The GE SPEEDTRONIC™ Mark V Gas Turbine Control System has long been a vital part of the industrial and utility sectors, especially in controlling and protecting gas turbines. Though now considered obsolete in favor of newer models, the Mark V system remains a significant milestone in the evolution of turbine control technology. Based on over 40 years of development, it represents the digital implementation of automation techniques that have shaped turbine operation, protection, and sequencing. Here’s a breakdown of its key features, which made it one of the most advanced control systems of its time.
1. Triple-Redundant Microprocessors
At the core of the Mark V system is the triple-redundant 16-bit microprocessor controllers, providing enhanced reliability and fault tolerance. The use of three control processors ensures that even if one fails, the other two can continue to operate, providing backup and maintaining turbine control without interruption. This redundancy extends to critical control and protection parameters, where two-out-of-three voting redundancy is used to ensure data integrity and make real-time decisions based on the majority vote.
The advanced Software-Implemented Fault Tolerance (SIFT) technology further enhances the system’s resilience by allowing the control system to detect and mitigate faults before they impact turbine operations.
2. Comprehensive Turbine Control and Protection
The Mark V system is designed to handle a wide range of control functions for gas turbines, including:
- Speed, load, and temperature control: The system optimizes turbine performance across various operational conditions, such as startup, part-load, and full-load scenarios.
- Fuel control: The Mark V system is capable of controlling both liquid and gas fuels, ensuring the turbine operates efficiently regardless of fuel type.
- Emissions control: For turbines utilizing Dry Low NOx techniques, the system regulates fuel staging and combustion modes to meet stringent emissions standards.
- Inlet guide vanes and steam injection: These are controlled to meet operational and emissions requirements.
The system also provides automatic sequencing for startup, shutdown, and cooldown processes, ensuring the safe and efficient operation of the turbine from start to stop.
3. Advanced Diagnostics and Troubleshooting
A hallmark of the Mark V system is its built-in diagnostics. Operators can run power-up, background, and manual diagnostic routines to pinpoint issues across the control panel and sensor components. This helps in quickly identifying faults, whether at the board level for control panels or at the circuit level for sensors and actuators.
Furthermore, online replacement of boards is supported, ensuring minimal downtime during maintenance activities. Faults are displayed with clarity, allowing operators to perform troubleshooting and repairs efficiently.
4. Enhanced Operator Interface and Control
The operator interface of the Mark V system features a color graphic monitor and keyboard, providing clear feedback on turbine status and operational conditions. Operators can enter commands via a cursor positioning device, which includes a sequence execution system to avoid accidental turbine operation. For critical applications, a redundant operator interface is available to maintain communication with the turbine control in case of external data link failures.
The interface is backed by the Common Data Processor (C), which links the operator’s inputs with the three control processors: R, S, and T. This system ensures that control commands are processed accurately and that all communication remains consistent across multiple operators and control systems.
5. Protection Against Adverse Operating Conditions
The Mark V system features triple-redundant hardwired protection for critical turbine functions. This includes:
- Overspeed protection: Ensuring the turbine does not exceed safe operating speeds.
- Flame detection: Monitoring for flame presence and ensuring turbine operation is safe.
- Synchronization: The system manages turbine generator synchronization to the power grid, with a backup check function embedded in the control processors for extra reliability.
These protective features work together to maintain the safe operation of the turbine and prevent damage due to adverse conditions.
6. Robust Hardware and Software Configuration
The hardware configuration of the Mark V system is designed to be highly reliable, with a modular construction that supports easy installation, maintenance, and upgrades. The system operates on 125 V DC battery power, with 120 V AC auxiliary power for ignition transformers and processor units. The system is housed in a NEMA 1A panel and uses modern microprocessors, including CMOS and VLSI chips, to minimize power dissipation while maximizing functionality.
The software configuration builds on triple-modular redundancy and SIFT technology, providing a robust control system capable of handling complex turbine operations and fault detection. The control processors exchange information on a voter link, ensuring data consistency and redundancy in real-time.
7. Scalability and Flexibility
The Mark V system is highly adaptable to different turbine models and operational requirements. Whether for single or multi-turbine configurations, the system can be tailored to meet the specific needs of each installation. The ability to incorporate minor modifications, such as adjustments to sequencing or the addition of new algorithms, makes the Mark V flexible enough to handle changes in operational requirements or environmental conditions.
8. Improved Maintenance and Reliability
The modular design and use of advanced diagnostics significantly enhance both reliability and ease of maintenance. The system’s robust construction ensures it can withstand demanding operational environments, while its modularity reduces the complexity of repairs and allows for quick replacement of components.
Additionally, the panel-mounted backup display ensures that turbine operation can continue even if the primary operator interface fails, guaranteeing uninterrupted operation.
Conclusion
The SPEEDTRONIC™ Mark V Gas Turbine Control System has set the standard for turbine control, offering advanced protection, real-time diagnostics, and automation. Though newer technologies have since replaced it, the Mark V’s comprehensive control features, reliability, and fault-tolerant design paved the way for subsequent advancements in turbine management systems.
Its ability to manage complex turbine functions with high levels of redundancy and protection, coupled with the user-friendly interface and enhanced diagnostics, made it one of the most trusted systems in power generation. Today, while it may be considered obsolete in the face of newer innovations, the Mark V remains an important chapter in the development of gas turbine control technology.
DS200DDTBG2A, DS200KLDCG1A, DS200RTBAG2A, are examples of Ge Mark V control system spare parts.