System Overview and Architecture 20140320

System Overview and
Architecture
Mark*VIe Control System
GE Power & Water Technical
Training
* Indicates a trademark of General Electric Company and/or its subsidiaries

Mark VIe Control System Architecture
Key focal points:
• GE Speedtronic Controller History & Application
• Primary System Components
▪ Controllers
▪ I/O Modules
▪ Networks
▪ HMIs
• Configurations
▪ Redundancy Options
▪ Voting
▪ Input / Output Processing
▪ Overspeed Protection
Slide 2
History
GE Controls History
1968 1970’s 1980’s 1990’s 1997
Mark I Mark III Mark V
Mark II Mark IV
Slide 4
GE Controls History
1999 2004 2007 2010
Mark VI Mark VIe Mark VIe Mark*
CPCI UCSA Migration
Slide 5
Mark VIe Applications
Hydro Heavy Duty Gas
✓ Turbine Control
✓ Balance of Plant (BOP) Steam Wind
✓ Distributed Control Systems

✓ Generator Aero-derivative Nuclear
✓ Vibration Monitoring
✓ Combustion Monitoring DCS/BOP
And More…
Slide 6
System Components
Primary Components of the System
ToolboxST*
HMI Servers CIMPLICITY
Controllers
Networks
I/O Modules
HMI
Viewer
or Server
Slide 8
Mark VIe Controller Options
UCCA or UCCC board in UCSA or UCSB stand alone

1
CPCI Chassis controller module
1
Slide 9
compact peripheral component interconnect
Basic Components of CPCI Chassis
Optional second
Main processor board power supply
UCCA or UCCC
Spare slots
Power supply
Cooling fan compartment
CPCI rack
Slide 10
CPCI Processor Board
Up to 1600 MHz CPU
10/100Base TX Ethernet
ports to the IONet
10/100BaseTX
COM port for Ethernet ports to the
configuring TCP/IP UDH
address Optional CDH1
1
Slide 11
Controller Data Highway. Port can also be used for Modbus over Ethernet. This port available on UCCC only
UCSA or UCSB Stand-alone Controller
Up to 1200 MHz CPU
10/100Base TX Ethernet ports to

the IONet
10/100BaseTX Ethernet ports to
the UDH
Optional CDH
COM port for configuring TCP/IP
address
Slide 12
I/O Modules
3 Parts
1. Terminal Board
2. Terminal Block
3. I/O Pack
S-type
Terminal
T-type Board
Terminal Board
Slide 13
I/O Packs
Plug into Terminal Boards
Digitize the signal
Communicate to controller(s)
Contain processor and data

acquisition boards
Status lights on front
Slide 14
Core Analog I/O Module
This is a special kind of I/O Module that accepts
thermocouple, milliampere current, seismic, LVDT,
and pulse rate inputs. Outputs are milliampere
current, servo-coil commands, and LVDT excitation.
Slide 15
Common I/O Packs
Refer to GEH 6721 Volume 2 for a comprehensive list
PDIO – Discrete I/O (24 Inputs / 12 Outputs / Pack)

PDIA – Contact Inputs (24 Points / Pack)
PDOA – Relay Outputs (12 Points / Pack)
PAIC – Analog I/O (10 Inputs / 2 Outputs / Pack)
PAOC – Analog Output (8 Points/Pack)
PCAA – Core analog I/O (various types)
PTUR – Speed Inputs (4 Points / Pack)
PTCC – Thermocouple Inputs (12 Points / Pack)
PRTD – RTD Inputs (8 Points / Pack)
PSVO – Servo command / LVDT feedback
Slide 16
Basic Network Architecture
3 – Key Networks
Network Printers
DCS †
PDH
UDH
IONet
†
There are currently multiple ways to integrate a customer provided Distributed Control System (DCS)
with the Speedtronic* control system. The above example represents either Modbus or GSM* over
Ethernet Slide 17
IONet connects controller(s) and I/O packs
<R> IoNet uses red Ethernet1 cables
Controllers
<S> IoNet uses black Ethernet1 cables
IONet
<T> IoNet uses blue Ethernet1 cables
I/O Packs and

Terminal Boards
1
Category 5e Slide 18
IONet switches have been carefully
engineered to meet the specific data traffic
demands of the Mark VIe control system
Use only GE-approved Ethernet switches in all

control system I/O networks. Unsupported
switches can prevent I/O modules from
receiving controller outputs.
Caution
Slide 19
UDH connects GE Control Systems and HMI
servers
…etc.
Like the IONet, the UDH uses Category 5e Ethernet cables.

