Oil & Gas Industry Applications

GE Oil & Gas
Oil & Gas Industry Applications
CONTROL SYSTEMS
Mark V
MAINTENANCE
Index
• Introduction to the Speedtronic Mark V
• Speedtronic Mark V features
• General Software Description
• Mark V Software Configuration
• Cimplicity
• Operating Procedures and Investigation
• Troubleshooting
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Index
Introduction to Speedtronic Mark V
 General overview of the control system
 Control panel architecture
 Operator Interface HMI
 Panel documentation
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Introduction to Mark V General overview of control system
Control System
Mark V is used for the control and protection of steam and gas
turbines both in electrical generation and process plant applications.
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Control System
Gas Turbine and

Generator or
Compressor
field cables
Unit Control Panel (UCP) Mark V
communication cable
HMI
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The Unit Control Panel
• Unit control panel is main control system that

include Mark V, Bently Nevada, FireFighting system
and other equipment.
• All the instrumentations are connected to UCP
trough field cabling.
• UCP controls all field equipments based on its
internal software, field signals feedback and
operator commands
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Introduction to Mark V Operatore interface HMI
The Operator Interface (HMI and )
• The HMI is connected to the Mark V in the UCP

• Can be rack mounted or desktop installed
• DOS or Windows operating system
• The internal software of the Mark V can be
modified from the HMI
• The operator can monitor the most important field
processes on the HMI
• The operator can give commands to the
Mark V through the HMI (e.g. startup the turbine,
change the speed)
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Introduction to Mark V General control panel architecture
The UCP and the HMI
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Introduction to Mark V Operator interface HMI
The UCP and the HMI
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The Unit Control Panel
UCP main sections:
• TCP – turbine control panel

• ACP – auxiliary control panel
• IOP – interface operator panel
• MP – marshalling panel
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The UCP / TCP section
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The UCP / ACP section
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The UCP / ACP
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The UCP / IOP section
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The UCP / MP section
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Barriers, surge arrestors
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Terminal strips
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Introduction to Mark V Panel documentation
Piping and Instrument Diagram (P&ID)
• Displays all the intruments and sensors present on

the field and the connection between them and the
UCP
• One page of the P&ID describes one coherent part

of the instrumentation (e.g. Lube oil system)
• Usually each P&ID page have a graphic page

ordered to it in the HMI
• This allows the operator to understand and

monitor/control all the instrumentation
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The Instrument List / Device summary
Lists the instruments connected to the UCP

providing:
• Signal name
• Customer tag
• Signal description
• Transmitter type
• Calibration range
• Analog setpoints
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The Functional description
Describes the Mark V internal software explaining

each procedure of the control processes, for
example:
• Startup process
• Shutdown process
• Different motors, heaters, valves sequences
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The Control system schematic
Describes the interconnection between the

standalone systems:
• Unit Control Panel with Mark V
• Operator Interface (HMI)
• MCC, DCP
• DCS
• Vibration and temperature monitor
• F&G controller
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Signal identification
• All the panel documentations are using standard

naming for the signals.
• For example we can find a device name 88HQ:
Motor 88 HQ
Hydraulic Oil
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According the standard naming, the number in the

signal name shows the device type:
-88 motor -28 flame detectors in C.C.
-52 feedback motor (<MCC) is running -39 vibration
-4 command start/stop motor (>MCC) -77 speed
-33 limit switch -45 Fire and gas trasmitter
-20 command for electrovalve -90 cmd to servovalve SRV/IGV
-96 general trasmitter -65 cmd to servovalve GCV/NGV
-26 temperature signal -49 overload
-63 pressure signal -27 undervoltage
-71 level signal -86 fault
-60 flow transmitter -3 permissive
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According the standard naming, the letters in the signal

name shows the signal type:
-E emergency -F fuel
-R ratchet -G gas
-Q oil
-H hydraulic Mark V software tagname prefixes:
-A auxiliary -L Logic (digital signal 0-1)

-A Analog signal
-K Constant signal
Examples:
-L52QA  lube oil auxiliary pump running
-A63HQ  hydraulic oil pressure
-L33HR  hydraulic ratchet limit switch
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Gas Turbine Fundamentals Panel documentation
Documents
Document title Document number

Schematic Piping Diagram
SOM56785
and Devices Summary
Functional Description SOM58327
Control System Schematic SOM58324
Unit Control Panel Layout SOM58325
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Index
Hardware Introduction
 Control Panel hardware configuration
 Mark V data communication networks
 Backup operator interface panel
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Hardware Introduction Control Panel
TMR / Simplex / LM Philosophy
Mark V provided in three different configurations:
• Triple Modular Redundant (TMR)

Employs three identical control processors (<R>, <S> and <T>) and each
performs identical operations for redundancy. Very stable and reliable.
• Simplex
Employs only a single control processor <R>, without redundancy
• LM
Different core hierarchy, more simple configuration, single control
processor <R>. Without redundancy, but higher calculation speed.
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TMR Mark V configuration
S R C
T P PD
QD1 CD
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Simplex Mark V configuration
R C
P PD
QD1 CD
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The Mark V setup
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Mark V LM UCP configuration
R2 R1 R5
R P1 PD
R3 Q11 Q51
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The Mark V setup
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The Mark V cores
Mark V cards
terminal board cards
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The Mark V cores
The cores can be devided to 2 main sections:
• Mark V cards – locations from 1 to 5

