

iDPU A iDPU B

iDPU A iDPU B
R S R S
iDPU A iDPU B
MCD51 MCD51

I/O I/O

R S
DUAL RING IO 网络
iLink NETWORK
I/O I/O

I/O I/O
I/O 模块
IO MODULES

I/O I/O

I/O I/O

I/O I/O

I/O I/O
DP Addr: xx DP Addr: xx

就地

8
General Technical Parameters

Power supply

Cabinet power Dual redundant power supply, 110V/220V AC (±10%)

Module power Dual redundant power supply, 24V DC (±10%)

Environment

Operating temperature 0~60℃ (IO module: -20~70℃ )

Humidity 5-95% (non-condensing)

Vibration Complete system: 5-200Hz, acceleration not exceeding 5m/s2

Part and component: 10-500Hz, acceleration not exceeding 10m/s2

Contaminant Dust particle size larger than 0.5uis, concentration smaller than 18,000 particles/L

Assembly

Standard cabinet protection NEMA 4 (IP56)

Standard cabinet dimension 800×600×2200mm (W×D×H)

I/O module dimension 209×129.5×51mm (H×W×D)

Capacity 28 modules/cabinet

Mounting Screw mounting

Codes and standards

Safety EN 61010-1, UL508A, CSA C22.2, IEC 60529

Electromagnetic compatibility EN 61326-1, CISPR11, IEC 61000-3-2, IEC 61000-3-3, IEC 61000-4-2, IEC 61000-4-3,
IEC 61000-4-4, IEC 61000-4-5, IEC 61000-4-6, IEC 61000-4-8, IEC 61000-4-11

9
Module Functional Description

Module Functional Description Specification

MCD50 IO Bus and power iLink bus input (R/S) ×1, output R×1, output S×1;
extension Dual 24V dc input and output

MCD51 IO Bus and power iLink bus input (R/S) ×2, output R×2, output S×2;
extension Dual 24V dc input, 24V dc IO power output x 4, 24V dc aux power outputs 4 x 2 groups

MAI50 mA/V analog input 16 input channels

16bit analog to digital conversion
Input signal ±10V, ±5V, 0(4)-20mA
Accuracy 0.1%

MAI52 mA/V analog input 8 input channels

16bit analog to digital conversion
Input signal ±10V, ±5V, 0(4)-20mA
Accuracy 0.1%

MAI54 mA/V analog input 8 input channels, fast sampling up to 100 times per second,
Individual 16bit analog to digital conversion
Input signal ±10V, ±5V, 4-20mA
Accuracy 0.1%

MAI51 TC/RTD analog input 16 input channels

16bit analog to digital conversion
Input signal thermal resistance (two-wire or three-wire sensor): Pt10, Pt100, Cu10,
Cu50, Cu100, BA1, Cu53
Thermocouple: E, J, K, N, R, S, T, B
Accuracy 0.2% (optional cold junction compensation)

MHT50 mA/V analog input 8 input channels, with HART protocol support
16bit analog to digital conversion
Input signal ±10V, ±5V, 0(4)-20mA
Accuracy 0.1%

MAO50 Analog output 8 output channels

12 bit digital to analog conversion
Output type 0(4)-20mA, Channel 7/8 with 0(1)-5V output support
Accuracy 0.1%

MHO50 Analog output 8 output channels, with HART protocol support

12 bit digital to analog conversion
Output type 0(4)-20mA, Channel 7/8 with 0(1)-5V output support
Accuracy 0.1%

MDI50 Discrete input 32 input channels

48V DC wetting voltage
1ms SOE accuracy
Last 4 channels also capable for pulse input 0-1.5kHz

MDI52 Discrete input 16 input channels

48V DC wetting voltage
1ms SOE accuracy
Last 4 channels also capable for pulse input 0-1.5kHz

10
 Module Functional Description Specification

MDI53 Discrete input 16 input channels

24/48/125V DC wetting
1ms SOE accuracy
Last 4 channels also capable for pulse input 0-1.2kHz

MDO53 AC relay output 16 output channels

Relay output, dry contact
Resistive load: 12A/250VAC; 12A/30VDC
Inductive load: 7.5A/250VAC; 6A/30VDC

MDO53A AC relay & digital output Totally 16 output channels

8 relay outputs, dry contact
Resistive load: 12A/250VAC; 12A/30VDC
Inductive load: 7.5A/250VAC; 6A/30VDC;
8 digital outputs, 100mA@24v dc each (requires extension relay board)

MDO54 Digital output 16 output channels

100mA@24V DC maximum for each channel (requires extension relay board)

MDO55 Digital output 16 output channels

Transistor output, source, 0.25A for each channel, 2A for all

MDO56 Digital output 16 output channels

Transistor output, sink, 0.25A for each channel

MVP50 Valve position control 2 LVDT inputs, supporting 3/6-wire transmitter, open-circuit detection and
adjustable excitation frequency/amplitude
2 analog input channels, 0-20mA, 0-5V, +/-10V
2 servo output channels, +/-40mA, +/-10V, channel fault detection
2 analog outputs, 0-5V
6 discrete inputs

MSP50 Speed measuring and 1 rotational speed input, 1-20000Hz, 0.01% resolution, supporting magnetic
protection resistance, Hall and eddy current probe
6 analog inputs, 0-20mA, 0-5V, +/-10V; 0.1%
8 discrete inputs, 1-50ms digital filtering, supporting SOE
6 digital outputs, 24V dc, 0.1A, supporting SOE

