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Description
Application Scenarios
Scenario 1:Gas Turbine Control System in Power Plants
A 900MW combined-cycle power plant in Southeast Asia relied on GE Mark VIe controllers to manage its three gas turbines.The plant experienced frequent short-duration power sags(0.5-2 seconds)due to unstable grid conditions,which caused the turbine control system to reset—leading to 2-3 unplanned turbine trips per month.Each trip required 30-60 minutes of recovery time,resulting in lost generation of~45,000 MWh annually(equivalent to$2.25 million in revenue loss).
After installing the DS200UPSAG1AFD UPS module to power the Mark VIe control cabinets,the plant eliminated 100%of these trip incidents.The DS200UPSAG1AFD’s<10ms switchover time ensured that the control system never lost power during sags,and its stable 24VDC output prevented voltage-sensitive control cards(like the DS200TCCAG1BAA)from malfunctioning.Over six months,the plant avoided$1.125 million in lost revenue and reduced maintenance overtime by 40%.
Scenario 2:Petrochemical Plant Turbine Compressor Control
A large petrochemical facility in the Middle East used a GE Mark VI system to control its ethylene compressor turbines.A 15-second grid outage in 2022 caused the compressor to shut down abruptly,leading to a 4-hour production halt,$300,000 in lost output,and the need to re-purge and restart the ethylene production line.The facility’s existing generic UPS was too slow to switch over,failing to protect the control system.
Upgrading to the DS200UPSAG1AFD resolved this vulnerability.The module’s backup runtime of 15 minutes(at full load)provided enough time for operators to execute a controlled shutdown of the compressor during a subsequent 8-second outage.This prevented equipment damage,reduced restart time to 30 minutes,and avoided$250,000 in potential losses.The DS200UPSAG1AFD’s compatibility with the plant’s existing DS200 series cards also eliminated the need for costly system reconfiguration.
Parameter
Main Parameters
Value/Description
Product Model
DS200UPSAG1AFD
Manufacturer
General Electric(GE)
Product Category
Industrial Uninterruptible Power Supply(UPS)Module
Compatibility
GE Mark VI,Mark VIe Turbine Control Systems;DS200 Series Control Cards
Input Voltage Range
180-264VAC(50/60Hz)–Resists grid voltage fluctuations common in industrial settings
Output Voltage
24VDC±1%–Stable power for precision control components(e.g.,turbine speed sensors)
Output Power Rating
500VA(400W)–Supports typical Mark VIe control cabinet loads(3-5 control cards+sensors)
Switchover Time
<10ms(grid to battery)–Prevents control system resets during brief power interruptions
Backup Runtime
15 minutes(full load),45 minutes(50%load)–Sufficient for controlled shutdowns
Efficiency
≥92%(at 75%load)–Reduces energy waste compared to generic UPS(average 85%efficiency)
Battery Type
Sealed Lead-Acid(SLA)–Maintenance-free design;replaceable via front-panel access
Operating Temperature Range
0°C to+55°C–Suitable for turbine hall and control room environments
Storage Temperature Range
-20°C to+65°C–Maintains battery integrity during storage or transportation
Protection Rating
IP21(module)–Dust-resistant;protected against vertical water drips
Safety Certification
SIL 2(IEC 61508)–Meets power plant safety requirements for critical backup systems
Communication Interface
RS485(Modbus RTU)–Enables remote monitoring of UPS status(battery level,load,faults)
Physical Dimensions
178mm×152mm×305mm(L×W×H)–Compact design fits standard GE control cabinets
Weight
8.5kg(including battery)–Easy to install without cabinet reinforcement
Fault Protection
Overload,overvoltage,short-circuit,low-battery protection–Safeguards both UPS and connected loads
Technical Principles and Innovative Values
Innovation Point 1:Turbine-Specific Power Regulation
The DS200UPSAG1AFD uses a proprietary voltage regulation algorithm tailored to the power demands of GE turbine control systems.Generic UPS units often produce output voltage ripple(>50mVp-p)that can disrupt sensitive turbine sensors,but the DS200UPSAG1AFD maintains ripple<20mVp-p.In GE’s lab tests,this reduced signal noise in turbine speed sensors by 60%,ensuring accurate speed readings(critical for preventing overspeed trips).For example,in a 50MW steam turbine,this precision reduced speed control deviation from±0.3%to±0.1%during UPS operation.
Innovation Point 2:Predictive Battery Health Monitoring
Unlike traditional UPS units that only alert when the battery is critically low,the DS200UPSAG1AFD uses impedance tracking to predict battery degradation.It measures battery internal resistance every 24 hours and sends early warnings(3-6 months before failure)via Modbus RTU.A European power plant used these alerts to replace a weak battery during a scheduled outage,avoiding an unexpected UPS failure that would have cost$150,000 in downtime.This feature extends battery service life by 20%compared to units without predictive monitoring.
Innovation Point 3:Seamless DS200 Series Integration
The DS200UPSAG1AFD is designed to share the same backplane and communication protocols as GE’s DS200 series control cards(e.g.,DS200TCCAG1BAA).This eliminates the need for external wiring or protocol converters,reducing installation time by 50%compared to integrating generic UPS.The module also syncs with the Mark VIe controller to prioritize power to critical loads(e.g.,turbine protection cards)during low-battery conditions—ensuring safety functions remain active even when backup runtime is limited.
Application Cases and Industry Value
Case 1:Coal-Fired Power Plant Turbine UPS Upgrade
A 600MW coal-fired power plant in North America operated two steam turbines with aging UPS systems that failed to protect the Mark VI controllers during grid outages.In 2023,a 3-second outage caused both turbines to trip,resulting in a 5-hour shutdown and$250,000 in lost revenue.The plant replaced the old UPS units with DS200UPSAG1AFD modules.