(main control processors, I/O signal processing, communication
managament, power distribution)
• Terminal Board cards – locations from 6 to 9
(physical connection to the I/O signals by field wires)
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The Mark V cores
Explanation of the card locations:
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The Mark V cores
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The Mark V cores
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The Mark V cores
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The Mark V cores
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The Mark V cores
• <PD> core
Distributing power to all the other cores. Contains switches and fuses for
protection. Also called Power Distribution Module, PDM
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The Mark V cores – the PD core
 protection
core (TCEA X/Y/Z)
R S T C D X Y Z
<R> core
(TCPS)
floating dc bus
<S> core
(TCPS)
Resistor
bridge
<T> core
(TCPS) excitation PDM
for
terminal
<C> core boards 125 VDC
(TCPS) Input LP
FILTERS
<D> core
(TCPS) 230 / 115 VAC
AC/DC (50 / 60 Hz)
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The Mark V cores
• core
Protective core. Most important signals are connected here:
• speed pickup for overspeed monitoring

• flame detectors input
• trip solenoid valve control
• emergency trip pushbutton
• generator / main bus signals
received for autosynchronization
management
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The Mark V cores
• <C> core
• external communication with the HMI
• non-critical analog I/O signals (4..20 mA, RTD, TcK)
• handling of <CD> core signals
• <CD> core
Handles non-critical digital I/O signals (pump status indication, alarms,...)
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The Mark V cores
• <R>, <S>, <T> cores

• turbine logic sequence execution
• critical analog I/O signals (4..20 mA,
RTD,TcK,LVDT,servovalves)
• redundant handling of <QD1> and core
signals using voting logic on TMR panels
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The Mark V cores
• <QD1> and <QD2> cores

Handle critical digital I/O signals
<QD2> is optional, provides I/O expansion if needed
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The Mark V cores
• <D> core - optional

Ensures communication redundancy with the HMI for the <C> core.
Doesn’t substitute the task for handling the analog I/O signals on <C> and
the digital I/O signals on <CD> cores.
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Mark V network communications
Includes 3 different networks:
• Stage Link
(external connection between Mark V and the HMI)
• Data Exchange Network (DENET)
(internal connection between the Mark V cores)
• I/O Network (IONET)
(internal connection between the main cores and the cards)
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STAGE LINK communication
• The STAGE LINK is for external communication

• ARCNET protocol used on coaxial cable
• Between the <C> core of the UCP and the HMI
• One or more units can be connected
• BNC type connectors are used
• Importance of the end line termination resistor
• Different addresses used for Mark V and HMI
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STAGE LINK connection
STAGELINK SINGLE ARCHITECTURE
HMI Mark V
Termination resistors:
93 
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STAGELINK MULTI UNIT ARCHITECTURE

HMI 1 HMI 2
3A 3B
addresses
Mark V 1 Mark V 2
C C
FE FD
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ADDRESS SETUP
Mark V – keyboard of the

<C> core
HMI – DIP switches on the card
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DENET communication
• DENET is an internal communication

• Connecting the <R> <S> <T> and <C> cores
• Used for data exchange for signal voting
• Ensures maintenance of any of the <R> <S> <T>
core while the turbine is running
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IONET communication
• IONET is an internal communication

• Permits data exchange between the main cores
and the other cards
• Flat cables
• RS-485 serial protocol is used
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IONET communication
TMR IONET configuration

for <R>, <S> and <T> cores
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Analog I/P A/D D/A Analog O/P

<R>
Digital I/P 2/3 2/3 Digital O/P
A/D D/A
,, <S> ,,
2/3 2/3
A/D D/A
,, ,,
<T>
2/3 2/3
A/D D/A
,, <C> ,,
1/1 1/1
DE net
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The core displays
• The core display is used to display useful

information about the main cores (e.g. name,
diagnostic status)
• Only on <R>, <S>, <T> and <C> cores
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The core displays
• The name of the core

• Status of the core
• CPU utilization in %
• Time display
if corresponds to the HMI system time, then the synchronisation
between the Mark V and the HMI is suitable
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The core displays
The status of the core (system diagnostic):
• A7 – the system works properly

• A6 – mismatch in the system configuration
in this case the hardware and the software is OK
• A5 – usually means hardware problems
• A4 – usually hardware and also software
problems
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Difference for Simplex Mark V

• Only <R> main processor is installed, <S> and
<T> are not present
• All other cores are installed
• The <QD1> and <QD2> cores provide only non-
redundant data processing
• But the core is still triple-redundant also in
the Simplex system providing redundant
processing of critical protection signals
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Difference for Mark V LM
• Simplex architecture, with only the <R> main

controller
• No <C> core installed, communication task is
handled by <R> core
• <PD> core is the same for power distribution
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• <P1> is the same as and still triple redundant

for protective signals
• Simplified hardware architecture but increased
computing speed
• Typically used for aeroderivative machines with
high shaft speed
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• <R> core
• turbine logic sequence execution
• external communication with the HMI
• internal communication with the <R1>, <R2>, <R3>, <R5>
cores
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• <R1>, <R2>, <R3>, <R5> cores