TMR ETS Protection Module

• Speed inputs: 3
• Signal type: sine wave, square wave, triangular wave
• Measuring range: 1~20000Hz
• Measuring accuracy: 0.05%
• Built-in rotational speed signal generator provides online rotational speed channel
validation
• SOE: 1ms
• Response time: <5ms
• DI: 42 channels/48VDC
• DO: 6 relay outputs(2oo3)/220V AC 8A (Resistive Load), 220V AC 4A (Inductive load) 11
OptimumC Software
OptimumC is a new-generation
DCS-dedicated software
platform developed by GE,
which supports previous DCS
hardware platforms including
XDPS-400+/400e (OC4000)
series and the latest Nexus
Control System. It is designed
to provide acquisition and
processing of industrial field
data, process control and
human-computer interaction,
and provides a professional,
user-friendly software
operating environment,
enabling efficient industrial
process control strategy
and convenient system
maintenance and management
for users.
12
Software Architecture
The OptimumC software consists of two packages: the controller software
package (OptimumC Controller) and the HMI software package (OptimumC
Workstation). The software accomplishes real-time monitoring for entire control
system via interface of the real-time database OCDB from the distributed control
by GE.
The controller software package is installed on the Nexus iDPU controller,
enabling process control functions such as data communication, process I/O
interaction and real-time control. The system software platform is the QNX®
Neutrino® real-time multiple task operating system.
The HMI software package is installed on the Nexus HMI computer, accomplishing
such tasks as DCS system configuration, control logic configuration, industrial
engineering real-time control and system maintenance and management. The
software package supports Microsoft Windows 7/Windows 10, and offers the
following features:
• System application console
• Integrated system configuration tools
• Process graphic building tools
• Real-time process monitoring software, including process graphic display,
trend display, etc.
• Historical data collection software
• Report production and collection software
• System self-diagnosis and alarm management software
Software Features
Stemming from relentless efforts in the field of industrial process control for decades and carrying forward the merits of
previous control software products by GE, the next-generation OptimumC software provides enhanced performance in
terms of software functionality, user experience and system security, with the following technical features:
System Management
• Integrated system configuration
tool and standardized
configuration interface that
prevent against possible errors
due to manual modification
• One-stop management tool that
allows for remote configuration
and management for the entire
control system via one engineering
station
• System program daemon and
self-start functions prevent
against accidental termination of
important system software
• Multiuser support and security
management, hierarchical user
access, and authority distribution
management for system control
nodes
• Integrated system console that
calls associated application
software rapidly and conveniently
• Multilanguage support that allows
of online language switching
Control Application Development Environment
• Control configuration
• Graphical configuration tool that provides functional block configuration per
IEC61131-3
• Enriched predefined functional algorithm library (basic control algorithms, power
plant-specific control algorithms, advanced control algorithms and system
diagnostic functional blocks)
• Online automatic maintenance of system database without the need to reset
controllers or engineering stations
• Enhanced security features including logic lock and password protection
• Online configuration and debugging that support control logic and require no
recompilation or controller resetting
• Supports process control simulation via virtual controller and I/O channel
simulation technology
• Rich content included in a predefined process control shape library (static/
dynamic), which can be customized based on user preferences
• A variety of predefined dynamic links that provide real-time human-machine
interaction for convenient and quick process control
• Creation of system process graphics through prebuilt templates, ensuring
consistency of project interface style and offering ease of modification
• Process graphic menu editor based on EXCEL spreadsheets, which supports rapid
automatic generation of screen menus
• Automated tools are also available by GE that migrate previous versions of
DCS application configurations to the new OptimumC platform efficiently and
conveniently
Function block based control application configuration
13
Real-time Monitoring
• Distributed real-time database that supports a system scale exceeding 200,000 tags
• Peer-to-peer system software architecture without system bottlenecks; flexibility of
functional configuration for HMI nodes that meets redundancy requirements
• A variety of flexible third-party communication interface capabilities that support several
international standard communication protocols such as Modbus,IEC 60870-5-104 as
well as Profibus-DP, meeting the needs of system function expansion conveniently
• Process display with ergonomic design and convenient guidance for process operation
that satisfies operator requirements for long-term monitoring
• Powerful data retrieval functions and rapid identification of process faults, covering trend
triggering, historical playback, graphics push, etc.

System Diagnostics and Alarming

• Abundant, multi-layered system diagnostic information: System network → Controller → I/O
network → I/O module → I/O channel
• Predefined system diagnostic algorithm

Network layer Controller layer

IO network layer IO channel layer

14
Process Analysis and Maintenance

• Collection and retrieval of mass historical data (for

months or even years, including all real-time process
data and control system events)
• Detailed system operation log for the convenience of
accident analysis and judgment
• Trend analysis
– Seamless connection of real-time trending and
historical trending
- Real-time trend data refresh rates of up to 40ms
- More than 5,000 user-defined trend groups (depending
on disk space)
- Up to 16 trend points supported on each trend window

• Historical data collection

– �Historian station capable of processing 200,000
process points
- Minimum 0.5s collection cycle for important control and
monitoring points
- All process data to be kept for a minimum of one year
- High fidelity, rapid compression storage that meets the
demand of long-time historical data archiving

• Reporting tools
– �Multiple report types including periodic, event-based
and triggered
- Up to 4 data sources supported
- As many as 1,000 user-defined templates supported
- Graphical interface configuration

15
Virtual DPU Technology
Nexus VDPU (Virtual Distributed
Processing Unit) provides similar data
processing functions as a standard
DPU controller, and runs on HMI
stations for simulation testing on DPU
configurations. It can also be used as
data processing software for external
communication interfaces.
A virtual DPU provides the A virtual DPU offers the
following features: following functions:
• Operation on HMI stations that • Integrated control logic testing via
simulates functions of a real control simulation
controller • Online analysis, debugging and
• Operational interface is identical to optimization of control logic
the appearance of a real controller • 3rd-party communication interface
• Control configurations are identical • External control system interface
to the functionality of a real
controller
• Virtual DPUs are configurable in
redundancy
• Up to 64 virtual DPUs supported for
simultaneous operation

Fieldbus Control System (FCS)

As automation technology evolves, fieldbus technology is being increasingly
used in production process control thanks to its intelligence, reduced cabling and
installation cost, preventive maintenance capability and many other merits. The
Nexus Control System gives full support to fieldbus technologies such as Profibus
DP and Profibus PA.
The Nexus integrated fieldbus master station, DP Master, connects to the
controller directly via high-speed dedicated ports ENET3 and ENET4, which serve
exclusively for the connection between the Nexus Control System controller and
the DP Master module and are independent of general I/O module networks. They
provide higher bandwidth and faster response, while not interfering with I/O data
communication.