The protocol is EGD (Ethernet Global Data)
Slide 20
PDH connects HMI servers with remote
viewers, printers, historians, and external
interfaces. No direct connection to the
control system.
External Interface Network Printer
Cat 5e Ethernet cables. TCP/IP, GSM or Modbus over

Ethernet protocols
Slide 21
Data Highway Ethernet Switches
The UDH and PDH networks use Fast Ethernet switches called
VLAN (virtual LAN).
Two switches can be used with an interconnecting cable to
provide redundancy.
Use only GE-approved Ethernet switches in all

control system I/O networks. Unsupported
switches can prevent I/O modules from
receiving controller outputs.
Caution
Slide 22
Link to Distributed Control System (DCS)
Most common connection types:
Serial Modbus slave Modbus slave GSM OPC UA, DA, AE
From HMI Server via TCP/IP via TCP/IP via TCP/IP
Slide 23
Human-Machine Interface (HMI)
The operator interface to the Mark VIe control system.
A computer with a Windows OS, CIMPLICITY graphical
user interface, and WorkstationST* application which
communicates with the Mark VIe controllers over
Ethernet.
Product features important for plant control:
✓ Dynamic graphics ✓ Point control panel right-
click menu
✓ Alarm displays
✓ HMI access security
✓ Trending
Slide 24
HMI Basic Description
HMI server is the hub of

the system
Channels data between

the UDH and the PDH
Provides data support,

repository for alarm
messages, and system
management
Slide 25
HMI Hardware/Software Features
Hardware Software
Desktop Workstation Windows Operating System
– 19+” monitor WorkstationST* Application
– Keyboard & Mouse CIMPLICITY HMI/Scada
Panel Mount Display ControlST
– Touch Screen with Mouse
& Keyboard Full Backup Software
Multiple Network Interface Cards Antivirus Software

(NIC) for UDH and PDH
Slide 26
Turbine Historian
Provides historical data archiving and retrieval
functions.
Proficy* Historian or OSI Soft – PI Historian
Slide 27
Network Time Server
Information Network (PDH) – 10/100MB Ethernet
HMI Operator Stations
Network Time Server
GPS Antenna
+/-2m Time Coherence Between Controls

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

10/100 MB Ethernet
Control Control Control Control
System System System System
Mark IV or V Migration, Mark VI,

Mark VIe, EX2100, EX2100e, LS2100
Slide 28
Configurations
Scalable Redundancy Options
Redundancy allows us to increase our running
reliability. Mark VIe provides scalable levels of
redundancy. We can divide this redundancy into
two groups: Controller and I/O
Slide 30
Fault Detection
• In order for a redundant system to
increase running reliability it must
detect and annunciate faults to ensure
the components are operating
properly
• Fault detection must be determined as
close to the output as possible because
a failure to control the outputs is the
most damaging scenario
• Mark VIe detects faults at the I/O
packs
Slide 31
Controller Redundancy
R R S R S T
Simplex Dual TMR

• Lowest cost • Better Running • Better Running
• No Online Repair Reliability than Reliability than
Simplex Dual1
• Online Repair • Online Repair
1 Due to increased fault detection capability Slide 32

I/O Redundancy
Single pack single network (SPSN) Single pack dual network (SPDN) Two single pack single network
▪ Non-critical single sensor I/O ▪ Non-critical single sensor I/O (2SPSN)
▪ No redundancy ▪ Redundant network ▪ Redundant sensors monitoring the
▪ Can be used when controllers are ▪ Can be used when controllers are same process point.
configured in: Simplex, Dual, or configured in: Dual, or TMR ▪ Redundant network
TMR ▪ Redundant data acquisition
▪ Online repair
▪ Can be used when controllers are
configured in: Dual, or TMR
Dual pack dual network (DPDN) Triple pack dual network (TPDN)
Triple pack triple network (TPTN)
▪ Special case for inputs only ▪ Special case for outputs and
▪ Most common TMR configuration
▪ Single input signal is “fanned” inputs
▪ Single input signal is “fanned”
▪ Redundant network ▪ Single input signal is “fanned”
▪ Redundant network
▪ Redundant data acquisition ▪ Redundant network
▪ Redundant data acquisition
▪ Online repair ▪ Redundant data acquisition
▪ Output voting in hardware
▪ Can be used when controllers are ▪ Output voting in hardware
▪ Online repair
configured in: Dual, or TMR ▪ Online repair
configured in: TMR only
configured in: Dual only
Slide 33
Designated Controller
Although three controllers, R, S, and T,
contain identical hardware and software,
some of the functions performed are
unique. A single designated controller
can perform the following functions:
• Provides initialization data to other
controllers during startup
• Keeps the Master time clock
• Provides variable state information to the
other controller if one controller fails
Designated
Controller
Indication
Slide 34
Designated Controller Determination
Each controller nominates itself

based upon a weighted algorithm
which takes into account:
– Control State
– UDH Connectivity
– IONet Connectivity
– NVRAM Health
The order of precedence is:

