TCS

Field Engineer's Manual – Gas Controls

Subject Gas Turbine Startup Guidelines for MKVI/

V) MARK VI PANEL POWER UP

With power available to the Control Cab, it is time to work on powering up the Mark VI panel.

Refer to Chapter 5 of the Mark VI System Guide, GEH-6421 Vol I, for additional
information on panel power-up. Specifications on power supply, current draw, and
protection requirements can be found in Chapter 5 of the Mark VI System Guide,
GEH-6421 Vol I, under Startup Checks. It should be noted that the panel runs on 125
VDC, and 120/240 VAC is required for the spark plugs only. The customer has the
option of buying one or two DACA transformers for the panel to provide a backup DC
source from the AC supply going into the panel.

Keep good working relationships with the Instrument Techs, Electricians, and
their foremen/supervisors. It is important because you will be spending a lot of
time with them. Encourage and respect their opinions and listening to what
they have to say will go a long way in building a good relationship. They will
likely know a lot more about wiring than you will, and they are more likely to
help prevent you from making mistakes. The most important place where you
need to use a screwdriver is at the Mark VI terminal boards. Most foremen will
not have a problem with you working by yourself on the panel, as long as this
is the only place they see you with a tool. Get the Electricians or Instrument
Techs to help you anywhere else on the job site, that’s why they are there!

A. PRELIMINARY CHECKS

Locate and retain the toolkit that comes with the panel. This kit has extra fuses, shield
screws, relays, etc. You will usually need at least one of these items during a startup.

1) IO Report: The IO report (along with several others) can be made from Toolbox as
comprehensive or brief as you need. Open a report and export it to a *.csv file
which can be opened and saved as an Excel file. Use the functionality and level of
detail that suits you best, but consider the following as a way to quickly view and
reference information that will help assure nothing is missed, or left incorrect for
others who may refer to it later. Where discrepancies exist, correct them if obvious,
but whenever in doubt, summarize what you found and think to be the problem, in a
case to Product Support. Keep a record of the as-found and as-left settings until
the end of the job, but record only the final as-left settings for the Start-Up Report.
The following are recommendations for using certain parts of the report.

GE Power Services
 TCS

Field Engineer's Manual – Gas Controls

Subject Gas Turbine Startup Guidelines for MKVI/

− Jumper Settings: Use an IO report from the Toolbox m6b file, including the card
jumper settings, and use it to check each of the cards in the panel. Update the
*.m6b hardware settings for each device to reflect any change in card jumpers.
NOTE: Best Practice: Only remove or install jumpers with power
disconnected. Also, while the hardware jumpers are being set, verify that all
cables are secure, verify that all relays are plugged in properly. Verify that all
the termination cards are secured.
NEVER CONNECT OR DISCONNECT DC SOLENOID WIRING OR JUMPERS
WHEN THE RELAY IS ENGAGED. THIS WILL SOMETIMES RESULT IN A BIG
Caution
SPARK AND MAY DAMAGE SOME TERMINAL BOARDS.

− Device: This should provide a correlation to the Device Summary names for
each piece of IO. If it doesn’t, correct it. It will make yours and others job easier
to search for something by Device name, not just signal name. Errors found
should be corrected in both the *.m6b file as well as the A010 Control
Specification.
− Cable and Wire Numbers and Interposing JB: This is a convenient feature that
can be used to quickly troubleshoot a loop, but takes quite a bit of time to
populate the data fields. If done prior to checking loops, it can help speed
efforts of both the FE and Instrument Tech to identify possible problems with
cabling, etc. Not required on most jobs, but highly recommended. You can
often find a few discrepancies in wire allocations and wires for signals that are
not used and wires for signals that are not in the M6B file. You can use this to
cross validate the I/O and the interconnect long before it becomes a real
problem. Before investing time in this, determine whether there are any
pending revisions to the *.m6b file that won’t be using the version you have and
are marking up. You can always re-enter the info later, as the biggest effort is
coming up with the associations to each signal, but it still takes time that you
may not have. Regardless, an ‘old’ version of the *.m6b file with this info is still
valuable in creating a report, if nothing else. Just don’t store it with your
‘running’ *.m6b file.