16
The fieldbus technology for Nexus Control System provides the
following features:

Comprehensive redundant design of Nexus FCS

• Controller redundancy • Network communication interface device
• Profibus-DP Master station module redundancy redundancy

• Redundant DP communication channels • Bus power redundancy

(including media converter) • Link device redundancy
• Network medium redundancy

Redundant Nexus system network

Redundant Nexus controller

DP switch

DP segment: n Active terminator

Redundant DP bus

DP/PA coupler

Redundant DP device

PA segment junction box

Integrated fieldbus master module within the Nexus platform

As an I/O extension module of Nexus, the DP Master may connect to the Nexus controller module
directly without any intermediate interface module. With a DP Master, the Nexus Control System can
connect to a variety of intelligent field devices offered by third-party suppliers including transducers,
actuators, motor control centers (MCC), flame monitoring devices, intelligent electronics, etc. The
design, configuration, maintenance and screen operation for fieldbuses (including the HART protocol)
are seamlessly integrated with the Nexus configuration tools and are enabled in the same software
environment on the Nexus engineering station.

17
Fieldbus Testing Platform Flexible FCS Configuration
GE provides a complete testing and demonstration system for fieldbus, which Layout plans are decided based on a
is used in production workshops and includes a complete fieldbus system. The variety of specific conditions such as how
fieldbus system consists of the controller, a fieldbus master module, power discrete the fieldbus devices are, their
supply, fieldbus power module, all types of Nexus IO modules, HMI stations distance to electronics, disturbances
(including engineering station software), network switches, mounting rack and environmental factors. The following
and cabinet Profibus-PA junction box, PAsegment protector, and the actual DP picture illustrates one of the options:
and PA fieldbus devices. This platform combines testing and demonstration
• Share the same controller with general
functions, being a complete system for fieldbus technology testing.
I/O modules
This demonstration system provides the following features: • Each pair of DPU accommodates up to
• Performs interconnection and interoperability tests for all fieldbus device 15 pairs of DP Master
samples (including instrumentation and actuators) connecting with real • Similar configuration experience with
Nexus FCS, and submits an inter-operability report on a timely basis Nexus general I/O
• Performs interference tests for the bus and proposes on feasible solutions
• Performs test on bus cable to choose appropriate fieldbus cable

1 DPU Field Electrical room

2 Switch Power supply

Optionally, twisted-pair
3 DP Master DP cable can be applied
for bus connection with
4 PB-YHUB no need of optical media
converter

5 DP/PA coupler

6 PA junction boxes

7 PA field devices

8 DP device

9 Media converter
DP device
field box
10 Active terminator

11 Optical cable

12 DP device field box

13 DC24V power supply

18
Intelligent Remote IO The intelligent remote box
The intelligent remote IO - Nexus IDCB measures temperature signals of field
of Nexus has the following
thermocouples or RTDs remotely and converts the temperature signal to
features
digital signal which is then transmitted to the controller via two redundant • Direct communication with
RS485 networks. Field-mounted, it is placed in-situ at industrial sites within Nexus controller with no need
harsh environments (on the boiler wall, on generator enclosures, on feed for protocol conversion
pump skids, etc.). The remote case features a sealed metallic enclosure that is • Nexus MAI51-based intelligent
characteristic of high strength and resistant to moisture, dust, vibration and temperature module
UV exposure.
• 16 channels with support for
The remote case is directly fed by 220V AC power without an external power TC/RTD temperature sensors
module. Use of local mounting saves signal cable and expensive compensating
• Reliable 115200bps
lead wire significantly. The case provides built-in cold junction compensation
communication rate, far
that does not occupy additional channels. One of its major advantages over
exceeding other intelligent
similar intelligent remote cases by other manufacturers is its high integration
remote case products in today's
and compatibility with the Nexus communication protocols, saving the need
market (9600bps)
for extra communication programming and allowing plug-and-play capability.
• 220V AC power supply
• Superior protection, with
standard cabinet up to IP56
enclosure rating
• Wide range of operating
temperature: -20~70 ℃
• Dimension: 380*300*95 (mm)

TC/RTD Input TC/RTD Input

24V dc (8 Channels) (8 Channels)
I/O Link (iLink) S R

External view of intelligent remote case

19
DEH-VI Steam Turbine Control System
With over a 100 year proven record in steam turbine
manufacturing, GE is the leader in steam turbine control
systems. The DEH-VI steam turbine control system currently
being used is integrated with the Nexus Control System
platform. The DEH system features a number of special I/O
modules, unique to turbine control like valve position control
and overspeed protection modules. These modules provide
the following functions:
• Triple redundancy design for critical protective signals
• Triple redundancy overspeed protection hardware
• Rotational speed measurement and control with high
precision (up to 0.1 rpm)
• Redundant servo loop control
MSP50 Speed measuring MVP50 valve position
• Digital PID control for servo loop
and protection module control module
• Fail-safe outputs

ETS-VI Emergency Tripping System

The emergency tripping system ETS-VI on Nexus is a
complete 2oo3 protection system, which represents a cost-
effective, compact solution. Its universal parts are designed
to integrate with the Nexus Control System, while the core
protection function is enabled by dedicated hardware. The
core protection modules utilize triple-redundant hardware,
with a high-speed processing cycle time < 10ms. All DI
protection signals are fanned to triple-redundant processing
modules. Protection outputs accommodate hardwired 2oo3
voting before they go to the field device. ETS logic operates
simultaneously on three separate processing modules. The
ETS processing modules support online replacement and
maintenance and provide protective functions independent
of the DPU controller. The controller only provides status
monitoring, protection logic configuration and maintenance
of the ETS system.
The ETS-VI emergency tripping system on Nexus provides
extremely convenient ETS logic configuration and a secure
level ETS encryption, and is optimal for PLC based legacy ETS
retrofits.