• handles analog I/O signals
(4..20 mA, 1..5 V, RTD,TcK,servovalves)
• internal communication between the <R> and the ,
<Q11>, <Q51> cores
• <Q11>, <Q51> cores

Handles digital I/O signals
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• Stage Link and IONET are the same

• Instead of the DENET the COREBUS network is
used for data exchange between the <Rx> cores
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Mark V cards configuration
The main CPU cards
• DCCQ / DCCB: the main motherboard CPU card

of the core, executes the turbine logic sequence
• LCCQ / LCCB: daughter card of the DCC, helps in
calculations
<R>, <S>, <T> and <C> location 1
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Redundant analog signal cards
• TCQA, TCQB, TCQC cards for critical signals

• 4..20 mA inputs/outputs and voltage inputs
• LVDT excitation/feedback and servovale control
• thermocouple temperature inputs
• magnetic speed pickup sensors
• vibration inputs
<R>, <S>, <T> location 2/3/4
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Redundant analog terminal boards
• QTBA, TBQA, TBQB, TBQC, TBQD boards

• provide hardware connection to all types of
redundant analog input and output signals
<R>, <S>, <T> location 6/7/8/9
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Mark V cards configuration – hardware connection example
Refer to manual GEH-6195D appendix G for more details

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Non-redundant analog signal cards
• TCCA, TCCB cards for non-critical signals

• 4..20 mA input/outputs
• thermocouple temperature inputs
• RTD temperature inputs
<C> location 2/3
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Non-redundant analog terminal boards
• CTBA, TBCA, TBCB, TBQA boards

• provide hardware connection to all types of
non-redundant analog input and output signals
<C> location 6/7/8/9
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Digital signal cards
• TCDA – digital input/output signal processing

for critical and non-critical signals
• TCRA – relay card for digital output signals
<CD>, <QD1>, <QD2> location 1/5
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Digital signal terminal boards
• DTBA, DTBB – digital input signals hardware

connection for critical and non-critical signals
• DTBC, DTBD – digital output signals hardware
connection for critical and non-critical signals
<CD>, <QD1>, <QD2> location 6/7/8/9
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Core power supply card
• TCPS – core power supply card

• receives 125 Vdc supply from PDM module
• provides ±24 Vdc, ±15 Vdc and ±5 Vdc as
operating voltage supply for all the other cards
<R>, <S>, <T> and <C> location 5
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 protection core cards
• TCEA – contains the CPU circuits for critical

protection, three redundant TCEA cards are
installed
• TCTG – trip related card, holds the trip relays,
monitors emergency trip pushbuttons and
generator breaker conditions
 location 1/3/4/5
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 protection core cards
• TCEB – provides interconnection of protection

signals between the terminal board and the
signal cards
• PTBA – terminal board, provides the hardware
connection of the protection signals
 location 2/6
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<PD> power distribution core
• TCPD – provides circuits to distribute the

incoming main power supply to all the other
cores
<PD> location 1
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Mark V cores and cards
<C> core
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<R> core
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<S> core
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<T> core
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<CD> core
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<QD1> and <QD2> core
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 core
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<D> core
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BOI – Backup Operator Interface
• The BOI – Backup operator interface is used in

the case of lost communication between the
UCP and the HMI
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• Mounted on the external door of the UCP

• Process alarms can be displayed
• Some important signal values are displayed
(e.g. speed, FSR, exhaust temperature)
• Operator can send some very basic commands
like turbine mode selection, start and stop
commands, load selection
• Not installed on Mark V LM
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BOI connection
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TMR voting system
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TMR voting system
• On a TMR system critical signals are processed

by three I/O cards
• Input signal voting takes place inside the main
controllers (software voting)
• Output signal voting takes place on the I/O
cards and terminal boards (hardware voting)
• Some voting examples:
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QD IONET PROC DENET PROC DENET PROC
LCC DCC
DTBA DCC R
or TCDA VOTE
S R
R T
DTBB R Seq.
Contact
Input
LCC DCC
DCC R
TCDA VOTE
S S
S T
S Seq.
LCC DCC
DCC R
TCDA VOTE
S T
T T
T Seq.
VR Voting
VS Mismatch
VT DCC
QD Contact Input Voting System C
PVR PreVote
Diag.
PVS
PVT
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TMR voting system
Logical input voting examples
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PROC IONET QD
Numbered from 1 to 30
DCC R
R TCDA
S TCRA - 1 NO
T NC
30 output
Seq.
DTBC
C
RD 30 relé
DCC R SOL
S TCDA
S
Px Mx
T
Seq.
PD - 110Vdc
Numbered from 31 to 60
DCC R
T TCDA
S
T
Seq.
30 output
TCRA - 2
DTBD
RD 30 relé
QD Contact Output
Voting System
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TMR voting system
Analog (median) input voting examples
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Index
General Software Description
 Operating system and software structure
 TCI and Cimplicity
 HMI and software tools
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General Software Description <HMI> Operating Interface
Human Machine Interface (HMI)
• industrial computer
• monitoring the plant
• customizing Mark V (I/O, sequence)
• not critical, doesn’t sequencing
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• Intel Pentium processor

