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SPEEDTRONICTM Mark VI TMRFeed Pump Turbine Control
These instructions do not purport to cover all details or variations in equipment, nor toprovide for every possible contingency to be met during installation, operation, andmaintenance. If further information is desired or if particular problems arise that are notcovered sufficiently for the purchaser�s purpose, the matter should be referred to GEIndustrial Systems.
This document contains proprietary information of General Electric Company, USA, and isfurnished to its customer solely to assist that customer in the installation, testing, operation,and/or maintenance of the equipment described. This document shall not be reproduced inwhole or in part, nor shall its contents be disclosed to any third party without the writtenapproval of GE Industrial Systems.
Section Page
Introduction..................................................................................................................2Architecture .................................................................................................................2Inputs and Outputs .......................................................................................................5Control and Protection Functions ................................................................................6
Application Software Arrangement ......................................................................6Speed Control .......................................................................................................6Valve Control .......................................................................................................8Trip Protection......................................................................................................9Contact Input Trips .............................................................................................10Overspeed Protection..........................................................................................11Thrust Wear Protection.......................................................................................13Vibration Protection............................................................................................14Eccentricity Monitor ...........................................................................................14
Packaging...................................................................................................................15Power .........................................................................................................................16Operator Screens........................................................................................................17
gGE Industrial Systems
GEI-100474
CIMPLICITY is a registered trademark of GE Fanuc Automation North America, Inc.Ethernet is a trademark of Xerox Corporation.SPEEDTRONIC is a trademark of General Electric Company, USA.Windows NT is a registered trademark of Microsoft Corporation.
2 •••• SPEEDTRONIC� Mark VI TMR Feed Pump Turbine Control GEI-100474
IntroductionThe feed pump turbine control is part of the SPEEDTRONICTM Mark VI family ofturbine controls which are available for all GE turbines. The control is designed toprovide a small core of basic control functions that can be expanded in smallincrements for various levels of control, protection, and monitoring for the turbine,the auxiliary systems, and the pump.
Feed pump turbines are commonly applied in pairs with both pumps required for fullload on the main unit. The typical Mark VI control for this application is a tripleredundant control system (TMR), which contains the control and protection for bothturbines. Each turbine can be operated independently, and separate field terminationsare provided to facilitate maintenance of one turbine while the other turbine isrunning. Individual TMR or Simplex controls can be supplied for each turbine, ifrequired.
Several levels of operator interface are available. These include an operator interfacethrough a communication link from a plant distributed control system (DCS), a localor remote operator interface from a PC, or a hardwired interface. In addition, acommon PC based operator/maintenance interface and common softwaremaintenance tools can be provided for a Mark VI feed pump turbine control, a MarkVI reheat steam turbine control, and an EX2000 generator excitation control withpeer-to-peer communications on an Ethernet network.
ArchitectureThree control modules are supplied with identical hardware and software for thecritical control and protection functions. Each module consists of a card rack witheither a 13 slot or 21 slot VME back-plane with a processor card, communicationcard, and I/O cards. An example analog I/O is the automatic speed/flow referencefrom the feedwater control system. The signal for turbine A (typically 4-20 mA) isconnected to a terminal board, which is separate from the terminal board for turbineB. The signal is conditioned with passive circuits on the terminal board and thenconnected internally to the three control modules. An analog I/O card in each moduleconverts the signal from analog to digital for transmission to the communication cardthat selects the median value of the turbine A speed/flow reference from the threeanalog I/O cards. The voted value is then sent to the processor card in each modulewhere the application software is executed. The elapsed time to read every input,vote the data, execute the application software, and output to the control valves is 20ms (the frame rate). Diagnostics continuously run during this time to determine anydiscrepancies in the voted data. If a fault is detected, the defective card can bereplaced while the turbine is running.
GEI-100474 SPEEDTRONIC� Mark VI TMR Feed Pump Turbine Control •••• 3
PS
<R>Control Module
X
PS
Y
PS
<T>Control Module
Z
<S>Control Module
Ethernet
<P.A> <P.B>
Emergency OverspeedProtection Modules
Controllers 1. Control 2. Protection 3. Monitoring
CIMPLICITYR Display SystemWindows NTTM Operating System
Ethernet
Unit Data Highway
Operator / MaintenanceInterface
Communications To DCS1. RS232 Modbus Slave/Master2. Ethernet TCP-IP Modbus Slave3. Ethernet TCP-IP GSM
To Mark VI Reheat Steam Turbine Control
To EX2000 Generator Excitation Control
P.S.CPUI/O
P.S.CPUI/O
P.S.CPUI/O
Ethernet - IONet
Softw
are
Votin
g
Ethernet - IONet
Ethernet - IONet
X
Y
Z
P.S.CPUI/O
P.S.CPUI/O
P.S.CPUI/O
Typical Control System Architecture
4 •••• SPEEDTRONIC� Mark VI TMR Feed Pump Turbine Control GEI-100474
An Ethernet based IONet is used to transmit data between the control modules andthe emergency overspeed modules that are used on turbines that do not have amechanical overspeed bolt. In these applications, the median value of three passive,magnetic pickups provide speed feedback from each turbine to the control modules,which perform speed control and the primary overspeed protection. Three additionalspeed sensors are used for an independent emergency overspeed signal to thecorresponding emergency overspeed module for that turbine. Two out of threemagnetic relays vote the resultant primary and emergency overspeed trip outputs tothe hydraulic trip solenoids. In addition, triple redundant trip solenoids are suppliedon each turbine to maximize the system fault tolerance.