20
 Integrated
Monitoring of Nexus
and Mark VIe Systems
Mark VIe and Nexus are now
one of the most important lines
of control products from GE,
which share unified processes
and norms for research
and development, identical
communication protocol
(EGD), and a consistent design
philosophy and standard for real-
time data communication. These
common grounds facilitate easy
integration of monitoring Mark
VIe from Nexus Control Systems.
The integrated monitoring of
Nexus and Mark VIe systems
provides the following features
and functions
• High-speed real-time data sharing
between systems through EGD
protocol
• Equipment-level real-time monitoring
for gas/steam turbine via Nexus
Control System operator stations
• Integrated process alarm
management (alarm surveillance and
acknowledgement)
The integrated monitoring of
Nexus and Mark VIe systems
brings these values to
customers
• Full support of Nexus based BOP
DCS operator stations for process
monitoring over MarkVIe controlled
gas/steam turbines
• Shared EGD communication
protocol with Mark VIe, which allows
communication on the level of real-
time control network (UDH), with no
protocol conversion

• Integrated control system diagnostics • Direct connection of UDH switches

Mark VIe control Nexus control
and monitoring on Nexus HMIs between Nexus and Mark VIe systems,
cabinet
MarkVIe 控制机柜
cabinet
Nexus 控制机柜
with network redundancy for fault
• Unlimited Mark VIe communication tolerance
points, allowing Nexus to obtain all
Mark VIe process points • No need for hardwiring or
communication gateways between
• Redundant inter-network the two systems, simplifying the
connection, automatic undisturbed design
communication connection switching
• Direct sharing of process variables
• Direct connection between systems between controllers, easily enabling
via UDH and PDH switches without APS
any communication bottleneck
• Consistency of operator interfaces
• Real-time health monitoring and
alarming for network connection • Possibility of cost reduction for Mark
between systems VIe through shared equipment such as
Nexus sends control Historian Station
command to Mark VIe • Possibility of direct connection with
Bentley Nevada TSI equipment.
Mark VIe data is
MarkVIe侧的数据可
Nexus process control UI
Nexus 控制界面 displayed on Nexus HMI
以显示在Nexus侧 Mark VIe 控制界面
MarkVIe process control UI

21
High Fidelity
Simulation Technology
GE has launched an integrated simulation The high fidelity simulation technology by GE has the
and control solution that combines the following characteristics:
online optimization simulation system
• 1:1 high fidelity of simulation
based on virtual DCS technology and a
miniature version of DCS. The solution • Training on operation and accident handling conforming to real-world
applies a customized 1:1 high-fidelity conditions
simulator with seamless hardware/software • Operations personnel grading
integration, establishing a platform for
• Operating standard improvement and operation optimization
operation training, accident analysis, and
scientific research for thermal control • Historical data playback for investigating into root cause of accident
and experimentation. This platform is • Accident review and anti-accident exercises
characteristic of, flexibility, ease of use,
• DCS optimization and nondestructive thermodynamic test
greater scalability, and openness. The DCS
integration allows of the ease of accessing • Thermodynamic fault diagnosis and control optimization test platform
a miniature version of DCS and control (CISP-200)
optimization system, helping to genuinely • Hot standby platform for spare parts
reflect the actual operation and control • Support of one-server multiple-model, multiple-server one-model, and
conditions for automation in the power multiple-server multiple-model
plant. It helps to quickly train operators on
mastering operation of units, operational • Multi-group training available on separate model instance
modes and the process of dynamic • Mobile simulation station
response of the devices. It also enables
them to accurately judge and appropriately
handle accidents, with the aim to ensure
operational safety and stability of the units.
The platform helps thermal engineers
familiarize themselves with the DCS system
software, hardware, and the characteristics
of the system operation as soon as possible.
This training enables them to test, diagnose
and locate relevant software and hardware
failures, and facilitates research of possible
optimization. Ever since its launch, the
integrated simulation and control solution
has been widely recognized and highly
DPU Distributed
praised by power plants, once again setting Processing Unit
VDPU Virtual DPU for
the pace for the field of simulation. Process Model
Process Control
SDPU Virtual DPU
Power Plant Physical Process for Process
Simulation
HMI Human-Machine
Interface
IHMI Instructor Station

