GE Mark V, Mark VI & Mark Vie Gas Turbine Controls

Full Simulation

Expert Course Faculty

Lies Tahri

Course Overview

The 5-day operations and Maintenance course is designed for plant personnel involved in the daily operation and maintenance of either Mark V control systems, Mark VI or Mark Vie and HMI. The course will enable operators and technicians to configure HMI displays and confidently, manipulate HMI software tools as well as diagnose problems in Gas Turbine SPEEDTRONIC Control Systems. The course is designed to provide a solid background in turbine governing systems. Participants increase their skills in HMI features, configuration and troubleshooting. The use of a Gas Turbine simulator for the Mark V will allow students to view various operational problems and introduce the concepts of configuration, troubleshooting and fault finding. For the Mark VI and Mark Vie, the simulation is software based and runs with the use of a “key” Dongle and will allow each student to work individually.

This course provides participants with practical hands-on training in operation and Maintenance of gas turbine power plants under normal and abnormal conditions. Participants learn safe and efficient plant operation methods, plant startup, normal operation, plant shutdown, and dealing with typical problems that occur in gas turbine power plants,. The training is conducted using advanced real-time simulators that simulate typical plant problems in a realistic environment for the participants to understand, analyse, troubleshoot and respond to the problems. Participants are required to deal with associated alarms, analyse and discuss the cause and the effects of the problem scenario and to take corrective actions to restore the plant to normal conditions.

Simulation-based training is one of the most effective methods of training the operation and Maintenance personnel of industrial plants. Simulators allow plant personnel to observe the consequences of their actions without any direct impact on actual plant operations. Through simulation-based exercises, trainees can learn how to respond to emergencies and how individual actions and decisions affect entire processes in an environment that mirrors situations they would normally encounter in a plant or facility.

Each course is 5-Day duration using the respective simulation either Mark V, Mark VI or Mark Vie depending on the client Turbine Controller. A fully concise training manual will be provided will be provided for each delegate. Your key learning outcomes from attending this 5 day training course:

• Get familiar with the types of GE Gas Turbines and their applications. • Understand and read Gas Turbine schematics and identify instrumentation devices/uses. • Acquire knowledge of the various GE Gas Turbine Systems and explain

operating requirements for Lube Oil, Hydraulic Oil and Fuel Systems. • Be able to explain start-up, synchronising and loading procedures • Be able to troubleshoot, fault finding and configure sequencing • Be able to configure operating displays and Trip Historical display. • Be able to use the software tools that are used to troubleshoot alarms, • Edit the sequencing, configure the Inputs and outputs (both hardwired and networked) • Be able to calibrate Servo-Actuated Valve ,LVDT's and other device • Appreciate the principles of emissions control and the various methods of achieving this

Who Should Attend

This is an excellent course for plant operators/technicians responsible for the day-to-day operations of a Gas Turbine. The course will also benefit maintenance personnel who are involved in the troubleshooting of operational problems. Shift supervisors and Team Leaders will also find the course beneficial. .

COURSE: MARK V Operation and Maintenance

DAY 1: • Presentation of the program. • Participants special interests • Equipment Review: Turbine and Control System Basics • Use of Documentation: Device Summary, Control Specs, I/O Report • Speedtronic Mark V hardware • Function, Interpretation and Use Mark V modules: Control/Protection and Power Supply • Internal and external Mark V wiring • Lab Exercises

DAY 2:

• Overview of HMI documentation and reference manual • HMI Directory / File structure • TCI (Turbine Control Interface) • HMI troubleshooting: Software Troubleshooting, Arcnet and DCS communications • Operator interface facilities (TCI functions) • The logic forcing display • The rung display • The prevote data display • The trip history display • Alarm display • Trouble shooting procedure • The backup operator interface • Control sequence editor • Control sequence documentor • Short / long term trending: Configuration and Troubleshooting • Historical trip display (Long Term Storage: Configuration and Troubleshooting) • View Programs: Troubleshooting Tool for dithering problems • Alarm display : Set up, filtration & analysis • CIMPLICITY SCREEN EDITOR: frame containers, database etc. • Practical: Cimplicity Tutorial.

DAY 3

• Mark V software structure • Hardware and Software Voting (TMR and SIFT) • Fault Finding using Mark V Studio Tool (Dynamic Control Sequence Program: CSP ). Logic tracing • Practical Troubleshooting Exercises: CSP, Primitives, Big Block Language (BBL). • Sequencing Exercises: Adding an Alarm, Analog Input, Contact Input etc. (IO report, assign file, control

constant, MK5MAKE, Sequence editor). • Unit SU & SD sequences: Step by step procedure • Control modes: Start-up/Speed/Temperature/Acceleration/Manual /Shutdown/IGV Control. • Overspeed test.

