GE Energy

Problem
Solved.
How can I improve
flexibility for new and
existing plants?

2010 GE Energy Customer Solutions Conference

GE Energy

Paul Abernethy - Segment Leader DCS

Why GE Plant Control ?

Integrated Control Systems (ICS) Power plant of the Future
August 2010
At the end of the day, all of the control subsystems in the plant must
follow the same design philosophies in order for the the centralized alarm
system view to be meaningful and useful

Power Feb 2010 How to Avoid Alarm Overload with Centralized

Alarm Management
Brandon Parker B&V

2/
GE /
October 14, 2010
Mark VIe - GE Energys Control platform

Simple & Combined Heavy Duty & Aeroderivative

Cycle Power Plants Gas Turbine & Generator

Steam Turbine
& Generator

Desalination

Fossil
Plant

ESBWR

Nuclear Power
plants
Renewables IGCC
3/
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October 14, 2010
Third Party DCS - Tying Plant Control Together
DUPLICATE
WORK STATIONS
DCS Operator Interface

Historian SEPARATE
NT
ENGINEERING SEPARATE
TOOLS TRAINING
Printer

CUSTOM
ENGINEERED
INTERFACE HMI

OSM
SEPARATE
SPARE PARTS

Subsystem PLC

HARD WIRED
SIGNALS

Turbine Mark VIe Generator or other

DCS
DCS
Mark VIe
Drives Duplication and Dependencies 4/
GE /
October 14, 2010
 Control Room Integration

Single interface for all equipment

Improves operator productivity
Better view of the plant for better
operational decisions

Operator
Interfaces
OSM

Boiler & BOP

ESD
Controllers

Subsystem Turbine Control Generator Excitation

Boiler & & Protection & Protection
PLC BOP IO
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October 14, 2010
 Single System for Plant Control
ONE CONFIGURATION
& DIAGNOSTIC TOOL
COMMON OPERATOR
INTERFACE
FULL PLANT
SIMULATION TOOL

Printer
TRAINING ON
SINGLE SYSTEM

Operator
Plant SINGLE SOE & Interfaces
ALARM DATABASE
EWS & Historian COMMON DATA
COORDINATED HIGHWAY
OSM
OPERATION

Boiler & BOP

ESD
Controllers

REDUCED
HARDWIRING
AVAILABILITY:
99.9967 %
Subsystem Turbine Control Generator Excitation
Boiler & & Protection & Protection
PLC BOP IO
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October 14, 2010
 Engineering Tools

Integrated alarms on same time base

Plant-wide Historian, time coherent ,
Printers
consolidated data for data-based
decisions
High speed trender, trip log, other high
powered tools
Operator
Plant Data collection and utilization
Interfaces Root
EWS & Historian Cause Analysis OSM

Boiler & BOP

ESD
Controllers

Subsystem Turbine Control Generator Excitation

Boiler & & Protection & Protection
PLC BOP IO
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October 14, 2010
Mark VIe Benefits
Plant Integration
Each HMI provides full Control from each Operator Station for All Equipment
Single Configuration and Diagnostic Tools
Plant Wide Historian: OSI Pi, Pi to Pi System Interface
Eliminates Engineered Interfaces between Turbine Control and DCS/SCS
Single design philosophy and single point responsibility

Quality of Plant Data

Common, Time Coherent Database for All Plant Equipment
Common Alarm System with SOE capability for all digital inputs
Remote Access Via Customer Data Link

Improved Plant Performance

Performance Optimization Products

Reduced Plant Maintenance Costs

Common Hardware Minimizes Spare Parts
Single System Training Requirements

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October 14, 2010
Plant Control Q & A

Hardware 39
GE Energy

Mark* VIe Software

System Overview & Networks

Organized Visual Overview

Visual Status Indication
Alerts to incorrect device connections
Available from Operator Screen

Detailed View by Network

Network events integrated into
Alarm Management System
11 /
GE /
GE proprietary Information October 14, 2010
Configuring Controllers (Dual example)

Tree View lists the items

that can be configured on
the General Tab. The List
of items changes when a
different tab is selected.

