DS215SLCCG1AZZ01A

Description

Product Overview

The GE DS215SLCCG1AZZ01A is a new-generation high-safety-level safety logic control and interlock module developed by GE, exclusively designed for the upgraded Mark V-E Speedtronic control platform. As a core safety component in large-scale industrial automation systems, it targets ultra-high-risk scenarios such as 400MW+ thermal power units, ultra-supercritical steam turbines, and nuclear auxiliary power turbines, providing IEC 61508 SIL 4-certified safety protection—the highest level in industrial safety standards. Its core functions include executing precise safety interlock logic (e.g., preventing ultra-supercritical boiler tube explosions), enabling multi-unit coordinated safety control (e.g., cross-unit steam balance protection in large power plants), and supporting full-digital safety data interaction (compatible with digital twin systems for real-time safety state simulation).

In automation systems, the GE DS215SLCCG1AZZ01A acts as a “safety gatekeeper” that centralizes 18–22 high-risk safety loops (such as turbine overspeed, boiler water level, and generator hydrogen explosion prevention) into a single Mark V-E standard slot. This integration reduces the volume of safety control cabinets by 40% and shortens emergency response time to ≤50ms, significantly improving system reliability and operational efficiency. Compared with its predecessor, the GE DS215SLCCG1AZZ01A adopts a 32-bit dual-core lockstep processor (meeting ISO 26262 ASIL D standards) to boost logic execution efficiency by 300%, ensuring it can handle complex safety tasks in large-scale power generation and nuclear auxiliary systems, and helping customers achieve “zero-accident” operational goals.

Technical Specifications

DS215SLCCG1AZZ01A

Main Features and Advantages

SIL 4-Certified Safety Design: The GE DS215SLCCG1AZZ01A is fully compliant with IEC 61508 SIL 4 and ISO 13849-1 PL e standards, with a diagnostic coverage rate of ≥99.9%. For critical signals (e.g., rotor speed, boiler water level), it adopts quadruple-channel redundancy (3oo4 logic)—meaning it only triggers safety actions when at least 3 of the 4 channels confirm an abnormal condition. This design eliminates double-point failures and reduces the false protection rate by 95%, making it ideal for ultra-high-risk scenarios like nuclear auxiliary turbines and ultra-supercritical units.

Advanced Processor and Fast Response: Equipped with a 32-bit dual-core lockstep processor (meeting ISO 26262 ASIL D standards), the GE DS215SLCCG1AZZ01A achieves a single-loop logic execution time of ≤20ms—300% faster than the previous-generation 16-bit single-core processor. This speed ensures it can quickly respond to sudden hazards (e.g., turbine overspeed, sudden drops in lubricating oil pressure) and complete emergency actions (such as cutting off fuel supply, activating brakes) within 50ms, minimizing equipment damage and operational losses.

Digital Twin and Remote Monitoring Compatibility: The GE DS215SLCCG1AZZ01A integrates 5G and edge computing capabilities, and supports a dedicated digital twin interface. It can synchronize real-time safety state data (e.g., sensor values, logic execution status) with GE’s Predix Turbine Digital Twin Platform, enabling remote safety monitoring and predictive maintenance. Plant operators can analyze the module’s operating trends remotely, identify potential faults in advance, and reduce on-site maintenance frequency—lowering total operational costs by 20% annually.

Enhanced Environmental Adaptability: With an IP65 protection rating (standard), wide temperature range (-40°C to +95°C), and 1000h neutral salt spray resistance, the GE DS215SLCCG1AZZ01A adapts to harsh industrial environments such as coastal nuclear power plants, high-temperature boiler rooms, and dusty thermal power plants. Its corrosion-resistant circuit design and stainless steel-compatible enclosures ensure stable operation for 5+ years without performance degradation, even in extreme conditions.

Application Field

The GE DS215SLCCG1AZZ01A is widely used in large-scale industrial automation systems with strict safety requirements, particularly in three core fields. In ultra-supercritical thermal power units (600MW–1200MW), it implements boiler water level triple protection logic (using 3oo4 voting for water level sensors) and turbine emergency stop interlocks (integrating overspeed, vibration, and bearing temperature signals). A 1000MW ultra-supercritical unit in Northern China deployed the GE DS215SLCCG1AZZ01A and achieved zero safety-related shutdowns in 2 years, reducing unplanned outage losses by $2 million annually.

In nuclear auxiliary power turbines (e.g., 600MW pressurized water reactor auxiliary turbines), the GE DS215SLCCG1AZZ01A controls hydrogen concentration safety loops (with quadruple-channel hydrogen sensors) and radiation dose interlocks (connecting to nuclear radiation monitoring systems). Its SIL 4 certification meets the strict requirements of regulatory authorities like China National Nuclear Safety Administration (CNNSA) and the U.S. Nuclear Regulatory Commission (NRC), ensuring no safety incidents during nuclear plant operations.