For retrofit applications, an emergency overspeed module is not needed because theturbine already has a mechanical overspeed bolt. The two existing speed sensors areused for speed control and primary overspeed protection. The third speed sensor isalready connected to a tachometer, and this instrumentation is normally retained. Amodification kit is available to replace an existing mechanical overspeed bolt with anemergency overspeed module. This modification also requires that the existingsingle, energize-to-trip solenoid be replaced with a new triple redundant, de-energizeto trip solenoid system for reliability.
The processor card in each control module has an Ethernet port for communicationto a PC based operator / maintenance interface with a GE CIMPLICITY graphicsdisplay system and a Windows NT operating system. The PC is commonly referredto as the Human Machine Interface (HMI). One PC can be used for both turbines ifdesirable, and it can be used for a variety of communication links to the plant DCS.This Ethernet network is called the Unit Data Highway (UDH), and it can also beused for peer-to-peer communications with a Mark VI for the reheat steam turbineand associated controls such as the EX2000 generator excitation system for the mainunit.
The HMI has full operator capability to issue any command or monitor any datapoint from either turbine with the local high resolution time tags for alarms (20 ms)and Sequence of Events (SOE) (1 ms). It can be connected on the UDH tosimultaneously monitor the Mark VI control for the feed pump turbines, the reheatsteam turbine, and the EX2000 generator excitation system on one or dual redundanthighways. Redundancy is implemented by connecting each highway to a separateEthernet driver in a separate control module. Other available features in the HMIinclude trending at 20ms, logic and analog forcing, and time synchronization eitherto a time source from the Plant DCS or directly to a global positioning satellite(GPS).
Operator displays normally show turbine A on the left side and turbine B on the rightside to allow operators to monitor both turbines simultaneously. Names ofapplication software data points have a suffix _A and _B to clearly distinguish theturbine to which they are being applied.
GEI-100474 SPEEDTRONIC� Mark VI TMR Feed Pump Turbine Control •••• 5
Inputs and OutputsI/O circuitry is designed for direct interface to the sensors and actuators on theturbine to eliminate the need for interposing equipment with its resultant single pointfailures, maintenance, and spare parts.
Typical I/O Allocations in TMR Control Systems
I/O Category �A� Turbine �B� Turbine Additional I/O Blocks NotesContact Inputs 24 24 24 125 V dc from Mark VI
Optical isolation, 1 ms SOERelay Outputs 12 12 12 Magnetic relays with form C contact
outputsTrip Solenoids 1/2/3 1/2/3 As requiredSpeed Inputs• Primary• Emergency
2 or 33
2 or 33
2 retrofit, 3 new unitsIn place of mechanical OS bolt
Servo Outputs 2 2 2 Only 1 needed per turbineLVDR Inputs 6 6 Only 4 needed per turbine4-20ma Inputs 10 10 104-20/0-200 Out 2 2 2 (1) 4-20 mA and (1) selectable4-20ma Outputs 0 0 16 Option for monitoringProximitors• Vibration• Position• Reference
841
841
841
Includes: 1X, 2X vibration, phase angle,buffered outputs with BNC connectorsfor remote monitoring.
RTD Inputs 0 0 16 Option: software linearizationGrounded or ungrounded10 ohm copper, 100/200 ohm platinum,120 ohm nickel
Thermocouples 0 0 24 Option: software linearizationGrounded or ungroundedTypes E, K, J, T
6 •••• SPEEDTRONIC� Mark VI TMR Feed Pump Turbine Control GEI-100474
Control and Protection FunctionsThe following control and protection functions are supplied with most controlsystems and implemented similar to the following descriptions. Many other featuresare available as required for the application.
• Speed Control
• Valve Control
• Trip Protection
• Contact Input Trips
• Overspeed Protection
• Thrust Wear Protection
• Vibration Monitor
• Eccentricity Monitor
Application Software ArrangementThere are four software segments in the Mark VI that contain application software.They are designed for independent operation of each turbine. These segments areexecuted sequentially in the order shown.
• SEQ_T1A Speed Control and Valve Control Turbine A
• SEQ_T2A All Other Control and Protection Turbine A
• SEQ_T1B Speed Control and Valve Control Turbine B
• SEQ_T2B All Other Control and Protection Turbine B
Application software for turbine A has an _A suffix, and application software forturbine B has a _B suffix. This enables operator and maintenance personnel toquickly identify which turbine the software applies to regardless of whether it isbeing monitored on an operator/maintenance interface PC or read in thedocumentation. There is a very small amount of software that is generic to the MarkVI system, which has no suffix such as the common alarm management system,power supply diagnostics, and the like. Although the alarm management software isgeneric, the application software that initiates these alarms is turbine specific withthe _A and _B suffix, and the alarm messages which appear on the monitor contain a(A) and (B) designation. All software documentation includes the (A) and (B)designation including the 1 ms SOE log on the printer.