R then S then T
Slide 35
UDH Communicator
Controller selected to send EGD and Alarm

Data over the UDH
Designated Controller is always a UDH
Communicator
When a controller does not receive external
EGD data from its UDH connection, it may
request the data be forwarded across the
IONet from another UDH communicator.
Slide 36
Voting
Voting in the Mark VIe control is separated into analog
and 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
Inputs from Designated Controller
Slide 37
Median Value Analog Voting
**
** Diagnostic on Input 1 because 910 deviates from the Median Value by more than the limit of 30.
Slide 38
TMR Input Processing Examples
TMR Benefit: The loss of a controller associated

with a simplex input does NOT result in the loss of
that data. The simplex data continues to arrive at
other controllers in the system.
Slide 39
Voting is automatically done in

Mk VIe. This is an example
of SIFT
Example: Most common TMR I/O. Medium to high reliability
Slide 40
Voting is done in application
code. SIFT feature not
implemented
Example: Special applications
Slide 41
Voting is automatically done in

Mk VIe. This is another
example of SIFT
Example: Pulse rate inputs to TTUR. There are 6 screws on

the terminal board used for 3 separate inputs
Slide 42
TMR Output Processing
FIELD
DEVICE
Each controller sends its calculated value to its I/O pack

Output voting is performed in the I/O module.
Slide 43
TMR Output Processing - Communication Loss
Broken Communication
FIELD
DEVICE
1. Pack can continue to hold the last commanded value

2. Be commanded to go to a specified output state
Default action is to go to a power-down state
Slide 44
Relay Outputs
Slide 45
TMR Analog Outputs
I/O Packs
2/3 current sharing circuit

that allows the three signals
to be voted to one
Slide 46
TMR Servo Outputs
I/O Packs
magnetic flux
summation
Slide 47
Turbine Overspeed Protection
3 different Levels
1. Control – Closed loop speed control using the
fuel/steam valves prior to grid synchronization
2. Primary Overspeed – Provided by the controller
usually through the PTUR I/O module
3. Emergency Overspeed – An independent triple
redundant protection system. In some places this
task (among others) is given to a completely
separate Mark VIe control system known as the
Mark VIeS.
Slide 48
Primary & Emergency Overspeed Protection
…or Mark VIeS
Slide 49

System Overview and Architecture 20140320

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System Overview and

* Indicates a trademark of General Electric Company and/or its subsidiaries

Mark I Mark III Mark V

✓ Distributed Control Systems

UCCA or UCCC board in UCSA or UCSB stand alone

Cooling fan compartment

10/100Base TX Ethernet ports to

Contain processor and data

PDIO – Discrete I/O (24 Inputs / 12 Outputs / Pack)

<R> IoNet uses red Ethernet1 cables

<S> IoNet uses black Ethernet1 cables

I/O Packs and

Use only GE-approved Ethernet switches in all

Like the IONet, the UDH uses Category 5e Ethernet cables.

Cat 5e Ethernet cables. TCP/IP, GSM or Modbus over

Use only GE-approved Ethernet switches in all

HMI server is the hub of

Channels data between

Provides data support,

Multiple Network Interface Cards Antivirus Software

Proficy* Historian or OSI Soft – PI Historian

HMI Operator Stations

Network Time Server

+/-2m Time Coherence Between Controls

Control Network (UDH)

Mark IV or V Migration, Mark VI,

Simplex Dual TMR

1 Due to increased fault detection capability Slide 32

Each controller nominates itself

The order of precedence is:

Controller selected to send EGD and Alarm

TMR Benefit: The loss of a controller associated

Voting is automatically done in

Example: Most common TMR I/O. Medium to high reliability

Example: Special applications

Voting is automatically done in

Example: Pulse rate inputs to TTUR. There are 6 screws on

Each controller sends its calculated value to its I/O pack

1. Pack can continue to hold the last commanded value

2/3 current sharing circuit

…or Mark VIeS

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