Mark* VIe Control System

Overview and Architecture

Mark VIe System

Learning Objectives:
• GE Mark VIe controller history and application
• System components
• Communications
• Control and protection
• Redundancy options

2
GE Controls History
1997 1999 2004 2007
Mark Mark VIe Mark VIe
Mark V VI CPCI UCSA

3
 GE Mark6e Plant Controls
Control Room Integration
• Single operator interface for all equipment
• Single configuration & diagnostic tool
• Plant-wide historian, time sync

OSM

HRSG & BOP

Controllers

Subsystem
PLC
Turbine Control Generator Excitation
HRSG & & Protection & Protection
BOP I/O

4
Mark6e Control System Overview
ToolboxST*
HMI Viewer Proficy*
HMI Server (CIMPLICITY) HMI

I/O Module
Blade SW (option)

Controller

I/O Network

Field

AT 8600 Series SW

5
 UCSA Stand-alone Controller
667 MHz Power QUICC II Pro
Freescale processor

10/100Base TX Ethernet
ports provide connectivity
to the IONets
For training only

10/100BaseTX Ethernet ports

provide connectivity to the UDH

COM port for configuring TCP/IP

address

6
I/O
T-type
Modules Terminal Board
S-type
Terminal Board

3 Parts
1. Terminal board
2. Terminal block
3. I/O Pack

7
I/O Packs
• Plug into terminal boards
• Digitize the signal
• Communicate with the Mark VIe

• All packs contain a Processor and data

acquisition boards
• Pack Diagnostics and status lights are
provided on front 8
Types of I/O Packs
Common Types

PDIO – Discrete I/O (24 inputs / 12 outputs)

PDIA – Contact inputs (24 points)
PDOA – Relay outputs (12 points)
PAIC – Analog I/O (10 inputs / 2 outputs)
PAOC – Analog outputs (8 points)

PTUR – Speed inputs (4 points)

PTCC – Thermocouple inputs (12 points)

PRTD – RTD inputs (8 points)
PCCA - Core analog module
PHRA - HART enabled analog input/output
PSCA - Serial communication I/O module

9
Power Sources

 Designed to operate on
modular power sources

 The power
distribution modules
(PDM) support 115/230
V ac
24, 48 and 125 V dc

 Power Converted to 28 V dc
for I/O packs, switches, and
controllers
 DCS Network Enterprise External network

Central Dispatch

Architecture Remote Monitoring

& Diagnostics

Supervisory Ethernet – Supervisory Equipment PDH

Engineering Workstations HMI Servers HMI Printers

Viewers

Control Ethernet – Controller-to-Controller UDH

Mark VIe
Controller
s
Turbine Control Generator BOP Exciter
Protection
Distributed I/O Ethernet - Controller to Packs IONet

Turbine & Gen Controls Plant Auxiliaries

Monitoring & Protection Excitation (EX2100)
Valves, Sensors, etc. Balance of Plant
Equipment

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Mark VIe IONet
UDH UDH

R S

Controller

12
IONet Details
Switc
h
Controlle Terminal Board &
r I/O Pack

IONet – Cat. 5 IONet – Cat. 5 Field

Field Wire
Device
100m / 328 ft 100m / 328 ft 300m / 984 ft

C o n t r o l le LocalI/O TB
r Pack F ie ld
U Switc D e v ic e
IONet-Cat.5 h IONet-Cat.5 F ie ld W i r e
C 100m/328' 100m/328' 300m/984'
C

A
Controller Cabinet
Remote I/O Cabinet
C o n t r o l le Distributed I/ TB
r O Pack F ie ld
U Switc Switc D e v ic e
IONet-Cat.5 h IONet-Cat.5 h IO Net - Cat. 5 F ie ld W i r e
C 100m/328' 100m/328' 100m / 328' 300m/984'
C
or
1 0 0 F X F ib e r
A 2,000m/6,600'

13
IONet Options

Control Cabinet Remote I/O Cabinet

Switc Switch
h
Controller

IONet – Cat. 5 Terminal Board &

IONet – Cat. 5 I/O Pack
100m / 328 ft 100m / 328 ft
or
IONet – Cat. 5
100FX Fiber
100m / 328 ft
2 km / 6,600 ft

Field Wire
300m / 984
ft

Field
Device

14
Unit Data Highway (UDH)

Ethernet based
communicatio
n
Connects controllers
and HMIs
Ethernet global data
(EGD (
Connects to the Mark
VIe controller

15
 Plant Data Highway
(PDH(
Plant level supervisory network
Connects HMI server with
– Printers
– HMI viewers
– Historians
– External interfaces
No direct connection to the
controller

16
Communications with Other DCS

3 most common types:

• Serial Modbus slave from HMI server
• Modbus slave over TCP/IP
• GE Standard Messaging (GSM) over TCP/IP

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 Redundancy
Fault tolerant options:
• Redundant control with Simplex I/O
• Redundant control with redundant I/O
 Simplex
 Dual Redundant
 Triple Redundant

Redundancy configured
in software
IONet

18
Simplex Example
UDH
R

Lowest cost
No online repair
Controller
Less fault tolerant

19
Dual Redundancy Options Example
UDH UDH

R S Better reliability vs.