Speed ControlThe Mark VI determines that the unit is stopped by monitoring the median value ofthe three passive speed pickups and the key phasor. A zero speed indication fromboth signals is required to initiate the zero speed logic (L14HR_A/B). A zero speedpermissive is provided to the turning gear based on this logic. These are dry, form Ccontacts from magnetic relays on the TRLY terminal board. Separate relay terminalboards are provided for the contact outputs to turbine A and turbine B.
Any significant discrepancy between the three speed signals initiates a diagnosticalarm which specifies the specific speed signal that is in disagreement, but theapplication software for all three control modules <R><S><T> continues to run onthe median value (TNH_A/B). Any one of the three controllers can be de-energized
GEI-100474 SPEEDTRONIC� Mark VI TMR Feed Pump Turbine Control •••• 7
for maintenance while the turbine(s) are running. The PC basedoperator/maintenance interface contains no control or protection software; therefore,maintenance of this equipment does not jeopardize either the speed control or theoverspeed protection system.
When power is applied, the system initializes in manual control and in the trippedcondition. The system can be operated in manual control (L43MAN_A/B) orautomatic control (L43AUTO_A/B). The L prefix in these logic signals is used forall logic signals in the system.
The unit can be manually started from either a hardwired interface in the maincontrol room or an operator/maintenance interface PC located local or remote. Someinstallations have a technicians interface \module on the control cabinet door that isused for tuning, trending, or editing application software, but not for operatorcontrol.
A contact from the main control room provides a momentary closed logic to thecontrol system that selects manual control. Raise and lower contacts can now begiven to the control system. Independent raise/lower slow contacts will initiate acontrol response at the manual slow ramp rate (KTNHR_RMS) and raise/lower fastcontacts will initiate a control response at the manual fast ramp rate(KTNHR_RMF). A K prefix is used for all tuning constant signal names. Constantscan be changed while the unit is running. The unit will continue to ramp at theserates as long as these contacts are closed. Contact outputs are provided to the maincontrol room for indication of the control mode and the current running speed.
Note Operators and maintenance personnel are provided speed indication in rpm forconvenience, but the control system is calibrated in percent to facilitate fast andaccurate calibration. A single control constant (KTNH_GAIN_A/B) is used to scalefrom rpm to percent speed.
Manual control from the operator/maintenance interface PC works in a similarmanner. Operator commands are initiated with a mouse or trackball. Selection ofcontrol modes must be followed by a confirming EXECUTE command to prevent anaccidental change in control modes. Raise/lower commands are initiated from amouse or trackball, which is designed to initiate a single, incremental change inspeed with each click to eliminate any significant, accidental speed changes. Araise/lower slow click will initiate a 1-2 rpm change, and a raise/lower fast click willinitiate about a 20 rpm change (adjustable). Significant speed changes can be madeby typing in the desired speed such as 5,000, which will cause the turbine to ramp to5,000 rpm. The control will not ramp to a speed setpoint that is above the speedgovernor limits.
While in manual control, a momentary automatic start command can be given toinitiate an automatic start sequence (L43ASTART_A/B). The speed will increase atthe manual fast ramp rate (K14TNHR_RMF_A/B) to a predefined threshold(K14H_ASTRT_A/B). Permissives for the start sequence are that the turbine is reset,in manual control, and that the speed is below the threshold limit. Once theautomatic start sequence is in progress, it can be stopped only by a manual orautomatic trip prior to reaching the speed limit. Any time the turbine trips, it can bereset while coasting down. This causes the speed reference to be preset slightly(about 100 rpm) below the current running speed. The adjustable offset(KTNH_POFF_A/B) eliminates overshoot due to the difference in speed between thetime that the reset command is given and the time that the system actually resets.
The operator should manually raise the turbine speed to match the speed reference ofthe feedwater control system prior to selecting automatic control. If the operator doesnot match speed, the control system will go into automatic control (L43AUTO_A/B).
8 •••• SPEEDTRONIC� Mark VI TMR Feed Pump Turbine Control GEI-100474
If the speed is above the low speed stop (L14LS_A/B), the speed will automaticallyramp to match the feedwater control system reference at the manual slow ramp rate(K14TNHR_RMS_A/B). When a null is reached (K14HNULL_A/B), the ramp ratewill change to the auto ramp rate (KTNHR_RA_A/B).
Diagnostics continuously monitor the feedwater control system reference(PREF_A/B) to alarm if the reference is above the high limit, below the low limit orif the rate of change is excessive. An excessive rate of change, will alarm and causean automatic transfer to manual control, but out of limits diagnostics will alarm only.A gross failure in the feedwater reference, such as disconnecting the field wire, willresult in a transfer to manual control. Implementation of this function should accountfor the maximum normal rate of change of the reference from the feedwater controlsystem.
Any control location can transfer the system from automatic to manual control withno change in the speed reference. If the main control room originally selectsautomatic control through contact inputs, then only the main control room caninitiate a transfer to manual control. If automatic control is selected from theoperator/maintenance interface PC, then any control location can transfer the systemback to manual control.