• Windows operating system
• monitor
• keyboard, pointing device (mouse or trackball)
• alarm printer
• ARCNET interface card
• serial (RS-232) interfaces for Bently Nevada and
DCS if needed
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Operator interface: vs <HMI>
• Differences between and <HMI>
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• Main reasons of upgrade:

• Old DOS based computer is now obsolete
• Old ARCNET card (ISA bus) not available
anymore
• Other computer components are also not
available
• In case of hardware failure retrofit to <HMI> is a
must
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• Main benefits of the <HMI> :

• Windows operating system instead of DOS
• Multitasking, multiple windows can be open
• Significatly more user friendly interface
• Vastly improved graphic pages and trending
possibilities through new Cimplicity grapic
interface
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• Improved graphic page navigation

• More easy to use and effective diagnostic tools
are available
• Advanced logic development tools
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General Software Description Software Structure
Main software components
• TCI (Turbine Control Interface):

managing the communication with the Mark V by
ARCNET (reading, writing signal values) and allows the
configuration of the Mark V
• Cimplicity
visualization software, displays the animated graphic
pages, and handles instructions from the operator
• CimBridge
forwards the information (variable values) between the
TCI and the Cimplicity
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General Software Description TCI and Cimplicity
Data Exchange
dfd CimBridge dfd

Cimplicity TCI
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TCI is part of the Turbine runtime system, which integrates the Mark V controller
and CIMPLICITY.
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• Cimplicity can be used as server or viewer

• Only server can communicate with Mark V
• Viewer can communicate with server for displaying
turbine data and controlling the turbine
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ETHERNET
ARCNET
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• Cimplicity server can not directly exchange data

with the Mark V, only TCI can
• Between TCI and Cimplicity the CimBrigde provides
data exchange
• TCI manages additional communication: serial
data exchange with DCS using MODBUS or GSM
protocol
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Directory structure
• C:\CIMPLICITY
Cimplicity application executables for Windows
• C:\SITE
Mark V configuration, pseudo drive: F:
• C:\Program Files\GE Control System Solutions\TCI
TCI executables for the Windows,
pseudo drive: G:
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Directory structure
• G:\LOG
LOG files for the TCI, can be used for troubleshooting
• F:\Cimproj
Cimplicity project files (graphic pages, project specific
configuration)
• F:\Unitn
all the configuration files for the Mark V (sequences,
I/O configuration)
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Directory structure
Cimplicity application Directory
Configuration directory :
- Cimproj for screens configuration
- Unit1 Mark V configuration files

TCI application directory
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HMI and software tools TCI tools
TCI tools introduction
• TCI tools are available for diagnostic /

maintenance purposes
• Installed together with TCI
• Accessible from the Start menu or from desktop
shortcut, opening the relevant unit’s icon
T1/T2/T3...
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Select the relevant unit
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TCI tool icons
Or use the desktop icons
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Command prompt
• Can be used to access DOS command prompt

• Certain maintenance commands are available, for
example I/O configurator, compiler or download to
Mark V
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Command prompt – TCI service control
• In the command prompt one can stop and start the

TCI service
• It’s needed in case of any modification is applied to
take the changes effect
• While TCI is not running all communication tasks
(with Mark V and with DCS) will be suspended
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Command prompt – TCI service control
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Demand display
• Very basic tool to display selected signals value

and handle manual pushbutton commands
• There are prepared displays typically to be used
during commissioning
• Custom user-defined displays may be also created
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Demand display
Click on display name to open
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Demand display
Create a new display
New display added
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Demand display
Add a new signal line
Type the signal name
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Dynamic rung display
• For viewing sequencing information

• Used for monitoring purposes only
• The control sequence can not be altered with it
• Green animation shows contact closed status
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Dynamic rung display
Navigation buttons
When opening, select the
sequence you want to see
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Logic forcing
• Logic forcing changes or maintains the logic state

of a point (0 or 1) regardless of the permissives
driving the point
• Only logic (digital) signals can be forced
• Be careful before forcing a point, only authorized
personnel should use it
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Logic forcing
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Prevote data
• Allows to view logic and analog I/O values before

the three independent processors have selected a
value through voting
• Useful for troubleshooting voting mismatches
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Prevote data
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Constant display
• Displays the value of each of the control constants

in the selected unit
• From this display the user can call up the Control
Constants Adjust Display to change any constants
that are adjustable
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Constant display
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Trip history
• Used for manual trip log collection

• Useful after a turbine trip or can be used also for
data collection when no trip has occured
• Collected data is displayed in notepad
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Trip history
For data collection after trip
For data collection without trip
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Trip log viewer
• Used to display automatically collected trip log

information
• Automatic collection is available for the last 10
trips
• Collected data is displayed in notepad
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Trip log viewer
Select the trip log based on time/date
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Trip history and Trip log viewer
• Information collected:
• Post Trip List: three 1-second post trip records
• 10 Second List: ten 1-second records
• 1-Minute List: five 10-second records
• 10-Minute List: nine 1-minute records
• 1-Hour List: five 10-minute records
• 4-Hour List: four 1-hour records
• Last 60 Process Alarms
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Trip history and Trip log viewer
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Alarm logger
• Matrix dot printer is connected to the HMI