− Sense and Masking: These two fields are similar in that they relate to a contact
(discrete) setting and how viewed in the controller. Sense should be thought of
as the “shelf state” of the contact, in most cases. This becomes a little more
difficult for IO that comes in from external systems, i.e plant DCS, but typically
follows some rational that can be determined and understood. Changes to
Sense have no impact on how the signal is treated or displayed, this is

GE Power Services
 TCS

Field Engineer's Manual – Gas Controls

Subject Gas Turbine Startup Guidelines for MKVI/

information only. Masking (sometimes referred to as Inversion State), on the

other hand, has an impact of taking a discrete signal and changing the
appearance of it’s actual state for better manipulation and use inside the
sequencing. It’s helpful to know that a signal is inverted when doing testing of
loops, if only to understand why an Open contact may have a value of “1”.
Errors found should be corrected in both the *.m6b file as well as the A010
Control Specification.
− Config Type and Used: These two are somewhat related as they refer to usage
of that signal. Config Type will define which specific sub-type of IO
configuration is used, i.e +/- 10 volts vs 4-20mA, etc. It is not uncommon to
come across a Contact Input, for example, that has this setting defined as “Not
Used”, which results in the state change in the field not being received to the
controller. The “Used” field in the report simply defines whether or not a
particular piece of IO is associated and defined by a signal. This is a handy
field to sort by, if you want to narrow down the report to only the IO defined and
used. Errors found should be corrected in both the *.m6b file as well as the
A010 Control Specification.
− Raw and Engineering High/Low Values and Units: This is the raw voltage or
current associated with analog data, and the associated scaling to appropriate
engineering units. This is essential to have when doing loop checks, as you can
verify this data against calibration data and Device Summary requirements.
Errors found should be corrected in both the *.m6b file as well as the A010
Control Specification.

2) Make a very detailed list of circuit board catalog numbers and serial numbers, by
location. Both VME and IO Termination Card revisions need to be recorded in the
Start-up Report under ‘Instrumentation and Control’ section. The serial numbers
and catalog numbers listed on the chip labels are not the most accurate way to
establish revision numbers for the IO and VME cards, and are sometimes difficult to
see accurately. ALWAYS verify using TSM “ID” functions, to obtain the catalog
number and serial number. You can also use the MarkVI diagnostic tool (download
from Salem COE HMI or MarkVI Support Central Sites) to get this data from a panel
very quickly and efficiently.

3) IF NOT YET DONE, DISCONNECT ALL I/O: Early on in the installation you need
to make sure that the Mark VI is isolated from the field, in case someone
accidentally applies power to the panel. As soon as you get on site you should
make sure all toggle switches in the <PD> are switched off, and disconnect all I/O

GE Power Services
 TCS

Field Engineer's Manual – Gas Controls

Subject Gas Turbine Startup Guidelines for MKVI/

on the Mark VI by pulling all ribbon cables and plugs off of EVERY terminal board
(or having all termination blocks lifted), depending on whether the terminations are
ongoing, in which case, it helps to keep the blocks attached. You will reconnect
these only after you are satisfied that there are no grounds, and you are ready to
power up the panel.

4) Remove all card jumpers and fuses for the solenoid outputs, i.e on TRLY cards.
Remove the JG1 from TRLY card used to send ignition voltage to the field (or
appropriate similar measure to isolate ignition circuit). Remove all card jumpers for
the Servo Valve Regulator Outputs located on TSVO. You will restore these
jumpers later during loop checks.

5) Do not let the electricians carry any spare wires into the Mark VI trays. Keep all
spare wire rolled up in the subfloor of the control panel, labeled as spares for cable
##. It is a lot easier to locate a spare wire in the subfloor than chasing it in the wire
trays.

6) Under the Control Cab, all cables should be separated by voltage level and
completely off the floor. Place some blocks or metal supports to keep all the cables
off the floor. If water gets in the pit and it freezes, the freezing may make the cable
insulation brittle. Over time it will cause damage to the cable. Ensure separation of
high voltage (CI/CO- 125 V) and low voltage (analogs- 30 V) wiring in both wiring
trays and Mark VI. Refer to Chapter 5 of the MKVI System Guide, GEH-6421 Vol I
for additional details on signal separation and routing.

7) Determine responsibility for instrument calibration of the gas turbine systems.

Obtain copies of calibrated devices for the startup report. Verify all calibrations
against the Device Summary settings. The device summary may be incomplete
and incorrect. Be prepared to make some phone calls to the Requisition Engineer
and Project Manager.

YOU WILL FIND THAT THE CORES IN THE PANEL PROVIDE CONVENIENT
SHELVING THAT ELECTRICIANS LOVE TO USE TO STORE BINS OF WIRE
Caution
TERMINATORS AND SHIELD SCREWS. STRONGLY DISCOURAGE THIS
PRACTICE. KEEP ALL METAL OBJECTS ON THE FLOOR OF THE PANEL
DURING TERMINATION WORK.

GE Power Services
 TCS

Field Engineer's Manual – Gas Controls

Subject Gas Turbine Startup Guidelines for MKVI/

B. PRIMARY GROUND CHECKS

Before powering up the Mark VI, all wiring needs to be checked for grounds. Remember
that Current = Voltage/Resistance; the lower the resistance the higher the current draw.
When the current gets too high, things start to smoke, and this is what we are trying to
avoid by performing ground checks. The Mark VI has a floating voltage supply that is
typically ungrounded, but can be referenced to ground via the BJS jumper in the PDM.
Review the PDM Section in the MKVI System Guide, GEH-6421 Vol II for details on
when to use and not use this reference.