Property Editor provides

a consistent way to edit
the item currently
selected in the Tree View

Component InfoView displays

feedback information about
the currently selected item.

Summary View provides a graphic

overview of the controller
12 /
GE proprietary Information GE /
October 14, 2010
I/O Configuration & Diagnostic Tools

Toolbar
Select
Select Category
Category View
ViewI/OI/O
Data
Data
I/O Calibration
I/O Calibration

Diagnostic Messages

Select
Select
Device
Device Active Pictorial of Equipment
Active Pictorial of Equipment
Terminal
Terminal BoardBoard
I/O Packs
I/O Packs w/Diagnostic
w/Diagnostic LEDsLEDs
I/O Network
I/O Network StatusStatus

Overview of I/O Network

Hardware ID
Hardware ID

Activity / Status Log

13 /
GE /
GE proprietary Information October 14, 2010
Passwords and Security

Security with Passwords

3 Levels
- View design
- Modify Data
- Modify Design
Sub-Levels for:
- Library
- Devices
- User Blocks

14 /
GE proprietary Information GE /
October 14, 2010
Configuration Management System

Revision / History Log

Complete System Coverage

Tracking of configuration changes
(who, what, when, why)
Compare between versions
Maintenance of master copy of
configuration in a defined repository
Easy backup/restore of master copy
Allows user comments
Differences Between
Versions

15 /
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GE proprietary Information October 14, 2010
Application Software - Help Files

Description of Macros
and application
keep

16 /
GE /
October 14, 2010
GE proprietary Information
Logic Configuration Environment
IEC/SAMA Style Logic
Reduced complexity
System Cross-Referencing
Self-Documenting

MOV

AUTO /MAN

COMMAND
MODULE NAME

On-Line live status

STATUS

OPEN

PERMISSIVE
CLOSE
M

OPEN

OVERIDE
Hot-links through system

CLOSE

ALARMS
FEEDBACK
Intelligent blocks
Dynamic Animation Embedded Graphic
Objects & Status
Dynamic block animation
17 /
GE /
GE proprietary Information October 14, 2010
Drag and Drop Wiring

Tool gives error if dragging

Boolean on analog, etc.

Variables can be drug from

Rails can be drug up or down rails to pins on blocks and vice
to create spacing or align versa
blocks

Pins can be drug to the Rail to

easily create cross- page local
references

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October 14, 2010
GE proprietary Information
Animated Block Shapes
Linear interpolator & equipment status visible in logic
Shapes Represent block Functionality Old Style
CALC_1 2

Non-Visible Configurable parameters accessible through right click True

A
ENABLE
OUT

A+ B EQUAT

Shape animated to represents status 1 B

MOV

AUTO /MAN

COMMAND
MODULE NAME

STATUS

OPEN

PERMI SSIVE
CLOSE
M

O PEN

OVERIDE
CLOSE
Color

ALARMS
Animation

FEEDBACK
Dynamic Embedded Graphic Rubber Blocks
Animation Objects & Status Extension

Better Images and Less Clutter Improve Readability and Troubleshooting

19 /
GE /
GE proprietary Information October 14, 2010
Where Used?

Select the point requested

Where used takes you to the
block where used

20 /
GE /
GE proprietary Information October 14, 2010
Finder (Search Tool)
Search Variables System Wide

21 /
GE /
October 14, 2010
GE proprietary Information
Modifying Control Constants

22 /
GE /
GE proprietary Information October 14, 2010
Forcing
Analog Values

Enter a new value

Boolean Values Added to or

subtracted

Current value

Change the .
current value.

Invert the current value

Prevent
overwriting
your value.