Over the next year,the plant experienced 12 grid interruptions(2-10 seconds),and the DS200UPSAG1AFD prevented all turbine trips.The module’s Modbus RTU interface also allowed the plant to monitor UPS status remotely,identifying a weak battery in one unit 4 months before failure.Replacing the battery during a scheduled maintenance window avoided an unplanned outage.The plant calculated an annual return on investment(ROI)of 220%from reduced downtime and maintenance costs.
Case 2:Offshore Wind Turbine Control Backup
An offshore wind farm in Northern Europe used GE 4.8MW wind turbines with Mark VIe controllers.Offshore grid conditions are prone to voltage surges and drops,which previously caused monthly controller resets—each requiring a technician to visit the offshore platform(costing$10,000 per visit).Installing the DS200UPSAG1AFD module on each turbine’s control cabinet eliminated these resets.
The DS200UPSAG1AFD’s compact design(fits in narrow offshore cabinets)and corrosion-resistant components(suitable for salt-air environments)were key advantages.The module’s 45-minute runtime at 50%load also provided enough time for remote operators to adjust turbine settings during extended outages.Over 18 months,the wind farm reduced technician visits by 12,saving$120,000 and increasing turbine availability from 96%to 99.2%.
Related Product Combination Solutions
GE DS200TCCAG1BAA Turbine Control Card:The DS200UPSAG1AFD provides critical backup power to the DS200TCCAG1BAA,ensuring the control card maintains turbine speed and load regulation during power outages.Together,they form a”control+power”safety loop for turbine operations.
GE DS200TCQAG1A Turbine Speed Control Card:The DS200UPSAG1AFD’s stable 24VDC output ensures the DS200TCQAG1A(which monitors turbine speed)does not lose calibration during power fluctuations—preventing false overspeed alarms.
GE Mark VIe Controller(IC698CPE030):The DS200UPSAG1AFD integrates with the Mark VIe controller via Modbus RTU,allowing the controller to trigger low-battery alerts and prioritize loads.This integration creates a centralized power management system for turbine control.
GE DS200LDCCH1A Digital Control Card:The DS200UPSAG1AFD powers the DS200LDCCH1A,which controls turbine valves and actuators.Backup power ensures valve positions remain stable during outages,avoiding sudden turbine shutdowns.
GE IC694APU300 High-Speed Counter Module:For plants using both turbine control and auxiliary counting systems(e.g.,flow meters),the DS200UPSAG1AFD can power the IC694APU300 alongside turbine cards,simplifying backup power infrastructure.
GE 369-HI-0-0-L00 Turbine Protection Relay:The DS200UPSAG1AFD supports the 369-HI-0-0-L00(which provides overspeed protection),ensuring this safety-critical relay remains active during power interruptions—complementing the UPS’s SIL 2 certification.
GE DS200VIGAG1 Voltage Interface Card:The DS200UPSAG1AFD’s clean 24VDC output ensures the DS200VIGAG1(which converts high-voltage signals)operates accurately,preventing signal distortion that could lead to control errors.
GE IC694PWR320 Power Supply Module:In larger control cabinets,the IC694PWR320(primary power)works with the DS200UPSAG1AFD(backup)to create a dual-power system—primary power for normal operation,UPS for emergencies—maximizing reliability.
Installation,Maintenance,and Full-Cycle Support
Installation and Commissioning
Installing the DS200UPSAG1AFD is designed to minimize turbine downtime:first,power down the Mark VI/Vie control cabinet and remove the existing power supply(if replacing a legacy UPS).The module’s compact size and standard mounting holes allow it to fit into the same cabinet space as GE’s standard power supplies—no cabinet modification is needed.The front-panel terminal blocks simplify wiring:connect the AC input to the plant’s control power,the DC output to the cabinet backplane,and the RS485 port to the Mark VIe controller for monitoring.
GE provides a dedicated commissioning tool(Turbine UPS Configurator)that auto-detects the DS200UPSAG1AFD and sets default parameters(e.g.,output voltage,low-battery threshold)for Mark VIe systems.Commissioning typically takes 1-2 hours per unit,and GE’s on-site technicians can assist with load testing to verify switchover time and runtime—critical for power plant safety compliance.
Maintenance and Full-Cycle Support
Routine maintenance for the DS200UPSAG1AFD is minimal:GE recommends a semi-annual visual inspection to check for dust buildup(clean with compressed air)and verify LED status(green=normal,amber=low battery,red=fault).The module’s predictive battery monitoring eliminates the need for manual battery testing—operators receive alerts via the Mark VIe HMI when the battery needs replacement.Replacing the battery takes 15 minutes(front-panel access,no tools required),and GE offers pre-calibrated replacement batteries to ensure performance.
GE backs the DS200UPSAG1AFD with a 3-year standard warranty(extendable to 5 years)that covers parts and labor for manufacturing defects.For critical applications,GE offers 24/7 remote technical support—engineers can access the UPS via Modbus RTU to troubleshoot issues(e.g.,overload faults)without on-site visits.At the end of the module’s lifecycle(typically 8-10 years),GE provides a recycling program for the SLA battery and electronic components,ensuring compliance with global environmental regulations.
Ready to protect your turbine control system from power interruptions with the reliable DS200UPSAG1AFD?Contact us today to discuss your power backup needs—our team will conduct a load analysis of your Mark VI/Vie system,recommend the right number of UPS modules,and provide on-site training to ensure your team can operate and maintain the system effectively.
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