The speed control algorithm (XTNCB03) is configured to run as an isochronousgovernor with no speed droop. The speed feedback (TNH_A/B) is subtracted fromthe speed reference (TNR_A/B), which results in the speed error (TNHE_A/B). Ifthe deviation between the reference and the feedback exceeds a predefined limit(KTNHDEV_A/B), then an alarm message is generated. This proportional plusintegral control is calibrated by the following tuning constants:
• KTNE_G_A/B Speed Error Gain Constant (%/%)
• KTNE_I_TC_A/B Integrator Time Constant (s)
• KTNE_DB_A/B Speed Error Deadband Hold Constant (%)
The final output of the speed control algorithm is the total power reference(TPWR_A/B), which provides a reference to the valve control.
Valve ControlThe following control description assumes a GE 200# oil gear system.
The total power reference from the speed control algorithm determines the valvestroke reference (V1_STROKE_A/B). This calculation is performed by a LinearInterpolator algorithm (ALIP00), which characterizes the flow versus the strokerelationship with 10 points using constants (KV1_FLOW#_A/B) and(KV1_STR#_A/B). Normally, the valve stroke reference and the output to the valveregulator (V1_OUT_A/B) are the same unless the valve is being calibrated.
Calibration is permitted if the turbine is tripped (L4_A/B = 0) and the speed is zero(L14HR_A/B = 1). Since there are two turbines, each V1 actuator is calibratedindependent of the other turbine�s V1 actuator including calibrating one turbine,which is stopped while the other turbine is running. Selection of the turbine-specificcalibration data is performed by selecting the appropriate turbine valve on thedisplay. Each half of this display will initiate a unique number to be generated in thedata base for (JADJ), which will force the output to the valve regulator(V1_OUT_A/B) to track the manual V1 calibration reference (GSADJ) instead of thenormal valve stroke reference (V1_STROKE_A/B).
GEI-100474 SPEEDTRONIC� Mark VI TMR Feed Pump Turbine Control •••• 9
All of the application software that has been discussed so far has been executed inthe main processor card (UCV_) and is completely configurable. Actual, closed-loopregulation of the V1 valve is performed in a dedicated algorithm in the servo card(VSVO) and run at 5 ms. The error between the output to the valve regulator(V1_OUT_A/B) and the position feedback from the main cylinder (the outer loop) iscalculated, and that error is compared to the pilot valve position (the inner loop). Apair of redundant LVDRs is used to provide feedback for the main cylinder positionand the pilot valve position with a high-select function for each LVDR pair.
Linear InterpolatorV1_FLO_R
Flow Reference
KV1_FLOW0 Args
InputV1_STROKE
A=BA
B
F(x)
x "10"
KV1_STR0
Size
Function
Out
Stroke Reference Servo Valve Output
SelectID Code
JADJID #
Enable
Input
Turbine is reset
Output V1_OUT
GSADJ Calibrate reference
K33V1_TRIP
L14HR L3ADJCalibratePermissive
Forcing InProgress
L43MAINT
Alarm - Maintenanceforcing mode enabled
JADJ - Valve calibration selectionfrom maintenance display
L43ADJ
ARAMPA>X
OutA<X
GSADJ_REF
Up
DownInput
Rate
Reset
KGSADJ_RR
Not used
Valve Regulator - Type 2
Bias - cylinder feedback
Gain - cylinder feedback
Reference
LVDR #1
Offset #1
Gain #1
LVDR #2
Offset #2
Gain #2
LVDR #1
Offset #1
Gain #1
F( )+
+
+
-
-
-
x
x
x
+-
x ++
Cylinder position
Cylinder LVDR #1 position
V1_POS
D/AConverter
A/DConverter
A/DConverter
A/DConverter
Servo Reference
Main cylinder positionfeedback inputs fromLVDRs. The secondLVDR is optional forredundancy.
Turbine stopped
L4 Turbine is reset
L14HP At overspeed OR
Copy
Enable
"0"A=B
A
BKJADJV1
JADJL83JADJ_V1
L83JADJ_V2
L83JADJ_V3AND
V1 In Calibrate Mode
Calibrate Mode Off
+-
x ++
Gain - pilot feedback
Cylinder LVDR #2 position
F( )
LVDR #2
Offset #2
Gain #2
+
-xA/D
Converter
Pilot position
Pilot LVDR #1 position
Pilot LVDR #2 position
+- x-
+-+
Lag1/(1+Ts)
High limit
Converg. gain
Conv. ref.
Lag TC
Low limit
IntegratorOutput
SVR_INTGRT_1Copy
SVR_CONVG_1 -TMR systems onlyConverge outputs of <R><S><T> to median
Pilot valve positionfeedback inputs fromLVDRs. The secondLVDR is optional forredundancy.
L83JADJ_OFF
No valve incalibration mode
Type Position Detection 2D First assigned LVDR 2E Max of (2) assigned LVDRs
V1_POS1
V1_POS2
V1_PIL
V1_PIL1
V1_PIL2
GE 200# Oil Gear System Valve Control
Trip ProtectionAll trip protection is imbedded in the triple redundant control modules. The tripsoftware is contained near the end of software segments SEQ_T2A and SEQ_T2B.All trip logic is OR�ed in software rung L4T_A/B and its two auxiliariesL4TX1_A/B and L4TX2_A/B. A logic 1 indicates a trip condition.