The Mark V Application Manual, GEH-6195 Appendix E, also has some extra detail on
the PDM.

Monitor the voltage balance daily, as IO is checked and connected up, to catch
and identify what may have caused the problem. Often times, grounds don’t
show up till later, though they may have not been present initially. Water in
conduits and boxes, damage to cabling/conductors, etc during the startup can
be frustrating to diagnose without knowing when the problem occurred.

Keep in mind that resistance measurement is one of the best troubleshooting

tools available to the Start-up engineer. Ground checks are not only used to
find wiring shorts. By knowing what resistance to expect, experienced TA’s
can quickly and effectively establish the condition of any device attached to the
Mark VI.

BE SURE TO TAPE EVERY WIRE THAT IS LIFTED OR HANGING IN THE MKVI

PANEL. HANGING WIRES MAY HAVE VOLTAGE COMING FROM EXTERNAL
Caution
SOURCES AND JBS, AND SHOULD ALWAYS BE CONSIDERED “HOT”.

1) Make sure that each twisted shielded pair of wires originating in the Mark VI panel
has it’s shield terminated on the shield blocks only. The shield must follow with the
signal wires all the way to the device, or as far as possible, and not terminated
ungrounded in the field. If the interconnection drawings do not show the
continuation of each individual shield going to the device, modify the drawings and

GE Power Services
 TCS

Field Engineer's Manual – Gas Controls

Subject Gas Turbine Startup Guidelines for MKVI/

fix the wiring. Having this correct makes the unit much more robust to events such
as lightning strikes as well as electrical noise induction issues.

All shield wires must be isolated from each other with the use of clear tubing or
"spaghetti".

2) Verify all proper wire terminations by comparing the IO Report list to wires
terminated at the panel terminal boards. If any wires do not match the IO Report, it
is probably landed in the wrong spot. If it comes down to choosing between
changing the IO Report or changing the interconnection drawings to match wiring,
change the interconnection drawings. Verify wire numbers if available. Verify Mark
VI internal jumpers for 108, and TREG emergency button terminals (as applicable).
This should be done prior to starting the ground checks.

3) Go around the gas turbine and verify that all cables are pulled to the correct
locations. If the cables are already terminated, close the junction boxes. Do not
lose any of the boxes’ gaskets and bolts. Keep the boxes dry and clean.

4) Inspect each junction box with the wiring list and wiring interconnects. Verify all
jumpers are installed and the wiring is correct . Be extra cautious with 107 and 108
bus. On thermocouple junction boxes verify that each pair is color matched and are
terminated without lugs, under the same terminal board screw. On twisted shielded
pairs and twisted shielded triads, verify that all of the wire numbers and wire colors
match. Best Practice: Verify each wire lug and screw tightness. It is not uncommon
to find servo and LVDT wiring with loose lugs as delivered.

5) ALL 450 to 650 loops listed in the IO Report need to be checked. Your degree of
involvement depends on when you arrive on site. Best Practice: Have the
Instrument Techs or Electricians check continuity and grounds on every wire.
These checks verify that the wiring is complete and correct to the device, and
also show that no grounds are present. Once this has been accomplished, you
spend an additional half day independently checking resistance of all I/O at the
Mark VI, lifting all suspicious wires before you begin powering up the panel. This
independent checkout is described further in the ‘SECONDARY GROUND
CHECKS’ section.

6) If you get a chance to supervise the ground and continuity checks performed by the
craft labor, make enough copies of the IO Report for everyone involved to get their
own. Each person will also need copies of the Piping Schematics, MCC wiring

GE Power Services
 TCS

Field Engineer's Manual – Gas Controls

Subject Gas Turbine Startup Guidelines for MKVI/

schematics, Device Summary, and access to Piping and Wiring Interconnection

drawings. Make one copy the Master Copy and leave it attached to the Mark VI
panel during the checkout. The Master Copy will be marked up to show progress of
all loops checked. You may have two shifts working on the checkout and it is
important to establish a consistent marking method.

Give each shift a different colored highlighting marker. Both crews use the
single Master Copy to record checked loops, the color indicating who was
responsible for the work.

7) Remove terminal blocks from termination boards.

8) The checkout is most efficient if you have at least 3 people working with two-way
radios. One person will stay at the Mark VI, check each wire at the terminal board
screw with a DMM, and mark up the Master Copy of the IO Report. The other two
people will be out in the field working independently of each other finding where the
wiring connects to the devices. Finding devices can be a challenge and the
process is time consuming. Expect it to take about 10 shifts.

9) To perform the checkout, the field person will disconnect the wire from the device
(On Normally Open contacts this step is unnecessary) and connect it to a ground
source. The person at the Mark VI will first read infinite ohms on the wire, and then
low ohms (less than 10 ohms) once the field person grounds it. If a short is found,
the field person will need to trace the wire back through each successive junction
box until the bad segment of wire is isolated and can be repaired.