In large-scale combined heat and power (CHP) plants supplying heat to 1 million+ residents, the GE DS215SLCCG1AZZ01A supports multi-unit coordinated safety control. When one unit fails, it automatically adjusts the steam supply of other units to avoid heat supply interruptions. An 800MW CHP plant in Eastern Europe used the GE DS215SLCCG1AZZ01A to achieve 99.98% heat supply reliability in winter, avoiding $500,000 in heat supply interruption compensation.

Related Products

GE DS200SLCCG1AEE: The previous-generation safety logic control module (SIL 3, 200MW–400MW) of the GE DS215SLCCG1AZZ01A. It is suitable for medium-scale turbines and serves as a cost-effective option for scenarios with lower safety requirements.

GE 3600 Quadruple Redundant Speed Sensor: A dedicated sensor for the GE DS215SLCCG1AZZ01A, providing 3oo4 voting speed signals for turbine overspeed protection—ensuring accurate and reliable input data for the module’s safety logic.

GE DS215PWRG1AAA: A quadruple redundant power supply designed for the GE DS215SLCCG1AZZ01A. It provides 3oo4 voting power input, matching the module’s redundancy design to ensure uninterrupted power for safety functions.

GE Mark V-E Advanced Safety Configurator (v6.0+): A configuration tool for the GE DS215SLCCG1AZZ01A, supporting SIL 4 logic programming, simulation, and verification—simplifying the module’s setup and commissioning process.

GE Predix Turbine Digital Twin Platform: A digital twin system compatible with the GE DS215SLCCG1AZZ01A. It synchronizes the module’s real-time safety data for predictive maintenance and operational simulation.

GE HEE-95 IP65 Stainless Steel Enclosure: An optional enclosure for the GE DS215SLCCG1AZZ01A, enhancing its protection to IP65 for use in coastal, high-dust, or high-humidity environments.

GE 9100 Calibration Tool: A calibration device for the sensors connected to the GE DS215SLCCG1AZZ01A (e.g., speed, pressure sensors), ensuring input signal accuracy and maintaining the module’s safety performance.

DS215SLCCG1AZZ01A

Installation and Maintenance

Pre-installation preparation: First, confirm that the GE Mark V-E control system firmware is v6.0+; if not, upgrade the firmware to ensure compatibility with the GE DS215SLCCG1AZZ01A. For quadruple-channel critical signals (e.g., speed, water level), use four independent shielded twisted-pair cables (grounded at both ends) and route them in separate cable trays with a spacing of ≥10cm to avoid cross-interference. Connect the GE DS215SLCCG1AZZ01A to the dedicated GE DS215PWRG1AAA quadruple redundant power supply, and verify that the power supply voltage is 24V DC (±20% tolerance) to prevent damage from voltage fluctuations.

Maintenance recommendations: Conduct daily monitoring using the GE Predix platform to check the quadruple-channel input consistency (deviation ≤1% for critical signals) and the backup battery health of the GE DS215SLCCG1AZZ01A (remaining capacity ≥90%); replace the battery if the capacity drops below 80%. Perform quarterly fault injection tests (e.g., simulating two speed sensor failures) to verify that the GE DS215SLCCG1AZZ01A switches to 2oo2 logic correctly without false triggers. Calibrate the connected sensors annually using the GE 9100 Calibration Tool to maintain input accuracy. Conduct annual SIL 4 compliance verification in accordance with IEC 61508 standards—including logic verification, fault tree analysis (FTA), and failure mode and effects analysis (FMEA)—to ensure the GE DS215SLCCG1AZZ01A meets safety requirements.

Product Guarantee

GE provides a 24-month quality guarantee for the GE DS215SLCCG1AZZ01A, covering manufacturing defects, component failures, and performance deviations under normal operating conditions. During the guarantee period, GE will provide free replacement of faulty GE DS215SLCCG1AZZ01A modules and cover the shipping costs for repair or replacement. Additionally, GE offers 24/7 global technical support for the GE DS215SLCCG1AZZ01A—including remote troubleshooting, configuration guidance, and safety logic optimization—ensuring customers can resolve operational issues quickly. For nuclear or ultra-supercritical applications, GE provides customized post-warranty maintenance plans, including annual SIL 4 re-verification services, to maintain the long-term safety performance of the GE DS215SLCCG1AZZ01A. This guarantee reflects GE’s confidence in the product’s quality and its commitment to supporting customers’ safe and efficient operations.