For Retrofit ApplicationsThe final logic state which determines whether the Mark VI will tell the trip solenoidto trip is L20PTR1_A or L20PTR2_B. This logic drives output ports in the threeVCRC cards which simultaneously drive relay drivers on the TRLY TerminalBoards. One relay on each of two TRLY�s is driven by the L20PTR#_ logic. Theserelays are energized when the turbine is running, and diagnostics monitor the currentthrough the relay coils to verify that the relays have actually energized. A single
10 •••• SPEEDTRONIC� Mark VI TMR Feed Pump Turbine Control GEI-100474
normally open contact from each relay drives an interposing HGA relay with a highcontact output rating for interface to the trip solenoid. The HGA relays are mountedin the turbine control cabinet, and the 125 V dc coils are suppressed. Both HGArelays are energized when the turbine is running, and a contact from each relay is fedback to provide confirmation that the relays have energized. Normally-closedcontacts from the HGA relays are connected in series on the high side of the SV12solenoid circuit to energize the solenoid if both HGA relays simultaneously de-energize. Connecting both relay contacts on the high side of the solenoid circuitallows a lamp circuit to be used to verify the solenoid coil condition since it isenergize to trip.
For Triple Redundant ApplicationsThese applications have three control modules and three sections of the emergencyoverspeed module driving three hydraulic trip solenoids that are de-energized to trip.Each solenoid is connected between the terminal board from the control moduleswhich supplies �125 V dc and the terminal board from the emergency overspeedmodule which supplies +125 V dc from separately fused feeders. Diagnosticsmonitor a contact feedback from each relay each terminal board and the voltageacross each solenoid. A trip from one control module will de-energize one tripsolenoid and not trip the turbine. A trip from two or three control modules will tripthe turbine. The solenoids can be tested on-line by tripping one solenoid at a time.
Contact Input TripsAll contact inputs are dry contacts that close if an alarm or trip condition occurs.Contact inputs are connected in a 125 V dc circuit that is powered from the Mark VI.Each contact input terminates on a single TBCI terminal board where it is internallyfanned to three separate VCRC cards in the control modules. Each card opticallyisolates each input and provides a 1 ms SOE time stamp.
Software in the control modules can be categorized as operating system software andapplication software. The operating system reads each contact input and exchangesthe data between the VCMI cards in each control module. Each VCMI calculates thelogical vote and passes the voted data to the application software to execute. As anexample, if the pump bearing oil pressure is low, the field contact closes whichresults in a logic 1 condition in all three modules. If an internal electronic componentfails in the <R> module, <R> could see a logic 0 when <S> and <T> see a logic 1.Since the data is exchanged between the VCMI�s, they will alarm a failure in thecontact input circuit in <R> while the correct logic 1 state is passed from <R>'soperating system software to its application software. Diagnostics are able todistinguish an internal logic failure from an external failure because a single fieldcontact that terminates on a single screw can produce a logic discrepancy only for aninternal failure.
External failures in the field switches and wiring are more likely to occur thaninternal failures; therefore, three field switches are normally used in trip circuits suchas the pump bearing oil pressure. One switch is set to close when the pressure dropsbelow the alarm level. Two additional switches are set at the trip level. Applicationsoftware will trip the unit if it sees two of these switches close. Diagnostics willalarm if there is a discrepancy between the three field switches or if a trip switchcloses prior to the alarm switch closing.
GEI-100474 SPEEDTRONIC� Mark VI TMR Feed Pump Turbine Control •••• 11
Typical redundant trip switches include:
• Header Pressure Trip
• Turbine Bearing Oil Pressure Low Trip
• Pump Bearing Oil Pressure Low Trip
• Vacuum Low Trip
• Pump Suction Low Trip
Overspeed ProtectionThere are two levels of overspeed protection excluding the normal speed controlfunction of the governor. The speed control algorithm (XTNCB03) will initiate anoverspeed trip command if the speed (TNH_A/B) reaches the primary overspeedlimit (KTNHOS_A/B). The mechanical overspeed bolt provides another level ofoverspeed trip protection. If the turbine does not have a mechanical overspeed bolt,then a triple redundant emergency overspeed (EOS) Module is used for each turbineto replace the mechanical overspeed bolt. In some retrofit applications, there is amechanical overspeed bolt and the EOS module as a customer requirement.
A test of the primary overspeed trip system can be initiated from the overspeed testdisplay when the pump is uncoupled and reset, and the speed is above the low speedstop and below the high-speed stop.
Note The control system has no automatic way of knowing whether the pump iscoupled or not coupled. Pushing the test button on the display will cause the speedreference to be ramped to 1% (KOS_BIAS_A/B) above the Primary overspeed tripsetpoint (KTNHOS_A/B) at a ramp rate determined by time constant(KTNHR_TC_A/B).
12 •••• SPEEDTRONIC� Mark VI TMR Feed Pump Turbine Control GEI-100474
J2
<P> Protection Module (EOS) - Section X
JR1
<R><S>
<T>Turbine CardIS200VTUR
ProcessorCardIS200UCV_
Pr/D
Shown for <R>
Same for <S>
Same for <T>
#1 PrimaryMagneticSpeed PU
FilterClamp
ACCoupling
Suppr.