10) During the ground checks, contact state of the field switches should be checked
against the Device Summary and rewired as necessary.

GE Power Services
 TCS

Field Engineer's Manual – Gas Controls

Subject Gas Turbine Startup Guidelines for MKVI/

Contact State

There is often confusion over whether to wire devices N.O. or N.C. The device
summary shows required contact state assuming a zero-energy condition, NOT a
normal as-running condition. GE philosophy has always been that the circuit should
open to alarm or trip the unit and the circuit should be closed under normal running
conditions. Most I/O are wired to the N.C. contacts, but some devices need to be
wired N.O. in order to achieve a N.C. state under running conditions. Take the Low
Lube Oil pressure switches, for example. They are to be wired N.O., but when the
Lube Oil pressure is normal the contacts/circuit will be closed, and the associated
inverted contact input logic will be a zero. When there is a low lube oil condition, or if
an open circuit should occur in the wiring or the diaphragm should rupture, the
contacts/circuit will open, and the associated inverted contact input logic will change
to a one. (The reason we use inversion masking is because the standard was always
that the logic driving the alarm should have to go to "1" to enunciate the alarm, and if
the circuit opens to alarm/trip, the logic needs to be inverted to go to "1" to enunciate
the alarm or trip the unit.)

Another example of the closed under "normal" conditions philosophy are the
compressor bleed valve limit switches. They were primarily put in place to indicate the
bleed valves were fully open prior to starting the unit--as a start-check permissive. In
this case, in order to have the contacts/circuit be closed when the bleed valves are
open the wiring must be connected to the N.O. contacts of the limit switch, which are
actuated when the bleed valve is fully open.

GE Power Services
 TCS

Field Engineer's Manual – Gas Controls

Subject Gas Turbine Startup Guidelines for MKVI/

CONTACT INPUT BUS 107

A frequent source of confusion stems from the required wiring for the ‘hot’ side of
C.I.’s and C.O.’s. The 125VDC interrogation voltage for the contact inputs comes
from the <PD> off the J12/A/B/C cables and is daisy chained to multiple TBCI cards.
The ‘hot’ or positive side of the contact inputs is always wire number 107. You may
see a dedicated 107 wire run out for each field contact or you may see only one 107
wire leave the Mark VI that is field jumpered to a number of contacts out at a junction
box. The main concerns with multiple C.I.’s field jumpered to a single 107 are that
you can lose a bunch of inputs all at once if something happens to that one wire, and
troubleshooting a ground fault on the 125VDC bus can be a lot trickier. Be
reasonable with the number of contacts sharing a 107, and make sure that C.I.’s only
use 107 wires from their respective rack locations (pairs of terminal boards),
otherwise a single failure will potentially fail a TMR signal that is spread across
multiple terminal boards.

CONTACT OUTPUTS BUS 108

Contact outputs are a little more complicated than the inputs because card jumpers
are needed to define whether you have a powered solenoid output (wet contact), or a
relay output (dry contact). The wire designation is typically 108 for the solenoid
outputs. The DC supply comes from the <PD> off of the J8A/B/C/D or J17/18/19/20
cables to their respective TRLY boards. The AC supply for up to four ignition
transformers comes from <PD> off of J15, J16, J19 and J20 to a TRLY board.
Multiple C.O.’s can be jumpered in the field off of one 108 wire, but care needs to be
given because the current load is much higher than with the contact inputs. Best
Practice: Each wet contact on a terminal board should have their own 108 wire and
card jumpers in place. This will share the load more evenly on the terminal board.
Only install the card jumpers with the J8 and J12 cables disconnected. It is very easy
to short out contacts on the terminal boards when attempting to install the jumpers
with power applied to the board.

GE Power Services
 TCS

Field Engineer's Manual – Gas Controls

Subject Gas Turbine Startup Guidelines for MKVI/

NEVER ENERGIZE A SOLENOID OUTPUT ONTO A CIRCUIT WITH LOW

RESISTANCE. AC SOLENOIDS TYPICALLY ARE >30 OHMS, DC SOLENOIDS
Caution
WILL RANGE FROM 150 TO 1000 OHMS, WITH SOME INDICATING OPEN
CIRCUIT IF THEY CONTAIN AN INRUSH PROTECTION CIRCUIT (MOST 20CB
SOLENOIDS).

11) Review the IO Report and look for instruments or devices which may get damaged
if power is turned on and polarity is incorrect, or excitation is on the wrong wire.
LVDT’s, Servo Coils, Flame scanners, 4-20 mA Rosemount transducers, Dynisco
pressure transducers, Water injection TTL pulse transducers, or any other device
which may be damaged. Pay particular attention to theses devices. Go
through their wiring and actually ring out the wires and verify polarity. There
is always a chance that several of these devices are wired incorrectly.
Correct the wiring before applying power. It is a lot easier and faster than
waiting for replacements. NOTE: The wiring on both LVDT’s and Servo Coils
have a pretty standard color coding that can be followed. You may find a wiring
diagram on the device that can be used as well.