23 /
GE proprietary Information GE /
October 14, 2010
Object Integration

A B C D E F G H I J K L M N O P Q R S T U V W X Y Z
00 00

01 01

02 TargetTemp 02
67.4926 76

03 GT

2.700 541
> Tr ue
03

04 04

05 05

06 NOT_1 2 06
EmergencyStop
A OUT_A IO_FireBurner
07
F als e
NOT_A
F als e T rue
AND True
B_AND_1.OUTPUT 0000 07
T rue T rue

08 08

09 09

10 10

MOVE_1 4
11 IO_WaterTemp CurrentTemp 11
SRC DEST
2.700541 2.6997411 MOVE_1.DE ST 0000
T rue
ENABLE
12 12

13 13

14 14

15 15

16 16

17 17

18 18

19 19

20 20

21 21

22 22

23 23

24 24

25 25

26 26

27 27

28 28

29 29
A B C D E F G H I J K L M N O P Q R S T U V W X Y Z
Last Modified Module Revision Customer Title Software P ath
V01.00.00A SimWH.WaterHeater_1.Boiler_1
Build Major Revision Ty pe S ite DM Number Requisition ToolboxST Version DWG Engineer
1/22/2007 11:03:19 V03.01.00B
Build Minor Revision Print Date P roc ess Application Serial Number Shop Order Number Machine Size Cont. on Sh. Sh. No.
1/23/2007 11:23:07 1/23/2007 12:06:23 PM 0000

Controller Configuration HMI Object Object Faceplate Permit Screens

Aligned with Logic

Device Control
Blocks Device Permissive
Standard Block With Security
Indication for
Library set
Provides Quick quick operator
Visualization of
Visual Indication Troubleshooting
Pre Defined Relation Device State
Of Device State
With HMI object
Auto-Populated
Access to Device
One step From Logic Sheets
Easy to Customize Permissives
Configuration

Configure
Automatic Association through System
Once

Drag and Drop and Right Click Capabilities

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October 14, 2010
Standard Object Library

Objects are
associated with
device control
modules in
controller(s)
Drag and Drop
object to Screen
Associate object
with device

25 /
GE /
GE proprietary Information
October 14, 2010
Right Click Menu Go To Logic

26 /
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October 14, 2010
GE proprietary Information
Add to Trend

Go To Definition in Logic

Add To Trends

27 /
GE /
October 14, 2010
GE proprietary Information
Alarm Management

Configuration
- Configured in the Controller
- Segregated by Alarm Class / Location
- Diagnostics available for all Hardware

Management
- Time-stamped in Controller
- SOE time stamped at I/O Card
- Status maintained by Controller
- Managed through Operator Station
- Long term storage by Historian

Operator Interface
- Sorting & Filtering by fields, controllers, etc.
-Go To opens the screen associated with alarm
- On-line Notes/ Comments can be added to
alarm message
28 /
GE proprietary Information GE /
October 14, 2010
System Approach to Alarm Management

System wide definition for alarm behavior

(Sound, Colors, Priority, etc)
External Alarms via OPC AE
Optional Server/Client Architecture
Setup flexibility based on customer and
application needs
Live and Historical View with same tool
Common right click menus (GoTo Logic,
GoTo Screen, etc.)
Operator Comments
29 /
GE /
October 14, 2010
GE proprietary Information
 WorkstationST Alarm Manager
Advanced Alarm Filtering

Filtering by Device, Plant Area, Type, etc.

Defined per Operator Interface Station
Filtering on any alarm configuration
parameter
Simultaneous Filtering on multiple
parameters
Storage of user defined Filters
Quick-Click on-the-fly filter
modification
Quick-Click Priority Function (Highest
Priority Active Unacknowledged Alarm)30 /
GE /
GE proprietary Information
October 14, 2010
Historian Overview

Data Link Export Data Data Accessible To All

for Reports and users on PDH
Analysis
Process Trends

GE (or PI) Historian

GE DCS Historian
Alarm & Event Process Data

Web Browser interface

Historical alarms and Events for Events, Alarms,
queries are easily configured Historical Reports, and
with point and click selections other Debugging
information
Mark VIe 3rd Party
DCS Devices
Alarms, Events and SOEs time 31 /
tagged at controller level GE /
October 14, 2010
GE proprietary Information
Historian Trends and Reports