22
IntelliMax
Energy Saving
Navigation
Boiler Performance
Optimization
Successful boiler operation has a direct
bearing on the thermal economy of a
unit. Optimizing boiler performance
mainly aims at optimizing and
regulating boiler combustion, improving
combustion efficiency and reducing
emissions. This online optimization
technology is suitable for both open
loop and closed loop operation.
Steam Turbine Sliding
Pressure Optimization
Changes in steam turbine principal
parameters will influence the
performance of the steam turbine and
even the entire unit to a large extent.
There should be an optimal sliding
pressure curve to maximize steam
efficiency. An optimum sliding pressure
curve can be obtained using GE's
performance optimization solutions,
and through in-depth analysis based on
specific conditions of the unit.
Plant Level Load
dispatching
This is designed to improve overall
heat rate and fuel cost for the plant.
The system optimizes the efficiency
and load dispatching for multiple units.
The load dispatching at a thermal
power plant level is based on the
characteristics of coal consumption
for the units. Since a plant-level load
requirement is defined, the load is
dispatched to individual units by the
principle of minimum coal consumption
across the plant within the allowed
band of the power of unit.
Temperature Control
and Optimization
for Superheated and
Reheated Steam
Improving steam temperature
control performance reduces
temperature oscillation and enhances
responsiveness of the load. A
multivariable control strategy will be
established based on actual demands
against issues customers have
encountered, providing high-precision
temperature control.
Cold End Optimization
Either the number of running circulating
water pumps (constant speed pumps)
or the optimum operation mode of
the circulating water pumps would
be explored under different operating
loads to find a point at which the
entire unit achieves the best thermal
economy, improving the unit's
operation efficiency.
Process Simulation and
Modeling
The process simulation and modeling
system can provide user with cost-
effective operator training, effective
IntelliMax Energy Saving Navigation
is a full set of advanced control
solutions GE provides that is built on
the automatic processing and control
of the distributed control system. It
introduces a variety of features such
as data acquisition, data processing,
loop control and communication, and
provides unit-level optimization based
on advanced control theories as well
as self-diagnosis and fault tolerance
capabilities.
control strategy, exhaustive system
troubleshooting, and expeditious
hardware fault diagnostics. Process
simulation provides a cost-effective
solution for:
• Operator training
• Control strategy validation
• Online and offline system
troubleshooting
This simulator mirrors the structure
and functionality of the actual DCS,
and can be upgraded along with the
real DCS, so there are no version
mismatches.
Historical operation data can be read
into the simulation system. By replaying
the production process history, plant
engineers can expedite root cause
analysis. In addition, the system can
also be used to conduct accident
avoidance drills to improve operators'
accident response capability.
The simulator can also support a
miniature version of the DCS. This
configuration can be used for system
hardware troubleshooting and for
detection of suspicious I/O cards for the
purpose of fault diagnostics on spare
parts. The simulation features a very
portable design, which can be installed
on a laptop computer for root cause
analysis and troubleshooting on the
hardware.
23
ST600 Small
Turbine Controller
The ST600 small turbine controller is a turbine servo controller based on the Nexus Composition
platform. It is suitable for controlling a steam turbine with one or two servo pilot
ST600 small turbine controller
actuators, focusing on industrial steam turbines below 50MW. The steam turbines could
consists of compact enclosure, iDPU
be used for driving generators for power generation and for steam and heat supply
controller, MSP50 rotational speed
on pure condensing units, back pressure units, single-extraction units. It can also be
measuring and protection module,
used for driving other mechanical loads, e.g. water pumps, compressors, etc. The servo
MVP50 valve control module, DC power
outputs are useful for all types of hydraulic servo valves/electrohydraulic transducers.
supply, extension relay and some
The valve control mode can be open loop or closed loop control via LVDT/oil pressure.
other key components. Rotational
ST600 controls start/stop sequencing of these units and also provides high-precision speed measurement and overspeed
control over relevant parameters during normal operation of the units, such as unit protection functions are enabled by
rotational speed, power, extraction pressure/flow, etc. It also provides overspeed dual redundant MSP50 modules..
protection and unit emergency shutdown protection. The controller is designed with
ST600 provides self-check and alarm
fail-safe outputs to ensure safety of the entire unit.
functions, and supports manual control
ST600 is delivered with a compact, integral enclosure that can be directly secured to or over valve position in partial failure
mounted within user's cabinet for the ease of installation. The enclosure may also be status for the convenience of user's
installed locally near the closest unit or installed remotely in control room. maintenance and replacement.
Enclosure of ST600 is equipped with a 10-inch colored LCD touch screen to display The modular design provides users
operation graphics, manipulate conditions, configure system, etc. and facilitates user's with the flexibility of configuration
on-site operation, monitoring, configuration and commissioning. The display also to a certain extent, enhancing the
simplifies the troubleshooting process by allowing users to check unit operation curves, performance or expanding the
history, SOE records, alarms, etc. capabilities such as DPU redundancy,
ST600 may be used for controlling single unit or for group control of multiple units. It power redundancy, etc.
provides two types of connection to DCS or master control operating system: hardwired • Modular structure
and digital communication.
• QNX6.3 real-time operating system
for the controller
Technical Specifications for ST600 Hardware
• Win 7 operating system for the HMI
Power supply 220V/110V AC, ±10%, 50 VA; • Nexus graphical configuration
Rotational speed 2 channels, 1Hz ~ 20kHz, accuracy, <5KHz, 0.01%, >5KHz, software for configuration, with
input 0.05%; dual-language support
Rotational speed Electromagnetic, eddy current, Hall, photoelectric; • Control object-oriented
probe configuration
LVDT input 2 channels, directly receiving 3-wire and 6-wire LVDT signals;
Analog input 14 channels, 4 ~ 20mA/-10 ~ +10V, accuracy ±0.1%
Discrete input 22 channels, SOE 1ms
Digital output 10 channels, 2 of which are for overspeed protection output
and the rest are configurable; contact capacity 30V DC/6A;
220V AC/6A;
Analog output 2 channels, 0 ~ 5V output, accuracy ±0.2%

24
Servo control loop 2 servo control loops, optional valve closed loop feedbacks Functions
including LVDT and AI; open loop output available • Speed control
2 servo control outputs: ±40m A, ±150mA, ±10V, accuracy • Load control
±0.2%
Frequency and amplitude adjustable dither signal is available • Steam inlet pressure control/
confinement
Frequency: 10 ~ 100Hz; Amplitude: 0 ~ 10%
• Steam turbine back pressure control/
confinement
Controller • Extraction stress/flow control/
Processor Intel 1.66GHz, 512M memory, 2GB Flash confinement

Operating system QNX RTOS • Operator automatic acceleration/

self-start by empirical curve
Operation period 40ms
• Automatic exceeding of critical
speed
Touch Screen • Automatic sync control

Processor Intel 1.66GHz, 8G Compact Flash • Grid connected with initial load
automatically for prevention against
Operating system Win 7 reverse power operation
Display 10-inch, resolution: 800x600 • Decoupling control for loading/
extraction

External Communication • Primary frequency modulation

10/100/1000M Ethernet
Communication protocol
System Technical Indicators
Range of rotational speed
control
• Small grid operation available
2 RJ45 ports
• Redundant hardware overspeed
Modbus, TCP/IP
protection
• Overspeed protection testing
• Maximum overspeed rpm value
recording
Jigger speed ~ Turbine shutdown protection speed,
accuracy ±1r/min • Valve position limiter

Range of load control 0 ~ 110% rated load, accuracy 0.5% • Valve testing
Speed governor droop Adjustable droop, set by unit droop curve • Valve leak testing

Range of pressure control
System reliability
SOE
Control loop period cycle
Installation and Environment
Within the range of steam turbine working conditions,
accuracy 0.5%
MTBF > 50,000 hours, system availability > 99.95%
1ms
Overspeed protection: 10ms; Servo loop: 10ms; Other
regulation control loops: 40ms
• Automatic static valve calibration
• Simulation testing available during
unit outage
• First-out trip indication in case of
turbine trip
• SOE recording
• HMI field operation display
• Online configuration supported
• Historical data collection