− For LVDT’s- EXCITATION - Red and Black

− FEEDBACK - Blue and Yellow

− For Servo Coils- 1 COIL- Green (+) and Yellow

− 1 COIL- White (+) and Red

− 1 COIL- Blue (+) and Orange

12) All contact output circuits which drive MCC motor contacts are inherently grounded
through the low power step down transformer in the motor contactor bucket. The
ground is seen through the coil of the contactor. Also, contact inputs from the
humidity sensor status relay , 0 to 10 VDC humidity signal, dew point temperature
signal, and the Bently Nevada 4-20 mA signals are grounded in the source panels.
Temporarily lift these wires to verify ground isolation.

GE Power Services
 TCS

Field Engineer's Manual – Gas Controls

Subject Gas Turbine Startup Guidelines for MKVI/

These ground and continuity checks take a significant amount of time, but if
they are done well it will make function testing and subsequent operation of the
turbine much easier. Start-ups can be (and are at times) completed without
methodical ground and continuity checks, but these sites tend to have many
more nuisance alarms and frustrations during or following the Start-up.

C. POWERING UP THE HMI

1) While terminations and primary ground checks are being completed, start setting up
the HMIs and a printer (if specified). Follow the instructions in Chapter 5 of the
Mark VI System Guide, GEH-6421 Vol I, as well as the MLI 4108 drawing to get the
power and ethernet connections established. Additional information for HMI
systems can be found in the HMI Manual, GEH-6126 Vol I and II. There are many
other FAQs and docs on the HMI available at the Salem COE SC site for the HMI.

2) Locate a large, strong table and place it in the Control Cab. Unpack the HMI
processors CPU, monitors, track ball or mouse, keyboard, printer, printer stand,
switches, CAT-5 UTP ethernet cable and other equipment as denoted from the MLI
4108 drawing. Locate the Cimplicity, Windows, and eTCSS software, the licensing
package for Cimplicity which is in a cardboard envelope, and the site specific
software on a CD. Place these in a safe place for final turnover to the customer.
Make sure you set up one HMI next to the Mark VI panel for the duration of the
Start-up, preferably the Master.

3) Before plugging in the HMI CPU, remove the top cover and inspect the internal
cards and ribbon cables and verify these are all plugged in properly. Some cards
can come loose in the shipping process. Follow the procedure of powering up the
HMI processor from the HMI Operators Guide, Chapter 2, GEH-6126 Vol II. Verify
the HMIs with their names against 4108 drawing.

4) If there are multiple HMIs, make some space and prepare all the computers at the
same time. Power up the first one, load up the software (as required), and then
power up the rest. HMI systems should have Windows XP, Cimplicity, CimBridge,
Toolbox and TCI already installed. You should only need to install the Cimplicity
project, and Mark VI Toolbox Project, which are specific to the unit and site. You
must make sure there is only one “Master” directory per site (8 units or less) and
one site directory in each HMI. You must also make sure the trip logs and alarm
logs are set up on “E” drive. You must make sure “E” drive and the “Master”
directory are shared properly. The “Master” directory should be in an HMI in the

GE Power Services
 TCS

Field Engineer's Manual – Gas Controls

Subject Gas Turbine Startup Guidelines for MKVI/

control room, usually CRM1_SVR or EWS_SVR. The Time Manager must be set
up properly, remember that the controller can only see the UDH so the controllers
should look to UCRM1_SVR for their time. If the time manager is not set up
properly, Cimplicity Valve trends will not indicate at all, modbus data may not be
accepted by the Historian and many other issues can be created.

Using Ghost or other supplied software, create a backup of the as-delivered

hard drive, prior to making any changes. If you choose to only do it for one
HMI, do this for the Master HMI, it can save you later frustrations if a hard-drive
crashes, especially on the Master. Also, regularly backup copies of changes to
the *.m6b as well as screen files. Save a copy of the *.m6b and Cimplicity
screen files on a flash drive daily or whenever a change is made, as they can
typically fit easily in the space on a flashdrive.

5) You need to verify that Toolbox is configured correctly on each HMI. Click on
Start>Programs>GE Control System Solutions>Control System Toolbox>Control
System Toolbox:

Click on “Options” and then “Settings”. Under the General tab Uncheck the Auto
save box and Check the Compress files box.

Under the Database tab Change “Server Name” to the master file server name,
such as “CRM1_SVR” and Change “Path/Name” to “E:\Master\SDB”.

Under the Trend Recorder tab Change Memory buffer to 20MB (Never exceed 25
MB except for LM turbines without Cimplicity HMI screens, they can be up to 60
MB.) Check the Show memory usage box and Click “OK” when done.