Configurable trends & Historical alarms and Events queries

reports Easily configured with point and click
Historical Cross-Plots selections

32 /
GE /
GE proprietary Information October 14, 2010
Historian Trends and Reports

Web Browser interface for Events,

Alarms, Historical Reports, and other
Debugging information
Export Data for
Reports and
Data AccessibleAnalysis
To
All users on PDH

Plant Data Highway

HMI Historian

Unit Data Highway

33 /
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October 14, 2010
GE proprietary Information
Historical Alarm Analysis

Pareto Alarm Frequency

Same Filtering Options Apply

34 /
GE /
October 14, 2010
GE proprietary Information
Dynamic Data Recorder

Trigger Variable
Capture Buffers
Time
in Controller(s)

Capture Buffers Data Sampling

Capture Buffers Pre-trip
19 hours @ 10 minutes
4 hours @ 1 minute
40 min.s @ 10 second Intervals
Mark VIe 19 min.s @ 1 second Intervals
45 sec.s @ 200 ms Intervals
15 sec.s @ Frame Rate
Post-trip
Up to 12 Capture Buffers per controller
5 sec.s at Frame Rate
96 Variables / Buffer

35 /
GE proprietary Information GE /
October 14, 2010
High Speed Trending
Features
Frame-Rate Resolution
Drag & Drop of Variables from logic or
HMI to Trender
Automatic Upload of Capture Blocks
Browser for Variables Selection
100s of Signals per Trend
- Mask & Unmask of Selected Variables
Left-Right Drag of Time Axis
Backfill data
Dual Cursor (Delta, Min, Max, Average)
Stacked Traces
Alarm Messages on Trip Trend
Events Log Linked to Trend
Export to .CSV

36 /
GE /
October 14, 2010
GE proprietary Information
Signals can be dragged and dropped onto the Trend

Trends collected at the rate of the control 37 /

GE proprietary Information GE /
October 14, 2010
Software Q & A
GE Energy

Mark* VIe Hardware

The Building Blocks
The Controller The I/O

The Software

The Networks
PSCA Processor
Features
Single board including:
Main Processor
Control Network Communications - Ethernet
I/O Net
IO Network Communications Ethernet
RS&T
USB and COM ports
Operating system: QNX Neutrino
Base mounting
18-36Vdc, 12 watts
UDH
Status LEDs
1 and 2
Environment
Operating temp: 0 to +65 C (32 to +149F)
Storage temp: -40 to +85 C (-40 to +185F)
Humidity: 5 to 95% non-condensing
No fans required
 I/O Network
Controller Local Network
I/O Module Field Device
Switch
Cat. 5 Cat. 5 Field Wire
100m 100m 300m
(328) (328) (984)

Controller Extended Network

I/O Module Field Device
Switch Switch
Cat. 5 Cat. 5 Cat. 5 Field Wire
100m 100m 100m 300m
(328) (328) (328) (984)
OR IEEE Specification 802.3u
100FX Fiber Wire Speed 100Mbps
2,000m / 6,600 multi-mode Cable Type UTP Cat. 5 / Fiber
15km, 40km, 80km single- Connector Type RJ-45 / SC

mode Max I/O Packs / Network 199

Topology Star
Time Synch Protocol PTP (IEEE-1588)
I/O Modules
I/O Module I/O Pack
Features
Dual 100MB I/O Net Ethernet Ports
Low I/O Density
On-line Repair per I/O Block
Operation -30C to 65C
Accuracy - 30C to 65C
6W Heat Dissipation / pack (approx.)
NFPA Class 1, Div 2 with Local Temp Sensor

I/O Pack plugs into I/O module assembly

Contains a local processor and data
acquisition board
Ventilated cover encloses passive signal
conditioning electronics on I/O module
assembly
Barrier or box type terminal blocks plug into
assembly
I/O Modules
Barrier Terminal Blocks Box Type Terminal Blocks
1, 2, or 3 I/O packs 1 I/O pack and dual networks

Derived from Mark VI I/O modules

Many new functions
Simplex and dual redundant
Derived from Mark VI I/O modules
Many new functions
Simplex, dual, and triple redundant
 Configuration

