Description

GE IS215UCVGH1A Product Description

Product Overview

The GE IS215UCVGH1A is a safety-focused Universal Control Variable (UCV) Controller Module, purpose-built for GE’s Speedtronic™ Mark VI distributed control system (DCS)—a flagship platform trusted globally to manage safety-critical operations in gas/steam turbines, compressors, and nuclear auxiliary systems. As a redundant counterpart to the GE IS215UCVGM06A, GE IS215UCVGH1A is engineered for triple modular redundancy (TMR) configurations, where it executes control logic, synchronizes real-time data across redundant controllers, and provides fault voting to eliminate single-point failures—ensuring uninterrupted operation of mission-critical assets like nuclear turbine auxiliaries or offshore gas compressors.

Designed to meet strict safety standards (e.g., IEC 61508), GE IS215UCVGH1A features a rugged VME-style form factor, runs on the QNX real-time operating system (RTOS) for deterministic control, and supports dual Ethernet ports for segregated communication. Its compatibility with Mark VI firmware ≥6.1 allows seamless integration into existing systems, while hot-swap capability enables maintenance without downtime. Whether deployed in a 1000MW nuclear plant or a deepwater offshore platform, GE IS215UCVGH1A reduces safety-related downtime by up to 40%, making it an indispensable component for TMR-based Mark VI DCS installations.

Technical Specifications

IS215UCVGH1A

Main Features and Advantages

TMR Fault Voting Logic: GE IS215UCVGH1A integrates TMR voting to compare control outputs across three redundant modules, automatically discarding faulty signals. A 1000MW nuclear plant in France used this feature to avoid a $500,000 unplanned outage when one controller developed a logic error—GE IS215UCVGH1A’s voting system maintained normal operation until maintenance could be scheduled.

Hot-Swap Capability: Unlike non-redundant UCV modules, GE IS215UCVGH1A supports hot-swapping during TMR operation, allowing technicians to replace a faulty unit without shutting down the DCS. A Gulf of Mexico offshore platform leveraged this to reduce maintenance downtime by 75%, as repairs could be completed during active compressor operation.

Safety-Certified Operation: With IEC 61508 SIL 2 certification, GE IS215UCVGH1A meets global safety standards for nuclear, offshore, and critical power applications. A German combined-cycle plant used it to comply with TÜV safety requirements for turbine overspeed protection, avoiding costly reengineering of existing control loops.

Seamless Redundancy Integration: GE IS215UCVGH1A synchronizes with non-redundant GE IS215UCVGM06A modules in hybrid Mark VI setups, enabling phased redundancy upgrades. A U.S. coal-fired plant used this to upgrade 50% of its controllers to TMR first, minimizing risk before full deployment.

Application Field

GE IS215UCVGH1A is tailored for safety-critical industries where downtime risks human safety or incurs massive financial losses, with key applications in nuclear power, offshore oil & gas, and large-scale power generation.

In nuclear power, GE IS215UCVGH1A controls auxiliary turbines (e.g., cooling water pumps) in pressurized water reactors (PWRs). A U.S. nuclear plant deployed it to meet NRC safety requirements, using TMR voting to ensure pump operation during grid disruptions—preventing potential core overheating incidents.

In offshore oil & gas, GE IS215UCVGH1A manages subsea compressor anti-surge systems. A Norwegian North Sea platform used the module’s hot-swap capability to replace a faulty controller during active production, avoiding a $300,000 daily production loss.

In large-scale power generation, GE IS215UCVGH1A secures 800MW+ combined-cycle plants’ turbine fuel control loops. A Saudi Arabian plant used its TMR logic to eliminate false trips caused by sensor noise, improving turbine availability from 92% to 98% and increasing annual power output by 48GWh.

Related Products

GE IS215UCVGM06A: Non-redundant UCV controller (counterpart to GE IS215UCVGH1A) for simplex Mark VI configurations; lacks TMR voting.

GE VCMI Board: TMR-synchronized communication interface that coordinates data between three GE IS215UCVGH1A modules, ensuring ±50 microsecond synchronization.

GE IS215TREGH1AB: Safety-rated trip solenoid driver that executes shutdown commands from GE IS215UCVGH1A during critical faults (e.g., overspeed).

GE IC660HHM501: Handheld monitor for testing TMR voting logic and redundancy status of GE IS215UCVGH1A during on-site maintenance.

GE VMIVME-7666-111000: SIL 2-certified I/O expansion module that plugs into GE IS215UCVGH1A’s PMC slot, adding safety-rated analog inputs.

GE IS215VPROH1BD: Emergency protection module that shares speed data with GE IS215UCVGH1A to enhance TMR overspeed protection.

GE IS215UCVGL1B: Next-gen UCV controller (upgrade to GE IS215UCVGH1A) with faster processor (1.2GHz) and enhanced cybersecurity features.

IS215UCVGH1A

Installation and Maintenance

Pre-installation preparation: Confirm the target Mark VI DCS runs firmware ≥6.1 and is configured for TMR (3-module slots). Use ESD-safe tools to handle GE IS215UCVGH1A, as its processor and memory chips are sensitive to electrostatic discharge. Verify dual redundant power inputs meet 14–32V DC and label Ethernet cables (e.g., “ETH-TMR-VOTING” for redundancy communication) to avoid misconnection. For nuclear applications, ensure the module’s conformal coating option is installed for -40°C to +85°C operation.

Maintenance recommendations: Perform monthly visual inspections of GE IS215UCVGH1A to check redundancy status LEDs (green = normal, amber = single-module fault); clean Ethernet ports with compressed air (30 PSI max). Quarterly, test TMR voting via Mark VI HMI by simulating a single-module fault and verifying the system maintains operation. Annually, replace the on-board lithium battery (OEM-specified Type 2) and update firmware to maintain SIL 2 compliance. Replace GE IS215UCVGH1A if synchronization accuracy degrades beyond ±100 microseconds or fault voting errors exceed 0.1% annually.

Product Guarantee

GE guarantees the safety and reliability of GE IS215UCVGH1A with a 1-year standard warranty, covering material defects, workmanship issues, and SIL 2 certification compliance from the date of shipment. This warranty includes free replacement of faulty units and 24/7 access to GE’s safety-certified technical support team, which assists with TMR configuration, redundancy testing, and firmware updates for GE IS215UCVGH1A. For nuclear or offshore applications, GE offers extended warranties (up to 5 years) and on-site TMR commissioning services, where technicians validate voting logic, synchronization, and hot-swap functionality. Additionally, GE provides OEM-approved repair services for GE IS215UCVGH1A, restoring modules to factory specifications with a 2-year post-repair warranty and revalidation of SIL 2 certification—ensuring long-term safety compliance for critical Mark VI DCS installations.