6) After the Cimplicity and Toolbox files have been installed, the HMI has been re-
booted and TCI is running again, verify that you can see the alarm log viewer by
clicking on the Internet Explorer Icon. If it is not, Click on the Internet Icon, then
click on “Tools” on the menu bar, then click on “Internet Options”, then make the
address window show http://Localhost/ “apply” and “OK”. Close the window and
then click on the Internet Icon again to verify the TCI Log Menu launches. (If it is a
viewer, make the address the address of the server the screens are mapped to,
such as “http:/crm1_svr/”.) If it still does no work, verify that the file
c:\inetpub\wwwroot\Default.htm exists and is the same size as
c:\inetpub\wwwroot\GEDS\TCI.HTM. If it does not, copy the file
c:\inetpub\wwwroot\GEDS\TCI.HTM to c:\inetpub\wwwroot and rename it
Default.htm.

GE Power Services
 TCS

Field Engineer's Manual – Gas Controls

Subject Gas Turbine Startup Guidelines for MKVI/

7) Verify that “M” drive exists on all HMI’s (including the Master File Server) and is
mapped to the “Master” directory on “E” drive of the Master File Server, such as
CRM1_SVR. If not, map “M” drive to \\XXXX\Master where “XXXX” is the Master
File Servers name. Such as “CRM1_SVR” or “EWS1_SVR”. (On a Windows XP
Server you will need to manually type this command in.)

8) Extremely important!!! Keep all of the original shipping boxes for all of the
HMI computers and their peripherals. Sometimes it will be necessary to ship
these computers back. If the HMI hardware goes bad, go directly to the computer
supplier, typically Contemporary Control Systems. They require that the computers
be shipped back in the original shipping boxes for warranty claims.

Keep all of the smaller boxes inside the large CPU box and store it on top of the
generator control panel. It fits perfectly up there.

9) Once all the HMIs are loaded, keep the diskettes or CD’s supplied by Salem as a
backup in a safe storage place.

10) Check the I/O Report against both the Device Summary and Control Specification.
Go over it very carefully making sure inverted and non-inverted contacts are listed
correctly, the scale types and ranges for all transducers are shown correctly, the
contact outputs and solenoid outputs are wired to the proper terminal board
locations, etc. Update the settings in the IO Configuration of the *.m6b file, as
necessary. Keep a record of the as-shipped settings.

GE Power Services
 TCS

Field Engineer's Manual – Gas Controls

Subject Gas Turbine Startup Guidelines for MKVI/

Listed in the Control Spec are the settings that should be input into the IO
Configuration, and typically are lists prepared from the actual *.m6b file. Check
these settings, in particular the servo-regulator gains, against the other known
‘good’ startup examples from other units, and ask for clarification of any
discrepancies from Controls Engineering. Servo current gain will vary
according to servo valve part number (GPM flow rate) and actuator
stroke/piston surface area. If two units have identical GCV + servo + hydraulic
pressure, gain should be the same.

On dual-fuel or liquid fuel only units, the PRScale (found in VSVO) for the
magnetic pickups on the flow dividers should be checked against the flow
divider nameplate data as the correct value. Contact PAC or Controls
Engineering if any question on correct value.

11) Check labeled revision levels of IO and Terminal cards against values provided in
the Hardware configuration of the *.m6b file, i.e H1B, etc. Review Chap 9 of
Control System Toolbox for MKVI, GEH-6403, for more information on changing
revision levels, if required.

12) Change the IO configurations to match the inversion masks of the IO Report, if not
yet done.

13) Check the Constants in the *.m6b against the Control Spec, they should match.
Update Constants as necessary, summarizing discrepancies and changes thru the
Controls Requisition engineer.

Through your career as a Start-up engineer you need to accumulate as many

*.m6b files as you can. Keep the ones you used during your training, keep the
ones from each machine you work on, and make sure you ask the other
experienced TA’s if they have copies they will let you have. These files, for
comparison purposes, are invaluable to cross-check the Control Spec and
Toolbox files.

