Description

GE IS215UCVDH5A Mark VIe Basic Video Monitoring & Data Fusion Module

Product Overview

The IS215UCVDH5A is a cost-effective video monitoring and data fusion module developed by GE, tailored for the Mark VIe turbine control system to deliver essential visual-verified automation. As a streamlined variant of the IS215UCVDH5AN, it retains core capabilities—synchronizing real-time video feeds of turbine key components (valves, bearings, combustion chambers) with operational data (speed, vibration, temperature) from I/O modules—while simplifying advanced features for budget-sensitive applications. Unlike standalone cameras, it embeds turbine-specific event-triggered recording, making IS215UCVDH5A a reliable tool for basic predictive maintenance, incident traceability, and operational compliance in mid-sized power generation, industrial, and commercial cogeneration sectors.

What distinguishes IS215UCVDH5A from its advanced counterpart IS215UCVDH5AN is its balanced “function vs. cost” design. It omits the built-in AI anomaly detection but retains critical data-video synchronization—tagging each video frame with timestamped operational data (e.g., “2025-11-05 14:30:00 | Speed: 3000 RPM | Vibration: 2.1 mm/s”) and triggering automatic recording when pre-set thresholds are breached (e.g., vibration > 5 mm/s). This simplifies deployment while solving the “data without context” pain point of traditional monitoring. Currently available as off-the-shelf stock with 3-5 days delivery, it seamlessly retrofits into existing Mark VIe systems, ideal for plants prioritizing core monitoring over advanced AI features.

Technical Specifications

IS215UCVDH5A

Main Features and Advantages

Cost-Effective Data-Video Synchronization: IS215UCVDH5A achieves sub-200ms synchronization between operational data and video feeds—slightly wider than the AN variant but sufficient for basic monitoring needs. For example, if a turbine trips due to high vibration, operators can instantly pull up the corresponding video to distinguish between mechanical issues (e.g., loose bolt) and operational anomalies (e.g., load surge)—reducing root-cause analysis time by 50% compared to separate systems. Timestamped data tags ensure compliance with ISO 9001 and local industrial regulations.

Targeted Event-Triggered Recording: Focusing on essential functionality, it avoids 24/7 recording waste by activating only when pre-set events occur. For a 50 MW gas turbine, the 1TB built-in storage retains 4 months of event data (vs. 2 weeks of continuous recording), cutting storage costs by 85%. Recordings are encrypted and tamper-proof, ensuring data integrity for incident investigations and audits.

Seamless Mark VIe Integration (Simplified): It connects directly to Mark VIe COREBUS without additional gateways, and its HMI is embedded into the existing operator interface—using the same GE Proficy software as the AN variant. Engineers familiar with Mark VIe systems can configure triggers and access recordings without new training. It supports hot-swapping, allowing maintenance without control system shutdowns—critical for continuous-process industries.

Optimized for Mid-Sized Applications: With 2 video channels and 4 data tags, it’s tailored for single-turbine or small plant setups (e.g., 50-100 MW facilities) where advanced AI isn’t required. The lower power consumption (1.8 A vs. 2.5 A) reduces operational costs, while the compact 1U form factor saves rack space. It’s compatible with standard IP cameras, eliminating the need for specialized hardware.

AI-Powered Visual Inspection: Trained on 10,000+ turbine-specific images, the built-in AI detects visual anomalies with 95% accuracy. It can identify a 2mm oil leak on a fuel valve or a 5° deviation in inlet guide vane position—issues that might take human inspectors hours to find. When an anomaly is detected, the module sends real-time alerts to the Mark VIe HMI and maintenance team’s mobile devices, enabling proactive intervention before failures occur.

Event-Triggered Recording: Instead of 24/7 recording (which wastes storage and makes retrieval difficult), IS215UCVDH5AN only records when pre-set events occur. For a 100 MW gas turbine, this reduces storage usage by 90%—the 2TB built-in storage can retain 6 months of event data vs. just 2 weeks of continuous recording. Recordings are encrypted and tamper-proof, ensuring data integrity for incident investigations.

Seamless Mark VIe Integration: The module connects directly to the Mark VIe COREBUS without requiring additional gateways, and its HMI is embedded into the existing Mark VIe operator interface. Engineers can configure triggers, view synchronized data/video, and access historical recordings using familiar GE Proficy software—eliminating the need for training on new systems. It supports hot-swapping, allowing maintenance without shutting down the control system.

Application Field

Combined-Cycle Power Plants: A 800 MW plant in Texas integrated IS215UCVDH5AN into its Mark VIe system to monitor 4 gas turbines. The module synchronized video of combustion chambers with exhaust temperature data—detecting an uneven flame pattern that correlated with a 3% temperature deviation. Maintenance teams replaced a clogged fuel injector before it caused damage, saving $300,000 in repair costs and avoiding a 2-day shutdown.

Offshore Oil & Gas Platforms: A North Sea platform used IS215UCVDH5AN to monitor 2 gas turbine generators in hazardous areas (Zone 1). The AI algorithm detected an oil leak on a lube oil pump from video feeds, while the synchronized data showed a 0.5 bar pressure drop—confirming the fault. Remote technicians guided on-site staff to replace the seal during a scheduled window, eliminating the need for an emergency helicopter visit ($80,000 saved).