FilterClamp
ACCoupling
Suppr.#2 PrimaryMagneticSpeed PU
FilterClamp
ACCoupling
Suppr.#3 PrimaryMagneticSpeed PU
0 to 14 k Hz
f( )
JX5
Termination BoardIS200TTUR
#1 Emerg.MagneticSpeed PU
FilterClamp
ACCoupling
Suppr.
FilterClamp
ACCoupling
Suppr.#2 Emerg.MagneticSpeed PU
FilterClamp
ACCoupling
Suppr.#3 Emerg.MagneticSpeed PU
Termination BoardIS200TPRO
J5
Median Select& OS Algorithm Buffer
J4Shown for <R>
J4
J4
Same for <S>
Same for <T>
Termination BoardIS200TRPG1
JS1
JT1
Termination BoardIS200TREG
JX1
JY1
JZ1
<PDM>24 or 125vdc
J1
J5
JY5
JZ5
Pr/Df( ) OS Algorithm BufferJ3
Connectors atbottom of
VME racks
<PDM>125vdc
J7
<P> Protection Module (EOS) - Section Y
<P> Protection Module (EOS) - Section Z
Same for Section Y
Same for Section Z
JR5
JS5
JT5
IS200VPRO
IS200VPRO
IS200VPRO
J2
Power
Hydraulic Trip Solenoids+
-
-
<R> Commun.
Trip signal toservo TB
TSVO (JD1)
J1
41
42
33
34
25
26
31
32
37
38
43
44
4 Circuits
4 Circuits
4 Circuits
3 Circuits
3 Circuits
3 Circuits
Primary and Emergency Overspeed System
A test of the mechanical overspeed bolt can be initiated from the same display whenthe turbine is uncoupled and reset, and the speed is above the low speed stop andbelow the high speed stop. This will cause the primary overspeed trip setpoint(KTNHOS_A/B) to be automatically moved above the mechanical bolt setpoint(KTNHMOS_A/B), and the turbine will accelerate to the trip limit.
An EOS module monitors a separate set of three passive, magnetic speed sensorswhich are terminated on the TPRO terminal board and connected internally to thethree VPRO cards with independent power supplies, processors, and I/O. Eachsection monitors the speed and calculates:
• Excessive overspeed (L12H)
• Fast overspeed detection - interrupt driven every 8 pulses (L12H_TP0)
• Excessive rate of change ±100 %/s (L12H_TP2)
• Turbine below 10% speed (L14H_ZE)
• Turbine above adjustable setpoint (L14H_MN)
The EOS module will trip independent of the control modules, and diagnostic data iscommunicated back to the VCMI cards in the control modules for alarming and/orcross-tripping. For example, the control modules expect to see a 10% speed signal(L14H_ZE) from the EOS module when there is a 10% signal from the primaryspeed sensors. If this does not occur, the turbine trips.
GEI-100474 SPEEDTRONIC� Mark VI TMR Feed Pump Turbine Control •••• 13
A test of the EOS module can be initiated from the overspeed test display when theturbine is uncoupled and reset, and the speed is above the low speed stop and belowthe high-speed stop. This will cause the EOS trip setpoint to be reduced below theprimary overspeed trip setpoint (KTNHOS_A/B), and the turbine will accelerate tothe trip limit.
Thrust Wear Protection
ProcessorCardIS200UCV_
K39AAA active alarm AB
AB
AB
AB
A>=B
A<=B
A>=B
A<=B
K39AIA inactive alarm
K39AAT active trip
K39AIT inactive trip
OR
ORL39AF1 probe fault
Trip L39AXT1
Alarm L39AXA1XAXPO01 - Axial Position Monitor
AXIAL1 input
L39AF2 L39AXT2
AXIAL2 L39AXA2
AXIAL3 L39AXA3
L39AF3 L39AXT3
Same as above for thrust input #2
Same as above for thrust input #3
L39AF1 Probe #1 Fault Alarm - 1 sec TDL39AF2 Probe #2 Fault Alarm - 1 sec TDL39AF3 Probe #3 Fault Alarm - 1 sec TD
2/3 TL39AF2L39AF1
L39AF3
L39AXFT
1 sec
2/3 ProbeFault Trip 2/3 T
L39AXT2L39AXT1
L39AXT3
L39AXT
1 sec
2/3 Probes AtTrip Level
OR TL39AXA2L39AXA1
L39AXA3
L39AXA
1 sec
Any Probe AtAlarm Level
<R><S>
<T>ProximitorCardIS200VVIB
Termination BoardIS200TVIB
JR1
Connectors atbottom of
VME racks
A/D
Shown for <R>
Same for <S>
Same for <T>
CL
NoiseSuppression
CL
NoiseSuppression
-24vdc
-24vdc
-28vdc
Probe Proximitor CL
NoiseSuppressionRange = -0.5 to -20 vdc
Accuracy = 1% of full scaleResolution = 14 Bits
-24vdc
Not Used
Not Used
Not Used
Not Used
J3/4
JS1
JT1
J3/4
J3/4
Buffered OuputsTo Bently Nevada
3500 Monitor
Input Terminations
JC1
JD1
JC1: Circuits 9-12 PositionJD1: Circuits 13, 14 KP
Sampling TypeA/D (16 bit)
Probe Proximitor
Probe Proximitor
Three redundant axial position probes are used to monitor the turbine thrust and themedian value is displayed on the main display. Axial positions for each probe aredisplayed in bar chart format on the proximitor display. Positions are displayed ingreen if the vibration is below the high alarm level and no fault is detected. Anabnormal condition will cause the specific bar to turn red.