Operation temperature 0 ~ 50 ˚C • Dual-language with online switching

supported
Indoor installation IP42 enclosure

Enclosure dimension L 500 x H 500 x D 300 mm

Weight About 18 kg

25
Automatic Plant
Start-up and Shutdown
System (APS)
Distributed control systems (DCS) have found up or shutdown at plant unit level. It functions
mature applications in a majority of power like an intelligent operation shift, acting as shift
plants. The development of thermal automation, chief-operator, stoker, driver and electrician for
however, is always oriented toward how to collaboration and operation during plant unit
optimize automatic control systems for the units start-up and shutdown and achieving the best
and to improve operating economy and market performance.
competitiveness for power enterprises given
Highly sophisticated, APS represents the
that the safety of unit operation is assured. GE
highest level of automatic control technology
has enabled the Automatic Plant Start-up and
for plant unit, and is the commander-in-chief
Shutdown System (APS) using Nexus, stepping
for all conventional subsystems in the DCS. To
into a new phase for the level of automation in
achieve APS, a certain level of correctness and
power plants.
completeness for the subsystems is required, with
APS is designed to provide automated start-up higher requirements raised for system devices.
and shutdown for plant units. The key advantages Reliable and accurate measurement is required in
are enhanced accuracy and correctness of plant the whole process for key measuring points of the
start-up and shutdown, reduced workload on system such as boiler drum level signal, ensuring
operators, shortened start-up and shutdown time, the APS meets the requirements for safety in
and eventually enhanced level of automation for operation of the plant unit.
the plant units. GE has made intensive and in-
Enabling unit-level APS brings the plant unit to
depth research into how to design and improve
a higher level of operation in an all-round way,
the automatic start-up and shutdown functions
while enhancing the accomplishment of unit-
in APS, thus bringing into full play the powerful
level automatic control, which is mainly reflected
features of this system.
on the improved interlock protection logic that
Based on the control thoughts of automatic improves the long-term safe operation of the unit.
start-up and shutdown for multiple machines in
Improved quality of automatic regulation helps to
plant units, APS is built upon a variety of systems
bring about whole-process control over all major
such as modulating control system (MCS), digital
regulating loops; as start-up/shutdown time is
electrohydraulic control system (DEH), boiler
shortened, extended economic operation of the
burner management system (BMS) and sequence
plant unit can be enhanced. Handling abnormal
control system (SCS) for boiler, steam turbine and
conditions during start-up and shutdown correctly
related auxiliary equipment, being as the center
and properly can improve the accuracy of fault
for plant unit start-up and shutdown dispatch,
handling for unit equipment. Automated step
information management and command control.
sequence operation standardizes the operation
APS sends out start-up and shutdown commands
specifications and minimizes mistakes by
to various systems, subsystems and equipment
operators.
according to start-up and shutdown curves and
prescribed programs, enabling automatic start-

26
System Design Philosophy
The control of APS over a power plant is enabled by the use
of the plant's conventional control system and high-level
control logic.
Conventional control system refers to a variety of
subsystems such as SCS, MCS, DEH, MEH, BMS, CCS, BYPASS,
ECS, etc. The conventional control system is independent of
APS, providing control for the power plant, when APS is not
put into service; as long as APS is switched in, conventional
control system provides support to APS, enabling automatic
start-up and shutdown control for the power plant.
The APS applies appropriate high-level control logic
by working conditions of the unit (cold, warm, hot and
extreme hot state), and sends control commands to various
subsystems and regulating loops via the data highway of
DCS.
For specific logic design, different configuration methods
such as modular, phased and structural become options.
On the one hand, this implements the control strategies
more clearly and effectively; on the other hand, it facilitates
commissioning and modification, and avoids situations in
which a logic change triggers a series of chain reactions,
improving system safety. The overall design philosophy is
• Modular design: Modular design is achieved with control
logics that provide specific functions.
• Phased steps: APS divides working conditions into phased
steps according to settings of the breakpoints during
start-up and shutdown of the unit, and provides the steps
with relatively independent operating characteristics, so
that the operator may intervene manually based on actual
conditions, without affecting execution of other steps. For
example, options of the breakpoint during the APS design
can allow system equipment commissioning in phases.
• Systematic and orderly judgment: APS takes into
full consideration a variety of important factors such
as primary judgment, secondary judgment, reverse
judgment, instruction time, allowed time, waiting time,
coverage area of judgment and its impact on program
relocation. In particular, it focuses on applications where
one device location is used as the criteria to influence the
execution of several functional groups.
• The program relocation function triggered by programming
testing and automatic switching of sequential control
device allows the sequential control device to track
actual working condition of the unit, enabling automatic
switching of the control device in any working condition
to adapt to current status of the unit without sending
commands in error. For example, whether to put oil
fueling in service during mill startup will be determined
by the APS program automatically according to specific
working conditions of the system.
• Design of subsystems is required to follow programs of
the APS and to interface well with APS. Unified interface
standards enable undisturbed switching and facilitate
independent commissioning and modification for the
high-level logic and lower functional blocks of APS and
the equipment control. Higher level systems can provide
necessary inter-coordination thanks to the coordination
control of APS.
• APS must ensure comprehensive and sufficient judgment
for the completion criteria and permissive start-up
conditions for the various phases and breakpoints,
and make judgment by different equipment working
conditions, reflecting real working conditions of the
equipment and eradicating erroneous judgement.
• When adhering to all low-level protection and interlocking
logics, an APS should also provide abnormal issue
handling and means of alarming and manual intervention,
ensuring operational safety and reliability of the unit.
Features of APS
• Highly efficient step sequence execution function block
STEP, switching FB MSFT and the device module with
various interfaces provide vigorous support to APS
• Applying the system simulation platform at the design
phase helps to test correctness of the APS without
generator unit outage and to shorten unit shutdown
during on-site commissioning
• APS may integrate GE optimization software to improve
the level of automation and optimize system operation
• Breakpoints are created based on actual system
conditions, which practice completely complies with the
demands for power plant operation
• Logic design is fully modular for the ease of upgrade and
modification
27
DCS Comprehensive
Diagnostic Services
As more and more high-parameter,
No. Test Item Required Unit
high-capacity thermal generator
condition
units are being put into service, the
importance of the Instrument and
1 Controller control cycle test Shutdown
Control system (I&C) is increasingly
prominent. Distributed control system 2 System response time test Shutdown
(DCS) is a primary control device of
plant I&C. With increased system 3 System real-time characteristic test Shutdown
uptime, whether the performance
indicators of DCS can continually meet 4 Common mode interference resistance test Shutdown
the demand of production safety in
a thermal power plant would have 5 Differential mode interference resistance test Shutdown
a direct bearing on the operational
safety, economy and stability of the 6 Electromagnetic interference resistance test Shutdown
unit. Therefore, the safety indicators
7 Redundant controller switchover test Shutdown
should be tested based on technical
standards in the industry using
8 Resolution test for sequence of events (SOE) Shutdown
scientific testing methods and
cutting-edge instruments, achieving 9 System load rate test Shutdown
accurate performance indicators and
parameters. 10 Controller synchronicity test Shutdown
GE provides users with not only
11 Control cabinet power supply adaptability test Shutdown
reliable, advanced control systems,
but also systematic maintenance
12 Controller power supply adaptability test Shutdown
and inspection services. GE offers the
following testing services against above 13 I/O signal input and output function test Shutdown
demands, helping customers monitor
system operation conditions. 14 Human-machine interface (HMI) test Shutdown