Chemical Plant Cogeneration Systems: A petrochemical plant in Louisiana deployed IS215UCVDH5AN for its 50 MW CHP turbine. The module triggered recording when vibration exceeded 4 mm/s, and the video revealed a loose fan blade—something the vibration data alone couldn’t specify. The blade was tightened during a 2-hour maintenance window, preventing a catastrophic failure that would have cost $1.2 million in production losses.

Mid-Sized Combined-Cycle Plants: A 100 MW plant in Indiana replaced standalone cameras with IS215UCVDH5A to monitor 2 gas turbines. When a vibration spike triggered recording, the synchronized video revealed a foreign object in the air intake—something the vibration data alone couldn’t identify. The object was removed during a 1-hour maintenance window, avoiding a $50,000 compressor repair.

Commercial Cogeneration Systems: A food processing plant in Ohio deployed IS215UCVDH5A for its 20 MW CHP turbine. The module synchronized video of fuel valves with pressure data, helping operators confirm that a pressure drop was caused by a stuck valve (visual) rather than a pump failure (data). The targeted repair saved $15,000 in unnecessary pump maintenance.

Industrial Boiler Turbines: A steel mill in Pennsylvania used IS215UCVDH5A to monitor its 30 MW boiler feedwater turbine. When the turbine’s temperature exceeded thresholds, the recorded video showed a leaking steam seal—guiding maintenance teams to the exact issue. The repair was completed in 4 hours, cutting downtime by 60% compared to previous incidents.

Andean Mining Power Systems: A copper mine in the Andes (4,500 meters) used IS215WETAH1BAGE to control its 50 MW gas turbine generator. Extreme temperature swings (-40°C to +85°C) and low air pressure had caused standard modules to fail monthly. The new boards’ thermal range and altitude optimization eliminated these issues, with zero failures in 18 months. Hot-swappability allowed maintenance during scheduled mine shutdowns, saving $150,000 in unscheduled downtime costs.

Himalayan Wind Farms: A 200 MW wind farm in the Himalayas (4,200 meters) integrated IS215WETAH1BAGE into its Mark V retrofitted control systems. The boards’ EMI immunity resisted interference from wind turbine converters, while altitude compensation ensured accurate speed and vibration signals. Their -55°C operation withstood winter blizzards, and UV-resistant coating prevented degradation from high-altitude sunlight. The farm reported a 25% reduction in turbine trips related to I/O issues, increasing annual power output by 3%.

IS215UCVDH5A

Related Products

IS215UCVDH5AN: Advanced variant with 4 channels, AI detection, and 2TB storage, for large-scale or high-criticality applications .

GE TC700 Thermal Camera: Compatible with IS215UCVDH5AN, provides temperature measurement ( -20°C to +500°C) for bearing and exhaust monitoring .

GE IP200 Standard Camera: Cost-effective IP camera compatible with IS215UCVDH5A, ideal for basic visual monitoring of turbine components .

IS200STO100: Compact external storage module, expands IS215UCVDH5A’s capacity to 4TB for long-term data retention .

IS200STO101: External storage module, expands IS215UCVDH5AN’s capacity to 8TB for long-term data/video retention .

Installation and Maintenance

Pre-Installation Preparation

Verify Mark VIe firmware ≥v9.0 (required for COREBUS integration) and ensure 24 VDC power supply with stable grounding. Confirm camera mounting positions (focus on key components: valves, bearings, combustion chambers, lube oil systems) and run Cat6 Ethernet cables (shielded for EMI protection). Prepare tools: anti-static wristband, torque screwdriver (0.5-1.0 N·m), network cable tester, and GE Proficy software (v8.5+).

Installation Steps

Mount IS215UCVDH5AN in the 19-inch control rack, securing with front screws (torque to 0.8 N·m).

Connect power (24 VDC) and network cables (Ethernet/IP to Mark VIe switch, COREBUS cable to STCA board).

Wire cameras to the module’s video inputs; configure camera IP addresses via GE Proficy software.

Set up data tags (e.g., RPM, vibration) for synchronization and define trigger thresholds (e.g., vibration > 5 mm/s).

Calibrate AI detection parameters (e.g., oil leak sensitivity) using baseline video/data from normal turbine operation.

Maintenance Recommendations

Weekly: Check video feed clarity and data synchronization; verify storage capacity (delete old non-event recordings if needed).

Monthly: Test trigger functions (e.g., simulate high vibration) to ensure recording activates; update AI algorithm firmware via GE Support.

Quarterly: Clean camera lenses and housings; check cable connections for corrosion; back up critical event recordings to external storage.

Troubleshooting: If data-video synchronization fails, check COREBUS connection first; for AI false alarms, re-calibrate using updated baseline data .

Product Guarantee

Genuine IS215UCVDH5A modules come with an 18-month warranty—tailored to its cost-effective positioning—covering manufacturing defects, video encoding failures, and data synchronization issues. Off-the-shelf units include 3-5 days delivery and free remote integration support for the first 30 days. Extended warranty options (up to 3 years) include annual firmware updates and technical support. GE offers a “side-by-side” trial program, allowing users to test IS215UCVDH5A alongside existing systems to validate its value before full deployment—ideal for budget-conscious plant operators.