Mark* VIe Architecture Historian

Condition
Information Network (PDH) - Ethernet Monitoring

Optimization

Operator &
Engineers Stations

Control Network (UDH) - Ethernet

Controllers Controllers

Switches Switches
I/O Network 100MB Ethernet I/O Network 100MB Ethernet

Process I/O Process I/O Turbine I/O Driven-Load I/O

Process I/O Remote I/O

Process Control Rotating Machinery Control

* Trademark of General Electric Company
Networks / Communications
(1) Information Network (PDH) - Ethernet
(2) Control Network (UDH) - Ethernet
Controllers
Switches
(3) IONet - Ethernet
I/O Modules
Modbus Serial & Ethernet
OPC Client / Server
GSM Protocol
IEC 61850
IEC 60870-5-101 or 104 Ethernet or Serial
DNP 3.0 Ethernet or Serial
HMI Client to PI Server Interface
Peer-to-Peer Communications
Controllers
Peer-to-Peer Communications
FOUNDATION Fieldbus H1 to HSE Linking Device
Profibus -DP, with Redundant Master Option
HART communications
CANopen for Woodward GS6 & GS16 Valves
Modbus Master RS232, 422, 485
Modbus Master Ethernet
HD Gas Turbine Control Architecture
Configuration

Operation
Information Network Condition
Ethernet Monitoring
Operator &
Maintenance
Stations
Control Network Generator
Ethernet Excitation

Controllers

Switches I/O Network - 100MB Ethernet

Driven Load
Generator
Compressor

Remaining Process
Power Island
Balance of Plant
HD Gas Turbine Control Distributed Architecture
Information Network (PDH) - Ethernet

Distributed turbine I/O minimizes

site wiring and maintenance

Control Network (UDH) - Ethernet

Controllers Triplex, located in PEECC

Controllers I/O Network Triplex
I/O Hardware Triplex / simplex, depending on criticality
Switches
I/O Network - 100MB Ethernet

I/O
I/O I/O
I/O I/O
I/O I/O
I/O I/O
I/O I/O
I/O I/O
I/O I/O
I/O
Cabinet
Cabinet Cabinet
Cabinet Cabinet
Cabinet Cabinet
Cabinet Cabinet
Cabinet Cabinet
Cabinet Cabinet
Cabinet Cabinet
Cabinet

Local GT GT GT Accessory Fuel Cond. Syngas Syngas

in PEECC Forward Enclosure Exhaust Module & Heating Module HL Module LL
Mid Skid
Representative of heavy duty GT Syngas application
Large Steam Turbine Control Architecture
Configuration

Operation
Information Network (PDH) Condition
Ethernet Monitoring
Operator &
Maintenance Optimization
Stations
Control Network (UDH)
Ethernet
Generator
Controllers Excitation

Switches I/O Network (I/O Net) - 100MB

Ethernet

Speed Servos Pressure PLU Protection TSI Auxiliaries

Main Unit Feed Pump Turbines

Time Synchronization
Information Network (PDH) 10/100MB Ethernet

Network Time Server

+/-2m Time Coherence Between Controls

Precision Time Protocol (PTP)
Or Network Time Protocol (NTP) +/-1m Time Accuracy

Control Network (UDH)

10/100MB Ethernet
Control
Control Control
Control Control
Control Control
Control
System
System System
System System
System System
System
With HMI CPU Clock
Accuracy = 30ms
Mark Ve, Mark VI, Mark VIe, EX2100, LS2100 Coherence = 30-200ms
Key Attributes