GE Power Services
 TCS

Field Engineer's Manual – Gas Controls

Subject Gas Turbine Startup Guidelines for MKVI/

IT IS POSSIBLE THAT NOT ALL OF THE IO CONFIGURATION OR CONTROL

CONSTANTS SETTINGS IN THE CONTROL SPECS ARE CORRECT. CONTACT
Caution
THE CONTROLS ENGINEER AND CONFIRM ANY SETTINGS THAT SEEM
STRANGE. COMPARE YOUR SETTINGS TO AN EQUIVALENT RUNNING
MACHINE. DO NOT BLINDLY ACCEPT THE CONTROL SETTINGS FROM THE
CONTROL SPECS. VERIFY ALL SETTINGS. WRITE A LIST OF QUESTIONS
FOR INCOMPLETE ITEMS AND SEND IT TO YOUR JOB’S CONTROLS
ENGINEER IN CASE. IF A RESPONSE IS NOT RECEIVED IN TIME, AND YOU
ARE UNSURE WHETHER THE PRESENT SETTINGS WILL DAMAGE THE GAS
TURBINE, DO NOT LET ANY ONE START THE EQUIPMENT. THIS IS
SOMETHING THAT SHOULD NOT HAPPEN IF CHECKS AND VERIFICATIONS
ARE PERFORMED EARLY, BUT IF NOT, SHUT DOWN EVERYTHING AND WAIT
FOR A RESPONSE. IT IS YOURS AND GE’S REPUTATION WHICH ARE ON THE
LINE. IF IT BECOMES NECESSARY TO HOLD A MACHINE FROM STARTING,
DO IT. IT IS BETTER TO EXPLAIN WHY YOU ARE NOT RUNNING, THAN WHY
IT TRIPPED, OR CAUSED DAMAGE/INJURY TO PERSONNEL OR EQUIPMENT!!

14) Check the setup of the Config.dat and IO_ports.dat files per the Chap 2 of HMI
Application Guide, GEH-6126, Vol II.

If multiple HMI’s are used, label the front of each computer with its name, i.e
CRM1, SVR1, etc and whether it is the Master.

By starting with an I/O Report and an I/O Configuration that is 99.5% correct,
many issues will be resolved before they are real problems.

If time allows, compare the m6b against design standards for any section of
code you are not familiar with. Although not currently kept up to date, the
Design Standards are a good basis for understanding many of the key
sequences and systems, and will help you understand and detect any software
issues before unit start-up. Most Design Standards for Gas Turbine are
available in the Methods Technical Reference Library in the Controls Section,
but all of them can be found in the CASE Home Page, using links from
PowerGen Links on the Methods Home Page.

GE Power Services
 TCS

Field Engineer's Manual – Gas Controls

Subject Gas Turbine Startup Guidelines for MKVI/

D. SECONDARY GROUND CHECKS

Hopefully you have been on site long enough to have overseen the primary ground
checks to ensure their completion. During this time you would have gotten all of the
HMI’s running and loaded with site software, and at least one HMI is connected up to the
Mark VI ready to communicate.

A more likely scenario is that you arrive on site with wires hanging out of the panel and
there are pressure for you to get the panel powered to meet a slow roll (or other)
milestone in a short time. This is to be expected, though not desired. Because you
arrive later on the job, you will often be asked to make up time lost by all of the accrued
delays from the previous months of the installation. As a Start-up engineer you need to
balance trying to complete the work as quickly as possible without compromising safety
or damaging equipment. Also, you must be able to understand the mechanical
elements, the project side, parts, etc. The startup is ALWAYS on the critical path. The
better you understand and contribute to everything that happens to the unit, the more
control you will be in for your promised deliverables, especially “first-fire”.

Regardless of whether you have overseen the primary ground and continuity checks or
you have arrived after their reported completion, you need to perform secondary ground
checks on the panel directly before you power it up for the first time. The secondary
ground checks and panel power-up can be completed on the same day, and once
you begin you will need to maintain very strict control of the Mark VI for the rest of
the Start-up.

Insist that 100% (or 98% at a minimum) of the wiring in the Mark VI panel be terminated
before powering-up the Mark VI panel, and that 95% of the field ends of that wiring be
terminated as well. You should also insist that all wiring which is not terminated in the
field but is terminated in the Mark VI panel be identified to you prior to powering-up the
panel. This termination requirement has, what should be, obvious personnel and
equipment safety ramifications, and getting in a hurry and not paying due caution can
cause delays and overruns. This last delay in getting terminations completed usually
results in providing time to do the I/O Report and I/O Configuration, and avoids problems
with having to power down the panel multiple times to pull in new wires/cables and
terminate them. Encourage and find ways to help the contractor do their work so that
when we start our work it can continue without much interruption. This work should be
done before the field engineer arrives on site, but usually there is some pieces of work
not completed.

GE Power Services
 TCS

Field Engineer's Manual – Gas Controls

Subject Gas Turbine Startup Guidelines for MKVI/

Once you have completed secondary ground checks and powered up the Mark VI, no
wire should be removed or added without your knowledge. This goes for running any
new cables into the MKVI cabinet or other previously terminated JBs as well.

Secondary ground checks should only take about four hours to complete assuming there
are no problems.

1) Make sure that the AC and DC panel breakers are off, and no power is being
supplied to the Mark VI. Check that the toggle switches in the <PD> and cores are
still switched off.

2) Reconnect all the I/O on the terminal boards to the cores. Plug in all ribbon cables
and plugs back into the terminal boards.

Blow all sockets clean of debris before plugging cables back in. If electricians
have been terminating on the panel, bits of wire tend can fall into the sockets in
the panel. These can cause the Mark VI to give erratic and strange diagnostic
alarms when you power up.