15 System fault tolerance test Shutdown

16 Unit safety assurance check Shutdown

17 Module maintainability test Shutdown

18 System storage usage test Start-up/shutdown

19 Statistics for access rate and serviceability rate Start-up/shutdown

of input and output points

20 System availability check Start-up/shutdown

28
System Platform Upgrade
and Expansion Services
Since GE launched the distributed control system and its
upgraded version early in 2000, the XDPS-400 (OC4000)
series of DCS products has been widely used in the power
sector in many countries and regions, receiving universal
recognitions from users, thanks to its superior system
stability, reliability and performance.
As the national economy and the undertaking of
environmental protection evolve constantly, higher
expectations have been put forward for the safety,
efficiency and operational stability of plant units, and higher
requirements are also being raised for control systems
and the level of process control. Advances in computer
technology, microelectronic technology, network technology
and advanced control theory and technology has made these
possible. Supply of obsolete parts also becomes an issue
due to technological progress, since the maintenance cost
is increasingly unacceptable. Considering the increasingly
tight budget control and service time control in today's
power sector, the traditional way of control system retrofits,
namely overall replacement of system platform, encounters
a number of constraints such as cost, schedule, etc., adding
to the difficulty of decision-making by enterprises. Risks to
operational safety of the units also increase alongside ageing
equipment performance. In addition, switchover between
different control systems results in unavoidable migration of
control logic, which cannot be sufficiently validated due to
restrictions of outage schedule and requires a certain period
of stabilization, increasing the risks to the operational safety
and stability of the units.
Taking into full consideration of the above factors, GE
has marketed simplified and flexible solutions for system
platform upgrades that help customers maximize the vitality
of existing DCSs at the lowest cost and within the shortest
timeframe, protecting customers' current investment and
ensuring long-term operational safety and stability of the
units. Meanwhile, the solutions also bring about up-to-date
control technologies and functional expansion capability
available from the upgraded system platform.
Upgrade Solution
GE provides a full package of system upgrade
solutions based on user's existing control
system
Nexus-based
XDPS400+/400e (OC4000) System Expansion
• GE provides support to current users of
XDPS400+/400e(OC 4000) system on adopting the
advanced mainstream Nexus control product and
technology for old system expansion
• No gateway is set up between newly added nodes and the
nodes of existing legacy GE DCS, allowing of direct access
to legacy real-time data network for interconnection
• No change is required for the software/hardware and
application configurations of the existing legacy GE DCS,
but engineering configuration is needed only for the
expanded part
• Realize the entire control system operation & monitoring
from existing legacy DCS HMIs, including the newly added
Nexus control panels
System Software Platform and HMI Upgrade
Scheme and Scope
• HMI computer upgrade to industrial control computer
with today's mainstream configuration and Windows 7
operating system.
• DCS software platform upgrade that provides latest
version of control software under the current system
platform of GE:
XDPS V2.0 platform
XDPS V6.0 platform OptimumC
XDPS V3.0/V6.3 platform platform
OC 4000 platform
29
Upgrade Implementation and
Timeframe
• Offline preparation of HMI hardware,
and software installation and
configuration.
• Offline preparation of the CF card for
controller software upgrade, on-site
replacement for upgrade.
• Field upgrade for all control system
software needs 2-3 working days
only, which can be accomplished
during any planned outage by the
customer.
Customer Value
• Retain all Hardware and wiring of
existing control cabinets
• All existing control logic
configurations remain unchanged
• Process graphics and operators'
operation experience remain
unchanged
• Powerful human-machine interface
station providing smoother
operating experience
• Up-to-date operating system and
continuous support of software
technology
• Support to latest XDPS-400
(OC4000) DPU controller, saving the
trouble of subsequent spare parts
supply
• DCS algorithm library with more
comprehensive, richer functions,
meeting higher demands for process
control
System Hardware Platform
Upgrade
Using the latest Nexus hardware
platform and the OptimumC control
software platform recently launched
by GE, users can perform partial
or overall step-by-step upgrades
for existing control systems, better
adapting to today's advancement of
control technologies such as fieldbus
and advanced control. This helps to
enhance the level of automation and
equipment management in the units,
meeting the requirements of grid on
unit control more satisfactorily.
30
Upgrade from XDPS-400 (OC 4000) to Nexus
Control System
Upgrade Scheme and Scope
• The DCS hardware platform is
upgraded to Nexus hardware
including controllers and I/O
modules, with the original cabinet
and external signal cables retained.
GE provides preinstalled controller
assemblies (including power supply
modules, controllers and I/O bus
network) for the upgrade of field
control cabinet.
• HMI computer upgrade to industrial
control computer with today's
mainstream configuration and
Windows 7 operating system.
• DCS network upgrade to 100Mbps
dual-redundancy high-speed
industrial Ethernet with star or ring
network topology.
• DCS software platform upgrade to
OptimumC control software with
1:1 conversion and migration of the
existing control configuration.
Upgrade Implementation and
Timeframe
• Factory hardware assembly,
configuration and testing for DCS
upgrade.
• Conversion of customer's latest
control configuration by automation
tools, and factory testing and
validation.
• System hardware upgrade on
customer site. Control cabinets
are upgraded through preinstalled
controller components. High
consistency of mounting dimension
and predefined terminal height
between Nexus I/O module and
original XDPS-400 (OC 4000)
terminal block, allowing installation
and wiring at the original location
of the terminal cabinet without the
need to rearrange field cabling.
• Field upgrade of DCS network; HMI
replacement.