• It can print hard copy history of any live alarms,
events or SOE depending on user settings
• Command to open the configuration:
• G:\EXEC\LOGGER.EXE
Select alarm types to be printed
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Index
Mark V Software Configuration
 Configuration file structure
 I/O configuration
 Sequences
 Compiler (MK5MAKE)
 Download configuration files
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Configuration Software Configuration file structure
Mark V configuration files
• All the Mark V configuration files are stored at

F:\Unitn directory
• We can view these files for information,
troubleshhoting purposes or authorized person
can modify them to alter the existing configuration
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The different levels of configuration
Variable Definition
Initialization
Logic sequence
Compiler
Download
169
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Variable Definition
Signal assignament to input/output channels and
IO.ASG
In/Out
scale definition
TC2KREPT.TXT Devices connection report
ALLOCSSP.ASG Alarm signals address definition

Alarm
ALARM.DAT Alarm signals display message definition

Internal
FACTORY.ASG Internal and constant definition files

SITE.ASG
Doc
LONGNAME.DAT Signals description file

170
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Initialization
Constant
CONST_Q.SRC Control constant value initialization

IO config
Configuration of all the I/O channels parameters and

IO_CFG.AP1 settings: 4-20mA, logic, Tc, vibration sensor, magnetic
pickup, servo, LDVT,...
171
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Sequences
SEQ_xxxx.SRC
Sequence
Control sequence segment files
MSTR_SEQ.CFG Keeps the list of all the sequence segment files
Complete control sequence documenter file,

Doc.
CSP.PRN automatically generated from the above files
172
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To view or modify the files contents
*.ASG
*.DAT Notepad
*.TXT Or
CONST_Q.SRC GEEDIT
MSTR_SEQ.CFG
CSP.PRN
IO_CFG.AP1 IO Configurator
SEQ_xxxx.SRC Sequence editor
173
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Configuration Software I/O Configuration
IO configurator
• DOS based tool

• Used for viewing and changing I/O channel
configuration and parameters
• After modification download in needed
174
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Configuration Software I/O Configuration
IO configurator
Digital inputs inversion mask settings
Analog 4..20 mA range settings
175
27/02/2017
Configuration Software Sequences
Sequence editor
• Similar to Dynamic rung display, but used for

modifications
• No live data is displayed on the rungs
• Can be used to modify existing sequences or
develop new sequence
176
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Configuration Software Sequences
Sequence editor
Toolbar for modifications and navigation
Select sequence file to open
177
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Configuration Software Compile and download
• Once modification is applied to the configuration

files, compile and download is neccessary to take
the changes effect
• For both procedures we need to use Command
prompt /DOS commands
178
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mk5make
• Compiles the logic sequence, the output is saved

on the hard disk ready to be downloaded
eeprom down T1 <core> user
• Starts the download of the compiled configuration

from the HMI to the T1 unit Mark V, command must
be repeated for each processor cores R/S/T/C/D
179
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• For Mark V LM the download command is different

udf
• Opens the download propmt
send *.ap1
• Starts the actual download procedure

180
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• After the download procedure all the cores must be

rebooted to take the changes effect
181
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• If any sequence has been modified, we should also

update the CSP.PRN file using the Sequence
documenter command:
seqdocmt
• If we changes alarm signals configuration, the

alarm list should be also updated:
alarm_l
182
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• Additional files are used to configure the HMI/TCI

communication parameters
• These are found in the F:\ root
• Store communication settings for
HMI <-> Mark V and HMI <-> DCS communication
183
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HMI communication
Mark V
Communication setup with Mark V, controller

CONFIG.DAT network addresses, multiunit settings
IO_PORTS.DAT Comminication setup with DCS, MODBUS serial link

DCS
settings and parameters
184
27/02/2017
• Both files can be viewed/modified using the

Notepad or the GEEDIT editor
• After modification to take the changes effect the
TCI service must be restarted
185
27/02/2017
Index
Cimplicity
 Screens navigation
 Applications
 Alarm display
186
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Cimplicity Operator screens
Introduction
CIMPLICITY is a very easy-to-use supervisory

monitoring and control software product.
It consolidates the collection
of data from your facility’s
sensors and devices,
and then transforms the

data into dynamic text,
alarm and graphic displays.
It gives you access to
real-time information, helping
you make appropriate decisions
to improve quality, productivity
and, ultimately, profitability.
187
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Introduction
Main project file
188
27/02/2017
Introduction
*.gef Workbench project
Screens
Points
Equipment
The Workbench window is divided into two panes. On the left is a folder/file tree that contains the
various tools and product options. By clicking on a folder or option on the left, you can view the
corresponding configuration items on the right.
189
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Introduction
Toolbar buttons
190
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Cimplicity Workbench
Project start / stop
Drivers being loaded
191
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Cimplicity operator screens
Principal screen
192
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Cimplicity operator screens overview
Unit selection
Speed raise/lower Master Reset
Open alarm screen