A redundant −23 V dc source is provided from the VVIB cards in the controlmodules for the proximitors and the resultant dc input is monitored for the axialposition. An alarm will occur if the position exceeds the alarm limit on any probe inthe active (K39AAA_A/B) direction or in the inactive (K39AIA_A/B) direction. Atrip will occur if the position exceeds the trip limit on two out of three probes in theactive (K39AAT_A/B) direction or in the inactive (K39AIT_A/B) direction. Thediagnostics will alarm a fault condition if they detect a fault on any probe, and anautomatic trip will occur if a fault is detected on two out of three probes. The faultdetection will automatically inhibit a false trip logic in the algorithm. The pump axialposition is monitored with a single probe to alarm an excessive thrust level in the
14 •••• SPEEDTRONIC� Mark VI TMR Feed Pump Turbine Control GEI-100474
active (K39AAA_P_A/B) direction or in the inactive (K39AIA_P_A/B) direction,and diagnostics will alarm a probe fault.
Vibration ProtectionThe VVIB cards in the control modules directly monitor Bently Nevada vibrationsensors. An X and Y probe is used to monitor vibration on the HP and LP turbinebearings and the inboard and outboard pump bearings. The main display shows aturbine-pump diagram with a bearing vibration level determined by the highestvibration level of each X/Y probe pair. Vibration levels for each probe are displayedin bar chart format on the proximitor display. Vibration levels are displayed in greenif the vibration is below the high alarm level and no fault is detected. An abnormalcondition will cause the specific bar to turn red.
The ac component of the proximitor input is used to determine the vibrationmagnitude, and the dc component is used to monitor the gap for fault detection. Ahigh or high-high alarm will occur if excessive vibration is detected on either probe.A fault alarm will occur if a fault is detected on any probe, and it will inhibit a falsealarm message of a high vibration level. Unique control constants are used to set thehigh (K39VA#_A/B) and high-high (K39VT#_A/B) alarm levels for each probe. Allturbine trips for the vibration system must be manually initiated.
Vibration data available in the data base and from buffered BNC connectors on theTVIB terminal boards includes:
• The unfiltered Direct Magnitude of the vibration input in (mils)
• The 1X Magnitude (mils) and Phase Angle (degrees)
• The 2X Magnitude (mils)
• The dc gap voltage (mils)
Eccentricity MonitorEccentricity is measured while the turbine is on turning gear. The algorithmcontinuously monitors the gap between the probe and the shaft for the time(K2REV_A/B) required for the shaft to make one revolution. The maximumdeviation in the gap per revolution is shown on the proximitor display bar chart. Analarm is initiated if the deviation exceeds the high alarm limit (K30EC_H_A/B) orthe high-high alarm limit (K30EC_HH_A/B). A probe fault will cause a separatefault alarm, and it will inhibit a false alarm message for a high eccentricity level.manual action is required to trip the turbine for a high or high-high eccentricitycondition.
GEI-100474 SPEEDTRONIC� Mark VI TMR Feed Pump Turbine Control •••• 15
Packaging
EOS Module3 Independent Sections
3 Control Modules
Mark VI Electronics
The standard turbine control enclosure consists of a NEMA 1, convection cooledcabinet with front access and top or bottom cable entrances. It is rated for continuousoperation in a 0 to 45 °C ambient and operation up to 50 °C during maintenanceperiods; however, it is recommended that this microprocessor based product belocated in an air-conditioned environment. Other types of enclosures are availablewith built-in cooling systems and purification systems as required for the application.
16 •••• SPEEDTRONIC� Mark VI TMR Feed Pump Turbine Control GEI-100474
There are various types of cabinet arrangements. The most typical arrangementconsists of a cabinet containing the three control modules and a separate cabinetcontaining the terminal boards and power converters/distribution. All of theelectronics are mounted on the back base (nothing on the side-walls). These cabinetsare relatively shallow at 23.6 in. (600 mm) deep and can be mounted either side-by-side or back-to-back. They are used on most new unit applications and are alsoavailable for retrofit applications if sufficient space is available. A more compactcabinet is frequently used for retrofit applications and is deeper and narrower. This isaccomplished by mounting the terminal boards on the side walls.