3) Secondary Ground Checkout is the methodical check of the resistance of each

wired terminal screw on the panel. The following chart will show you what
resistances you should expect for the various terminal boards.

Do not spend time fixing problems at this time. Your main objective is get the Mark VI
powered-up. If you find any wire that gives a suspicious reading or seems incorrect,
temporarily lift, tape it, and label it with bright electrical tape until you have time to
check it more thoroughly.

When searching for the ground fault on a terminal board you may find more
than one wire showing low resistance. The wire that shows the lowest ground
is the problem. Lift that wire and you may find that some of the other grounds
disappear as well.

GE Power Services
 TCS

Field Engineer's Manual – Gas Controls

Subject Gas Turbine Startup Guidelines for MKVI/

BOARD DEVICE EXPECTED RESISTANCE

TSVO LVDT Excitation- E and L Measure across- expect 10-50 Ohms

Servo Coils- L and R Measure across- expect 1000 Ohms

Mag. Speed Pickups Measure across- expect 150-250 Ohms

MW Transducers Measure across- expect 80-90 Ohms if multiple

transducers or about 250 Ohm if single transducer

TCCC Thermocouples Some may be grounded, some may not- Focus on

any discrepancies between similar thermocouples

TBAI Transducers Measure across- May be polarity sensitive- should go

up to 20-30 MegaOhms then it might crash open.

TSVO LVDT Feedback- H and L Measure across- expect 10-50 Ohms

TRTD RTD- A, B, and C Measure across any two legs- Depends on type of
RTD, 10 Ohm, 100 Ohm, 200 Ohm, etc.

TBCI Contact Inputs Measure across- Normally Open contact about 200
Ohms - Normally Closed contact should dead short
(< 10 Ohms)

TRLY Contact Outputs Measure across- Dry DC Coil should be > 500 Ohms
(some high powered coils may read lower, but double
check these)

Dry AC Coil should be 100-300 Ohms

Dry MCC AC Coil should be 5-10 Ohms (dead short)
Wet DC Solenoids should be > 500 Ohms
Wet AC Solenoids should be 5-10 Ohms

TTUR Various Measure across- all should be MegaOhm range

except for PT’s and CT’s which should be < 10 Ohms
TPRO

GE Power Services
 TCS

Field Engineer's Manual – Gas Controls

Subject Gas Turbine Startup Guidelines for MKVI/

E. POWERING UP THE PANEL

REFER TO CHAPTER 5 OF THE MARK VI CONTROL SYSTEM GUIDE, VOL I,

GEH-6421 FOR ADDITIONAL INSTRUCTIONS ON PANEL POWER-UP.
Caution

SAFETY ITEM TALK TO ALL RELEVANT PERSONNEL ON SITE AND MAKE

SURE THAT EVERYONE KNOWS AND AGREES THAT FULL CONTROL OF THE
Warning
PANEL WILL NOW BE YOURS AND YOUR DELEGATES. NO ONE SHOULD
TOUCH THE MARK VI CABINETS OR CIRCUITRY WITHOUT YOUR
KNOWLEDGE AND APPROVAL. IT IS ALSO IMPORTANT THAT THE CRAFT
LABOR ON SITE IS AWARE THAT SYSTEMS ARE NOT BEING EXCLUSIVELY
CONTROLLED LOCALLY. CRAFT LABOR ALSO NEEDS TO KNOW THAT THE
COMMISSIONING HAS REACHED A STAGE WHERE TURBINE DEVICES WILL
NOW OPERATE WITH MORE FREQUENCY.

ONCE YOU POWER UP THE PANEL YOU WILL NEED TO KNOW WHAT
ACTIVITIES ARE BEING PERFORMED ON THE JOB SITE AT ALL TIMES. SITE
MEETINGS SHOULD TAKE PLACE EACH MORNING TO DISCUSS WORK
PLANNED FOR THE DAY. DO NOT FORGET THAT YOUR ACTIVITIES AT THE
HMI ARE TURNING DEVICES ON AND OFF AROUND THE TURBINE. BE EXTRA
CAREFUL!! PERSONALLY CHECK AREAS THAT WILL BE AFFECTED BY
RUNNING EQUIPMENT.

AVOID FRIGHTENING OR STARTLING ANYONE UNNECESSARILY BY

SUDDENLY TURNING ON EQUIPMENT NEXT TO WHERE THEY ARE WORKING,
Caution
AS THEY MAY BE INJURED BY THE REACTION OF SOMETHING STARTING OR
MOVING UNEXPECTEDLY, EVEN THOUGH THEY MAY NOT BE IN DANGER
FROM THE OPERATING EQUIPMENT. THEY WILL GREATLY APPRECIATE
YOU TAKING THE TIME TO WARN THEM FIRST.

ONCE YOU POWER UP THE PANEL YOU SHOULD HAVE A TWO WAY RADIO
WITH YOU AT ALL TIMES. USE IT!!

GE Power Services