Language
selection
Navigation bar
193
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Main command pushbuttons
Close screen and
return to main screen
Motor selection
Motor start/stop
commands
Screen navigation
194
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Start and stop general procedure
Choose operating mode
Click START
195
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Cimplicity Alarm display
Alarm display
• Alarm and trip condition messages are displayed

on the Cimplicity Alarm screen
• Each alarm message includes a timestamp
retrieved from the controller internal clock
• Alarm shall be acknowledged by operators
• Message color change shows alarm type and
status
196
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Alarm display
Class ID Description Alarmed Acknoledged Normal
PRC Turbine process control alarm (and trip) PRC Alarm text PRC Alarm text PRC Alarm text
DIAG Signal unhealty and controller faults DIAG Alarm text DIAG Alarm text DIAG Alarm text
• Different alarm classes: PRC and DIAG

• PRC - Process Alarms : Site specific HMI Panel Text
Alarms, related to field conditions
• DIAG - Diagnostic Alarms : Mark V Hardware or
System Trouble alarms
197
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Alarm display
198
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Alarm history
• Alarm history information is collected by TCI

• Can be displayed using a built-in webserver and a
web browser opening the address http://localhost
199
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Alarm history
Alarm history
200
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Alarm history
201
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Index
Operating procedures and investigation
 Permissive to Start / Crack / Fire
 Startup and shutdown sequence
 Practice
202
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Operation procedure Start permissive
Turbine startup permissive
• Prior turbine startup obtaining the Startup

permissive is a must
• There is a dedicated graphic screen to view
individual permissive statuses and the cumulative
permissive as well
• Green color – OK,
red color – not OK
203
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• Any failed (red colored) permessive should be

investigated and the problem solved prior turbine
startup
• If all the permissives are fine, the cumulative „Unit
ready to start” will be displayed with green color
204
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• Additional permissive pages can be used during

the different phases of the startup sequence
Start check
L4 check
Crank check
Ignition check
Load check
205
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Select Start Up group
Click Start Checks
206
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Operation procedure Startup and shutdown
Turbine startup main steps Startup sequence
Ready to start
Start command
Auxiliaries started, starter motor started
Turbine is accelerated to cranking speed
Purging takes place
N Purge
completed?
Y
Firing timer is initiated, spark plugs are energized
N
Flame detected
No flame is detected Y
Trip A
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Turbine startup main steps
A
Fuel level is slightly reduced
N Warm-up time over
Y
Fuel level is increased exponentially for acceleration
Turbine accelerate until 14HS picks up which

indicates turbine has reached minimum governing speed
Auxiliary lube oil and hydraulic oil pumps are stopped
Full speed no load displayed
Complete sequence displayed
209
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100%
L3ARS
Aux ready to start
START Command 88QA = ON (aux. Pump)
Emergency test (max 30s) 88HQ = ON (hyd. Pump)
L3CRS (core ready to start) 88HR = ON (racket pump)
L3RS (Ready to start 88BA1/2 = ON (enc. Fan)
88QV =ON (oil separ. Fan)
L3PRC L1X = 1 (aux. Started)
PROCESS/LOAD PREPARATION
Pressurization, L3ARC Ready to crank
Encluosure purge, valve (start ing means system )
position of the load valves
MS5002C start-up sequence
Acceleration to crank
20%
(max 2min)
2min)
Purge
(K2TV=
20VG (vent valve)
CLOSED
L3RF (Ready to fire)
L2TVX (ingnition sparks) Ignition (max 10s) FLAME =1
18%
FSR
Operation procedure
Warm up (1 min)
14%
L4 =1 (master protective signal) L2VX = 1
NOTE:
(Acceleration)
GCV are re-closed.

Starting means
system OFF
80%
(Self substaining
< 60%
speed)
The turbine returns in crank mode.

IGV (from 34° to 56°)
vent valve (20VG-1) is re-opened, SRV anf

In case of NO fire after 10s the intersatage
Startup and shutdown
88QA = OFF (aux. Pump)

88HQ = OFF (hyd. Pump)
92.5%
Acceleration to operative speed (max 10min)
operative speed HP
Bleed valves closed.
L14HS = 1 minimum
L14HS  0 if TNH90%
TNH
LP 45%
LP speed control
NOTE:
L3 = 1
closed to
TNL
Nozzels are
The Second
operative speed LP
L14LS =1 minimum
time
the HP shaft.
maintain fixed
Stage variable
27/02/2017
210
Ready to load
L14LS  0 if TNL41%
TNL
TNH
Shutdown req.
HMI, Remote, Aux, Core
L94ASHD L94X= 1 (SD in progress)
L3 = 0
100%
unloaded
TNR 50%
TNR From LP to HP
unloaded
MS5002C Shut-down sequence
(max 5min)
Decelerating
88QA off (aux)

90%
88HQ off (hyd) L14HS = 0

Operation procedure
L14LR = 1
Flame
0.1%
Shut down no flame FLAME = 0
closed
SRV, GCV
Ventilation timer
Shutdown
Lube oil cooler timer