Simplex
Controller

Online repair
Dual I/O
options:
A - SPDN
B - 2SPSN
C -
DPDN D 20

- TPDN
TMR Redundancy Options Example
Most reliable
R S
T

Controller
Online
repair Voted
data
TMR I/O options:
A - SPDN
B - 2SPSN
C - DPDN
D - TPTN
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Designated Controller
-Provides initialization data to other controllers during startup
-Keeps the master time clock
-Provides variable state information to other controllers
-Designation based on Weighted algorithm monitoring the :
– Control State
– UDH Connectivity
– IONet Connectivity
– NVRAM Designated
Health
 If a numerical tie occurs: Controlle
R then S then T r
Indicatio
n

22
UDH Communicator

-Controller selected to send EGD and alarm

data over the UDH
-Designated Controller is always the UDH
communicator
-In the event that a controller cannot receive
UDH EGD data, the controller will request
the data over the IONet from the UDH
communicator
23
 Output Processing
1
2
3
FIELD
FIELD
DEVI
DEVIC
CE
E

1. Calculated data to switch

2. To Pack and Terminal board
3. To Field Device

24
TMR Output Processing

FIELD
DEVIC
E

-Controllers vote the signal output, voted output signal is

communicated to the I/O pack
-Depending on signal and terminal board type, the terminal
board will conduct the final hardware voting

25
Relay Outputs

26
TMR Servo Outputs

I/O Packs

magnetic flux
summation

27
TMR Analog Outputs

I/O Packs

2/3 current sharing

circuit that allows the
three signals to be
voted to one

28
Communication Loss
Broken Communication

FIELD
FIELD
DEVIC
DEVIC
E

1. Pack can continue to hold the last commanded value

2. Pack can be commanded to go to a specified output state
Default action is to g o to a power-down state
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Input Processing Options
Simplex I/O Dual I/O
IONet & Controller R R R R R R R S
S
Pack
T-Type T-Type
Terminal
Board
1 pack 1 pack 2 packs 3 packs
1 IONet 2 IONet 1 IONet 1/1/2 IONet

TMR
I/O
I/O Net & Controller R S T R S T
Pac
k T-Type
Terminal Board

Fanned Dedicated

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Input Voting

Voting is separated into 2 different categories

– Analog
– Logic
Inputs voted in Software (SIFT(
– Median select for analog
– 2 out of 3 for logic
– Voting disagreement
detector (voter
mismatch(
Dual controller no voting

31
State Exchange

Used in Dual and TMR

systems
Keeps controllers in
synchronization
Exchanges state info
through IONet
State information includes calculated values such as timers,
counters, integrators, and logic signals such as bi-stable relays,
momentary logic with seal-in, and cross-linked relay circuits. State
information is voted in TMR controllers and follows the
designated controller in dual or faulted TMR systems.
32
Median Value Analog Voting

33
Input Processing Examples

1 input to 3 controllers. Used for non-

critical inputs such as monitoring

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Input Processing Examples

35
Input Processing Examples

36
Input Processing Examples

37
Input Processing Examples

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Rate of Response (Frame Rate(
10 ms Frame Rate

Run Program

39
Human-Machine Interface
(HMI( HMI Viewer

• 2 Types – Servers and viewers

• Proficy (CIMPLICITY) GUI
• Servers - Can configure CIMPLICITY Project and
controllers.
• Servers - Provide Data to Viewers
• Viewers - Only for control and monitoring not
configuration
HMI or Control Software
Gateway HMI Software
HMI Server

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 HMI Software Features
Software
Windows XP or Windows 7
Acronis system restore software
Roxio backup software
Antivirus preloaded
ControlST CD preloaded
Proficy CIMPLICITY HMI

41
 HMI server
 HMI server is the hub of the
system.

 Channels data between the UDH

and the PDH

 Provides data support and

system management

 Captures data logs

 Allow Operation and

troubleshooting of the Process

42
Historian
 Provides historical data archiving and retrieval functions.
 Used PI Historian.

IMS2,IMS4,IMS6,IMS8,
IMS10,IMS12

43
Data Highway Ethernet Switches

 The UDH and PDH networks use Fast

Ethernet switches
 Star-type network architecture
 Two switches used with an interconnecting
cable provide redundancy

44
Typical DCS I/O cabinet

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Typical DCS controller cabinet

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Vocabular
y

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