High Performance Local processor on each I/O module. Compute power

grows as the system expands
Minimum Repair Time I/O modules can be replaced individually without
disturbing the rest of the system
Robust Controller rated 0 to 65C with no fans; I/O modules rated
30 to 65C with on-board temperature sensor
Reliable Communications Redundant network ports on each I/O module
Producer/Consumer model allows many consumers of single broadcast
 Plant / DCS Control Cabinets
Typical I/O Cabinet Material: Sheet steel 1.5mm (16-gauge)
Redundant switches Power
Two 115/230Vac inputs
Typically one UPS source
Grounding Two isolated planes:
Terminal block
Electronics and field ground
I/O Pack Cabinet and power ground
Cable Entry: Bottom
Door Handle: 3-point latch
Surface Finish
Dipcoat-primed, powder-coated in
4 spare slots RAL7035, light gray (textured)
Galvanized metal bases cover the
majority of the interior surfaces
Cabinet mounting base: RAL7022
Protection: IP42, IP 54
Lights: at top of front/rear door frames
Ground Outlets:
US style for 120Vac
Provision for 16 I/O modules
German style for 230Vac
Plant / DCS Control Cabinets
Typical Controller Cabinet

Redundant
Controllers

Independent & redundant

electronics and field wetting
power supplies

Power distribution
and monitoring
Redundant
IONet Switches
Technical Regulations and Standards
Core Technical Regulations and Standards
CSA/UL Certification - Certificate issued by CSA International
EU Directives - Declaration of Conformity issued
GOST-R certification GOST-R Certificate issued
UBC Seismic Code section 2312 Zone 4 most packaging versions comply
Battery Directive 2006/66/EC compliant via symbol on boards

Conformity Assessment Schemes

Regulation Scheme 3rd Party
CSA/UL Product Certification CSA International
CSA22.2 #1010.1
ANSI/ISA 82.02.01
EMC Directive Technical File Technology International
204/108/EC
LV Directive Technical Construction CSA International
2006/95/EC File
GOST-R Product Certification
Hardware Q & A
(Services and Support follows)

Software 10
GE Energy

Services and Support

Controls Connect Self-service Portal
Controls Connect is a secure, self-service knowledge management solution
that provides instant access from home or at the plant to GE Energy
Controls vast knowledge base.

Content
Documents GE News Knowledge Industry
& Events Base Intelligence

Find it
Yourself, Intelligent Search Options
Natural Language Processing
Fast! PDF Slicing for Larger Documents
Guided Search
Still Need Help?
Phone & Email
Product Support

Site & Content

Feedback
Online Portal

Addresses need for

Detailed technical documentation

Knowledge base of FAQs
Online Troubleshooting guides & wizards
Knowledge Technical Information Letters
Portal
Training support
News
Support links

58 /
GE /
October 14, 2010
Example:
Chuck's primary function :
Support plant operations
Maintain all I&C equipment
Troubleshoot, repair as needed
Problem:
One day a diagnostic alarm is set. Plant
operations contacts the I&C technicians
to get involved.
Chuck - Site I&C Technician
Interaction with portal:
Chuck was not familiar with that
particular diagnostic alarm, he refers to
the Controls portal, enters the diagnostic
alarm code in search. The search result is
an FAQ and related troubleshooting
guide. He proceeds in troubleshooting
and resolving the alarm.
Outcome/benefit:
Increased productivity of issue
resolution, sharpening of skill set for
the plants I&C technician, continued
uninterrupted operation of the plant.
59 /
GE /
October 14, 2010
Training
Customer Training
Standard GE training classes
Customized training classes
Experience full-time instructors
Available at multiple GE facilities and at customer site
Classes on controls and turbine-generators

Information Available Online

Schedule of classes
Course outlines
Locations and logistics
Registration
Contact and payment information

Hyperlink to GE Training Web site

OnSite Support* Remote Diagnostics
Features
Experienced engineering staff located in Controls & Power
Electronics Center of Excellence
Secure remote connectivity to excitation equipment
Flexible support service contracts
Event-based & periodic progress reporting
Infrastructure checks ensuring readiness-to-serve
24/7 access support personnel

Benefits
Improved response to technical needs
Reduced mean-time-to-repair (MTTR)
Scalable services to support additional
equipment

* Servicemark of General Electric Company

Spare Parts & Repair Services
PartsEdge & eCatalog
Price & Availability New, Reman,
Exchange, Repair

62 /
GE /
October 14, 2010
Services Q & A