88HR on L14HR = 1
(rachet) L94X = 0 (SD completed)
0.06%
L14HR = 1 and L14LR = 1

STOP condition
stopped +60s delay
Cooldown timer
88BA off
2h
88QF off
3h
27/02/2017
211
88QA off
10h
88HR off
L3ARS
100%
L3PRS (process)
Aux ready to start
START request
Emergency test start (L4ETST = 1)
(HMI/Remote)
ET passed (L3ETP = 1) max 20min
88BA1/2 on (encl. fan)
88QV on (min. Oil separator) Proc. Ready to lube (L3PMQA = 1)
(seal gas ok)
88QA on (aux. pump)
F&G N2 bottle bank enabled
L3ASP
L4 = 1 Process valves’ sequence start
Fuel gas warmup sequence
Fuel gas OK (P20baarg, T30°C)
PGT25+ start-up sequence
L3PRC (proc. Valves and seal gas)

L3ARC
88CR on (starting device)
NGG  1900rpm in max 303s
Synt. lube oil cooling fans on
2min
Purge
2100rpm
Operation procedure
KHS_CRK_REF
Fuel shut-off valves opened

Infravalve vent valve clesed Ignition (max 10s)
Metering in regulation 28FDX = 1 flame detected
Vibration ON
88CR off
4600rpm
Ignition)
And Tsynt 20°C )

5min
(max 2min from

WARM-UP
(max 30min)
(max 1.5min From ignition
GTWUDONE = 1 (warmup done)

NGGIDL = 6800rpm
6780rpm IDLE SPEED
5min elapsed and Tsynt 32°C

Seal Gas closed (booster stop)

AS and Load control active
 250rpm
NPTSYNIDL  L3=1, L3ARL

(fail to speen)
100%
3000rpm
Load control
If not  NPTBWYFSM = 1
2897.5rpm L14LS=1
NGG
6100rpm
NPT
time
27/02/2017
212
PGT25+ Shut-down sequence
Synt. Oil
sep. fan off
5min Syntetic oil cooling timer
100% 15min
NGG IDLE cooldown 88BA off (enc. fan)
Ventilation timer
2h
Off skid fan off
Off skid fuelclosed
6850rpm
NGGIDL = 6800rpm
Off skid vent opened
NPT PT cooldown timer (restart allowed with motoring)
4h
(Loss of flame)
L28FDX = 0
5min 88BA1/2 off (encl. fan)
GG cooldown 88QV off (min. Oil separator)
2745rpm 88QA off (aux. pump)
L14LS=0 F&G N2 bottle bank disabled
Reload 2100rpm
L14LR = 1 L14HR = 1
allowed MOTORING time
105rpm 300rpm
L4 = 0
Shutdown req.
Seal Gas opened (booster on)
NGG  300rpm and NPT = 0rpm

Infravalve vent valve closed
88CR off (starting device)

Unit stopped signal to DCS
HMI, Remote, controller, process
L3 =0 (PT unloading)
Fuel shut-off valves closed

AS and Load control active
Clutch disengadged
Synt. Oil L, LL disabled
Anti Hydrates closed

Metering valve closed
88CR on (starting device)

Hot by-pass closed
NOTE: 4h of system lock-out

in case of motoring not
Clutch engadged
Vibration off
started in 10min.
213
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Index
Troubleshooting
 LVDT calibration (AUTOCAL)
 Process alarm investigation
 Diagnostic counter
 Board replacement procedure
214
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215
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Troubleshooting
Are you ready to work? Do you know the risk?

Take care!
Before the activities, you have time to
think about the risk!
216
216
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Troubleshooting LVDT calibration
LVDT calibration
• For servovalve actuated devices, like SRV, GCV, IGV,

etc.
• During the calibration both end position feedback
voltages of the LVDT’s will be recorded and then
stored in the Mark V
• Before the calibration procedure the turbine must
be stoped, fuel isolated and lube/ hydraulic/control
oil systems started manually
• Calibration permissive L3ADJ must be forced to ‘1’
217
27/02/2017
LVDT calibration
218
27/02/2017
LVDT working principle

LVDTs are robust, absolute linear
position/displacement transducers.
The LVDT converts a position or linear

displacement from a mechanical reference
(zero, or null position) into a proportional
electrical signal containing phase (for
direction) and amplitude (for distance)
information.
The LVDT operation does not require an electrical
contact between the moving part (probe or core
assembly) and the coil assembly, but instead relies
on electromagnetic coupling.
• Do you know what is the phisical working

principle of a LVDT? 219
27/02/2017
LVDT calibration
IGV/NGV
Mark V 3 coil servovalve
<R> Coil 1
<S> Coil 2
<T> Coil 3
HO
drain Double LVDT

Feedback
220
27/02/2017
LVDT calibration
• To open the AUTOCAL tool use the command

G:\EXEC\AUTOCAL.EXE
• In the tree view select the device to be calibrated
• Calibration data appears and pushbuttons should
be visible on the right when system is ready for
calibration
221
27/02/2017
LVDT calibration
Recorded calibration
Select the relevant device reference values Pushbutton commands
will appear here
222
27/02/2017
LVDT calibration
• First Enable Command pushbutton to be used