Typical Cabinet Specifications
English Units Metric UnitsDimensions- Control Cabinet- Termin. Cabinet- Retrofit Cabinet
63.0 in. W x 86.6 in. H x 23.6 in. D63.0 in. W x 86.6 in. H x 23.6 in. D53.1 in. W x 86.6 in. H x 35.4 in. D
1,600 mmW x 2,200 mmH x 600 mmD1,600 mmW x 2,200 mmH x 600 mmD1,350 mmW x 2,200 mmH x 900 mmD
Weight per cabinet 1,000 lbs. (typical) 453.6 kgs. (typical)Temp. - Operate +32 to +113 °F 0 to +45 °C - Storage -40 to +158 °F -40 to +70 °CHeat 1,000 Watts (typical) 1,000 Watts (typical)Humidity 5 to 95% non-condensing 5 to 95% non-condensing
PowerThe turbine control is normally powered from redundant 115/230 V ac powersources. Provision for a floating 125 V dc source is also available. The ac powerconverters include an isolation transformer and a full wave rectifier to produce a 125V dc output that is high-selected. This redundant, internal 125 V dc bus is isolatedand fed to the various module power supplies through the power distribution module.Separate 125 V dc feeders are used to distribute the power to each contact input andrelay output terminal board. Each solenoid circuit has additional fuses on the positiveand negative sides. Diagnostics monitor each voltage source and each feederincluding the fuses in each solenoid circuit on the relay terminal board. Interposingrelays are used for retrofit applications with energize-to-trip solenoids.
Control Cabinet PowerSteady-State Voltage Frequency Load Comments120 V ac (108 to 132 V ac) 47 � 53 Hz
57 � 63 Hz6 A rms Harmonic distortion < 7%
240 V ac (216 to 264 V ac) 47 � 53 Hz57 � 63 Hz
3 A rms Harmonic distortion < 7 %
125 V dc (100 to 145 V dc) 6 A dc Ripple <= 5%
* Power source load estimate does not include the load of external solenoids.
GEI-100474 SPEEDTRONIC� Mark VI TMR Feed Pump Turbine Control •••• 17
Operator ScreensThe operator/maintenance interface is commonly referred to as the HMI. It is a PCwith a GE CIMPLICITY graphics user interface, a Microsoft Windows NToperating system, a Control System Toolbox with editors for the application softwareand unit specific screens. It can be applied as:
• The primary operator interface for one or multiple units including the mainreheat steam turbine and its generator excitation system
• A backup operator interface to the plant DCS operator interface
• A gateway for communication links to other control systems
• A permanent or temporary maintenance station
• An engineer�s workstation
All control and protection is resident in the turbine control, which allows the HMI tobe a non-essential component of the control system. It can be reinitialized orreplaced with the turbine running with no impact on the control system. The HMIcommunicates with the processor card in the turbine control through the Ethernetbased UDH.
Feed pump turbine control screens show a diagram of the turbine with the primarycontrol parameters. When two turbines are controlled from a single triple redundantcontrol system, the screens show turbine A on the left and turbine B on the right withidentical graphics. The basic diagram is repeated on most of the screens to enableoperators to maintain a visual picture of the turbine�s performance while changingscreens. All screens have a menu on the right-hand side of the display which has ahierarchy of an overview screen (for a multiple unit site), unit selection (feed pumpturbine, main unit, generator excitation), and a menu of all of the feed pump turbineoperator screens.
Typical feed pump turbine screens include:
• BFPT Main Display (Primary Operator Control)
• Offline Tests
• Online Tests
• Valve Calibration
• Proximitors for Turbine A
• Proximitors for Turbine B
18 •••• SPEEDTRONIC� Mark VI TMR Feed Pump Turbine Control GEI-100474
Feed Pump Turbine Graphics
The primary screen in the system is the Main screen. This single display can be usedfor auto/manual control selection, raise/lower, fast/slow commands, tripping,accessing alarm messages, and monitoring control parameters from both turbines.
All operator commands can be given through momentary pushbutton commands onthe screen. The command is sent to the Mark VI control where the applicationsoftware initiates the requested action assuming that the appropriate permissives aresatisfied. A response to the command can be observed within one second if it doesnot involve subsequent system time delays. As an example, if a Select Autocommand is given. A small pop-up window will appear above the Select Auto buttonfor the operator to verify that he/she really intends to select Automatic Control of theturbine. Upon verification, the application software checks the permissives andinitiates a transfer to automatic control that results in a Automatic Control message.
If the turbine was not ready for automatic control, then an alarm message wouldappear in the bottom left-hand corner of the display identifying the reason.
Note The purpose of the alarm queue is to identify any abnormal condition. Alarmmessages are displayed with 20 ms resolution and SOE are displayed with 1 msresolution. An alarm buffer is included with 10 MB or 30 days of storage.
GEI-100474 SPEEDTRONIC� Mark VI TMR Feed Pump Turbine Control •••• 19
The Trip Status display provides a graphical representation and status of all potentialturbine trips. This graphic also relates to the functional organization of theapplication software. If there are latched trips, then the operator must select theMaster Reset button. This references another screen to remind the operator of theneed to investigate and correct the reason for the latched trip prior to issuing aMaster Reset. A trip history log is included for all of the key control parameters andalarms scanned at 20 ms for 1 minute and at 1 s for 10 hours for each of 10 trips.
gGE Industrial Systems
General Electric Company1501 Roanoke Blvd.Salem, VA 24153-6492 USA
Issue date: 2000-08-31 2000 by General Electric Company, USA.All rights reserved.