• All field upgrades can be
accomplished with 2-3 weeks, which
can be provided during any minor
overhaul of the units.
• Remove all control racks from the
original control cabinet and retain
the cabinet frame only; mount
the controller assembly that is
preassembled in factory to the
mounting pillars of the original
cabinet to finish the field upgrade of
the control cabinet.
Customer Value
• The arrangement of all legacy control
cabinets and of the field signal
cabling within the cabinets does not
require reinstallation of cabinet or
rearrangement of the cabling, saving
installation time on site significantly
and shorting project timeframe
• All control logics that have been
subject to tested operating
validation help to prevent
against possible safety risks from
reconfiguration
• Graphical configurations and
operators' operation habits of all
legacy processes avoid retraining of
operators
• Powerful Nexus controller iDPU
provides hot standby redundancy,
and a built-in, richer algorithm
library and optimized power plant-
dedicated algorithm block
• I/O modules with fully redundant
design includes power supply and
I/O bus network, providing higher
system reliability
• Redundant 100Mbps high-speed
real-time industrial Ethernet
network lowers system network
load rate
• Powerful human-machine interface
station provides smoother operating
experience
• Fieldbus interfaces such as HART
and Profibus are supported with
greater system expandability
• Integrated system configuration and
distribution tools offer improved
ease of use
Maintenance/Yearly
Package Services
Currently, service maintenance
subcontracting is commonly used
by a lot of large-sized enterprises.
This approach reduces management
training for internal employees of an
enterprise; however, maintenance and
care for system devices, when delivered
by a dedicated service provider, can
better guarantee serviceability of the
devices. Targeting these demands,
GE dispatches dedicated, senior
engineers that provide customers
with professional and customizable
maintenance/yearly package services.
The following aspects are
included
• DCS comprehensive diagnostic
services
• DCS single event diagnostic services
(network load rate, I/O signal
functional test, etc.)
• DEH flow characteristics test
• Regular DCS inspection service
• Field technical services for overhaul
and repair
DCS Anti-virus Measures
by GE
Field Requirement
A DCS requires regular data extraction
of control configuration, failure
data and other necessary files from
HMI stations, and demands data
communication with SIS and other
systems. DCS also needs frequent
data exchange with external systems,
during which there exists risks of virus
infection on HMI stations, potentially
threatening the safety of production.
A regular antivirus measure for DCS
for now is installing general-purpose
antivirus software and strengthening
HMI station administration. A majority
of large-scale units currently adopt
distributed control systems that
integrate master and auxiliary control
networks. As many HMI stations
stay on one same network segment,
viruses may be easily transmitted
across the entire system as soon as
one of the HMI stations is infected,
resulting in slowed screen refresh on
HMI station, poor data communication,
and even network paralysis and
crash of industrial control computers.
Previous cases already exist in which
loss of production was caused by virus
infection to unit DCS in a power plant.
Disadvantages of
Conventional Antivirus
Software
• Virus library of the antivirus software
requires periodic upgrade through
download. As power plant DCS is
isolated from outer network, the
downloaded virus library is copied
to HMI stations via storage devices,
which adds to the maintenance
workload as well as the risk of being
infected.
• The DCS software is professional
software, whereas general antivirus
program may erroneously kill it,
making DCS unable to run and
endangering safety of running units.
• Any antivirus software relies on
virus libraries for virus identification
and cleanup, while an operating
DCS needs to generate new files
continuously and perform real-time
modifications. Frequently, these files
cannot be identified by the antivirus
software and are erroneously
detected as virus features, resulting
in data loss.
GE Antivirus Measures for
DCS System Software
With the whitelisting technology, GE
deploys a different solution to meet
customers requirements for DCS
antivirus.
Taking advantage of mature existing
software technologies, GE's solution
prevents against threats of malicious
software to the computer system
by setting up white lists for system
software.
Compared with
conventional antivirus
software, it has the
following features
• Persistent prevention against
viruses and malware threats without
required virus library updates
• Dynamic white list for enhanced
security and the ease of application
update
• Application updates controlled
by authority for enhanced system
security
• Protection for other file types in
addition to all applications
GE DCS antivirus control solution is suitable
for the HMI software platforms of all GE
products, and supports the Windows XP
operating system and above.
The implementation method is to
reinstall the original industrial control
computer, install the whitelisting
software, set up the software according
to its instruction manual, and enable
software-based antivirus protection
for the industrial control computer
of the DCS. One package of software
is installed per industrial control
computer. 31
GE Digital Solutions

GE Digital Solutions is an industry-leading innovator whose business involves sensing

and measuring, nondestructive detection, condition monitoring, and automation and
optimized control, enabling customers to achieve higher accuracy, greater efficiency,
and better safety with the aim to increased value and production. Its product
portfolio has been widely used in such sectors as aeronautics and aerospace, oil and
gas, power generation, transportation, etc. We have set up more than 40 enterprises
across 25 countries, and are a subordinate to GE Oil & Gas, providing industrial
customers with asset health solutions that are more environment-friendly, much
smarter, and even more efficient and effective.

China Customer Service Center Hotline: 800 915 9966

Customer Service Center E-mail: dscallcenter@ge.com

160 Wenjing Road, Minhang Development Zone, Shanghai, 200245

Phone: (021) 2403 6666
Fax: (021) 6430 2778
http://geoilandgas.ge.com.cn/digitalsolutions/

© 2018 Baker Hughes, a GE company – All rights reserved.

2018/03 version 1