• Click Start Calibrate to execute the procedure The
Mark V will move the device to full open end
position then back to full closed end position
• Relevant LVDT feedback voltages are automatically
recorded at both end positions and finally
displayed on the screen as calibration reference
• These calibration reference values must be noted
for all 3 controllers
223
27/02/2017
LVDT calibration
• Automatic verification can be done by using the

Verify Position or Verify Current buttons
• For manual stroking use the Enable Manual button
and then changing the Manual Setpoint field
between the range 0..100%
• After verification the average of R/S/T measured
voltage values (calibration reference) must be
manually inserted to the relevant device
parameters in the I/O configurator tool
224
27/02/2017
LVDT calibration
Recorded calibration
reference values
to be written here
225
27/02/2017
Troubleshooting Process alarm investigation
Process alarm investigation
Note the Alarm ID

of the alarm
226
27/02/2017
Alarm ID is used to
locate alarm in the alarm list
227
27/02/2017
Open the ALARM.LST
228
27/02/2017
Find the Alarm ID

noted before
Copy the alarm

signal name
229
27/02/2017
Open the CSP.PRN
230
27/02/2017
Search for the

alarm signal name
231
27/02/2017
232
27/02/2017
Troubleshooting Diagnostic counter display
Diagnostic counters
• Provides low level information on control and I/O

boards functions
• Detailed information about main controllers, I/O
channels status, etc.
• To be used by firmware designers and field
personnel only, not for plant operators
233
27/02/2017
Troubleshooting Diagnostic counter display
Diagnostic counters
Select card type and

option from tree view menu
234
27/02/2017
Troubleshooting Diagnostic alarms
Diagnostic alarms
• Diagnostic Alarms are caused by equipment

problems, and use settings factory
• Diagnostic Alarms identify the failed module to
help the service engineer quickly repair the system
• Displayed with specific color:
Class ID Description Alarmed Acknoledged Normal
PRC Turbine process control alarm (and trip) PRC Alarm text PRC Alarm text PRC Alarm text
DIAG Signal unhealty and controller faults DIAG Alarm text DIAG Alarm text DIAG Alarm text
235
27/02/2017
Troubleshooting Board replacement procedure
Mark V board replacement
• Make sure that power to the core is off

• Carefully disconnect cables
• Release all hold down tabs,
then carefully pull out board
• Set all jumpers and switches
on the replacement board in
exactly the same position as
those on the failed board
236
27/02/2017
• If the EPROMs from the failed board are good,

remove the EPROMs using an EPROM removal tool,
and install into sockets on the new board, making
sure that they are properly aligned
• If the EPROMs from the failed board are damaged,
replacement EPROMs must be ordered if spares are
not available
237
27/02/2017
• Install new board, making sure that all tabs snap

tightly into position
• Reconnect all cables, making sure that they are
properly seated in the connectors
• After power up, proceed
with eeprom download
to the relevant core
238
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Index
Question and Answers
239
27/02/2017
240
27/02/2017

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GE Oil & Gas

Oil & Gas Industry Applications

• Introduction to the Speedtronic Mark V

• Speedtronic Mark V features

• General Software Description

• Mark V Software Configuration

• Operating Procedures and Investigation

Introduction to Speedtronic Mark V

 General overview of the control system

 Control panel architecture

 Operator Interface HMI

Gas Turbine and

Unit Control Panel (UCP) Mark V

• Unit control panel is main control system that

• The HMI is connected to the Mark V in the UCP

UCP main sections:

• TCP – turbine control panel

• Displays all the intruments and sensors present on

• One page of the P&ID describes one coherent part

• Usually each P&ID page have a graphic page

• This allows the operator to understand and

Lists the instruments connected to the UCP

Describes the Mark V internal software explaining

Describes the interconnection between the

• All the panel documentations are using standard

According the standard naming, the number in the

According the standard naming, the letters in the signal

-A auxiliary -L Logic (digital signal 0-1)

Document title Document number

 Control Panel hardware configuration

 Mark V data communication networks

 Backup operator interface panel

Mark V provided in three different configurations:

• Triple Modular Redundant (TMR)

terminal board cards

The cores can be devided to 2 main sections:

• Mark V cards – locations from 1 to 5

Explanation of the card locations:

• speed pickup for overspeed monitoring

• <R>, <S>, <T> cores

• <QD1> and <QD2> cores

• <D> core - optional

Includes 3 different networks:

• The STAGE LINK is for external communication

STAGELINK SINGLE ARCHITECTURE

STAGELINK MULTI UNIT ARCHITECTURE

Mark V – keyboard of the

HMI – DIP switches on the card

• DENET is an internal communication

• IONET is an internal communication

TMR IONET configuration

Analog I/P A/D D/A Analog O/P

• The core display is used to display useful

• The name of the core

The status of the core (system diagnostic):

• A7 – the system works properly

Difference for Simplex Mark V

Difference for Mark V LM

• Simplex architecture, with only the <R> main

Difference for Mark V LM

• <P1> is the same as <P> and still triple redundant

• <R1>, <R2>, <R3>, <R5> cores