• Generator Synchronisation: Auto and Manual. Reactive capability curve interpretation (MW vs. MVAR). • Load Sharing and Shedding • Lab Exercises

DAY 4 • Changing an Operator Display • Creating a New Display • Creating a Demand Display with Push Buttons (Tools) • Mark V Servo valve Regulators (LVDT Calibration): Using the I/O Configurator • Use of DIAGC (Diagnostic Counters) • EEPROM Downloader • Hardware Troubleshooting (Use of LCC Display for A7 Troubleshooting: faulty cards,

ribbon cable, jumper settings). • Trip History Configuration and interpretation • Changing Control Constants (online and off line) • Flow Chart Explanation of Alarm Troubleshooting • Lab Exercises

DAY 5

• Trouble shooting real situations. E.g. Load rejection, unexpected trips • Practical Exercise: "Not Ready to Start" failure analysis for trips. • Software Back-up • Configuring a PC into an HMI • Evaluation

COURSE: MARK VI Operation and Maintenance

DAY 1

Introduction Speedtronic Mark VI GE Gas Turbine Fundamentals and control basics.

Speedtronic Mark VI hardware Panel, modular concept discussion Mark VI cards Internal and external Mark VI wiring Hardware documentation The main protection system VPRO Supply voltage.

DAY 2

Data structure of the operator interface <HMI> Brief discussion of the Windows 2000/XP based operator interface Most important files of the operator interface and their function Failure of the operator interface, what to do. Communications with the operator interface, Ethernet and DCS communications

Operator interface facilities, TOOLBOX and Cimplicity Watch Windows The M6B file, functions, modules and tasks The Finder Trip log Alarm display Trouble shooting procedure Control constants

Mark VI tools (TOOLBOX practice) Trend Recorder, Historical trip display, Alarms and SOE's

DAY 3

Mark VI software structure M6B file, MKVI I/O and functions Programming languages of the Mark VI Macro's and Modules

Practice: Making Mark VI software with TOOLBOX Digital input. Analog input with software by students

Digital input with software example by Students Gas turbine sequence

Control modes Start up and permissive for start IGV sequence Normal stop Emergency stop

Discussion of the following controls and sequencing Fuel control Start up, Speed, Acceleration, Temperature, Shut-down control and Manual FSR control Special control loops Inlet Guide Vane, Anti icing, Water / steam injection and Start and stop. control loops The protection systems Flame detection, Overspeed, Vibration, Exhaust temperature, Lube oil pressure and temperature, Fire protection system.

Discussion of the following controls and sequencing Synchronization, auto and manual Power factor control MVAR control

Dry Low NOx Explanation of the system Discussion of the controls, implementation in Mark VI controls and logics

DAY 4

Trouble shooting, alarm analysis and limited software changes in practice: Diagnostics of card failure-Card replacement procedure. Alarm display-Setup and configuration Alarm Management (flow chart explanation) Exercise of different simulated alarms trouble shooting Changing control constants, adding alarms, Trip Log display and interpretation.

DAY 5

Trouble shooting using simulation Configuring Trip log display Adding Sequencing (CI, CO etc.), Build, Downloading, HMI device Configuring a new Cimplicity screen. Case study: Unit "not ready to start". Start Checks, Trip logs. First failure analyses for trips (emergency stop)

Class Discussion and Evaluation of the course

COURSE: MARK VIe Operation and Maintenance

Day 1 • Introduction-Safety • Introduction to Student Documentation • System overview and Architecture

1. Panel/Hardware Identification, Description, Layout 2. Controllers 3. I/O Cards 4. Typical Panel Layout

• Lab#1 MarkVIe System Architecture • Review of GEH-6721 Vol. II • TMR/Duplex Panel Layout • Lab#2 MarkVIe System Architecture • Power Distribution Modules • ToolboxST2.x Basics • Password Structure • Demonstration of Basics • Monitoring the MKVIe

1. Inputs/Outputs 2. Local vs. Remote I/O 3. Forcing 4. Uploading 5. I/O Report

• Lab#3 Identify and Monitor I/O Points Day 2 • Monitoring the MKVIe

1. Software 2. block structure 3. help files 4. Linked Blocks

• Lab#4 Identify and Monitor Internal Software • Using the MKVIe Finder • Lab#5 Finder • Using the MKVIe Trender • Lab#6 Trender • Using Watch Windows • Lab#7 Troubleshooting Functions • Lab#8 Tune-up • Constants and Variables

1. Difference 2. Changing and saving

Day 3 • Editing application software • Making software changes permanent - Downloading to the Controller • Lab# 11 Code Generation • Configuring-I/O-points • Lab# 12 Digital I/O • Lab# 13 Software and Hardware I/O Editing • Lab# 14 Software and Analog I/O Editing • Adding another duplicate Unit – G2 • Review of Typical TMR software – G2 Day 4 • I/O PAC and Terminal board replacement • Viewing and troubleshooting I/O diagnostic alarms • Lab# 9 Hardware Diagnostics • Lab# 14 I/O Pack Initialization • Communication with Cimplicity -EGD Communication • Lab #20 Cimplicity Communication • Replacing the Controller card • Lab# 15 UCCx Controller Initialization • Using the Low Level Monitor (LLM)

1. Telnet to the Controller 2. Using LLM to access I/O PAC Information

• Adding and Modifying Alarms, SOEs and Events • Lab# 18 Add & Modify Alarms and SOEs • Peer to Peer to communications with MarkVIe

1. Communicating with Legacy Devices 2. Unit Data Highway (UDH)

• Lab #19 MarkVIe Peer to Peer Communications Day 5 • Configuring Trip and DDRs History • Viewing Trip History • Lab #24 Configure Trip History • Calibration using the MarkVIe • Lab #25 Lab Servo Calibration