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文章通過對 DCS系統(tǒng)在火電廠運(yùn)行中常見的故障及發(fā)生故障原因的分析，有針對性地提出了故障出現(xiàn)時的處理措施，可為火電廠在DCS系統(tǒng)的運(yùn)行和操作人員在實(shí)際工作中應(yīng)用提供借鑒。
　　作為火電廠安全經(jīng)濟(jì)運(yùn)行主導(dǎo)因素的熱控自動化設(shè)備DCS系統(tǒng)，近年來得到了普遍應(yīng)用，為火電廠機(jī)組安全、穩(wěn)定的運(yùn)行起到了積極的作用。但是，DCS系統(tǒng)的安全性和可靠性還有待提高，在運(yùn)行過程中經(jīng)常會出現(xiàn)這樣或那樣的故障，這些故障的出現(xiàn)，導(dǎo)致了發(fā)電機(jī)組的非計劃停運(yùn)，給發(fā)電企業(yè)造成不應(yīng)有的損失。
　　1、DCS系統(tǒng)常見的故障
　　隨著工業(yè)生產(chǎn)自動化的不斷興起、過程控制要求的日益復(fù)雜，一種綜合控制系統(tǒng)――DCS系統(tǒng)應(yīng)用而生了。由于目前各火電廠對DCS系統(tǒng)的應(yīng)用水平的限制，系統(tǒng)在運(yùn)行過程中難免會出現(xiàn)故障。常見的DCS系統(tǒng)故障有：電源系統(tǒng)故障、硬件(模件)故障、系統(tǒng)軟件故障和通信網(wǎng)絡(luò)系統(tǒng)故障。
　　1.1電源系統(tǒng)故障
　　電源故障是DCS系統(tǒng)的致命故障，一旦電源出現(xiàn)故障，不僅整個系統(tǒng)會停止運(yùn)行，而且還會導(dǎo)致機(jī)組的跳閘，造成非計劃停運(yùn)。
　　1.1.1電源系統(tǒng)出現(xiàn)故障的主要原因
　　電源方面的問題比較多，一是備用電源不能自投，雖采用UPS和APS雙路互為備用的供電方式，但在轉(zhuǎn)換時也會出現(xiàn)瞬間失電，導(dǎo)致機(jī)組跳閘;二是保險配置不合理及DPU電源內(nèi)部故障等造成電源中斷，導(dǎo)致系統(tǒng)運(yùn)行的停止;三是穩(wěn)壓電源波動引起保護(hù)誤動及接插頭接觸不良導(dǎo)致穩(wěn)壓電源無輸出;四是有的系統(tǒng)整個機(jī)柜通過一路保險供所有輸入信號或一路電源外接負(fù)載很大，導(dǎo)致模件的損壞;五是系統(tǒng)電源未采用UPS供電，冗余備用就更無從談起。
　　1.1.2電源系統(tǒng)故障應(yīng)采取的防范措施
　　要保證DCS系統(tǒng)的安全、穩(wěn)定，首先要具備合理的電源布置，其次要選用高質(zhì)量的電源模塊，并要保證較高的冗余率。再次是注意觀察電源的輸出電壓，防止出現(xiàn)波動。第四是對電源實(shí)行壽命管理，該更換的時候必須更換，絕對不允許等到電源出現(xiàn)了故障的時候才更換。
　　1.2硬件(模件)故障
　　DCS系統(tǒng)的硬件(模件)卡件可分為處理器模件、I/O模件及通訊模件三大部分，這三大模件的功能各自不同，常見的故障部位為過程通道和人機(jī)接口。
　　1.2.1硬件(模件)出現(xiàn)故障的主要原因
　?、龠^程通道故障也就是I/O卡件故障。引起I/O卡件發(fā)生故障的第一方面的原因是卡件因長時間工作而出現(xiàn)老化和損壞，這種工作的發(fā)生，一般是隱藏性的，只有參數(shù)出現(xiàn)異常，系統(tǒng)才會報警;第二個方面是連接線松動導(dǎo)致部分I/O模件與主機(jī)的通信中斷，在這種情況下，系統(tǒng)會馬上做出反應(yīng)，出現(xiàn)報警;第三個方面是外界強(qiáng)電信號竄入形成干擾而導(dǎo)致通道故障的發(fā)生。
　?、谥T如球標(biāo)和控制操作出現(xiàn)失靈和實(shí)效以及操作員站出現(xiàn)死機(jī)、鍵盤和打印機(jī)出現(xiàn)工作不正常的現(xiàn)象都屬于人機(jī)接口故障。
　　球標(biāo)操作失靈的原因有裝置因長時間工作發(fā)生老化或者被浮塵或油膩污染，致使觸點(diǎn)不能實(shí)現(xiàn)自行通斷，也或是電纜插頭接觸不良造成與主機(jī)的通信斷路。
　　控制操作實(shí)效的主要原因是因球標(biāo)的操作信號不能改變過程通道的狀態(tài)，有三種可能：其一可能是過程通道硬件發(fā)生故障;其二可能是操作員站所用軟件的缺陷;其三是設(shè)備超負(fù)荷或者過多地打開窗口，導(dǎo)致不響應(yīng)。
　　操作員站死機(jī)的原因基本與控制操作失效的原因相同。
　　鍵盤工作不正常的原因有：鍵盤組態(tài)出現(xiàn)錯誤、接觸不良、連接電纜松動或者在啟動主機(jī)時誤動了鍵盤，造成啟動缺失。
　　打印機(jī)出現(xiàn)工作不正常的原因：或者是配置不合理，或者是因?qū)Υ蛴C(jī)實(shí)施屏蔽而造成的。
　1.2.2硬件(模件)故障應(yīng)采取的防范措施：
　　在DCS系統(tǒng)的運(yùn)行過程中，為了減少硬件(模件)故障的發(fā)生，需要注意以下幾點(diǎn)：嚴(yán)格按照相關(guān)標(biāo)準(zhǔn)和規(guī)定為硬件提供良好的運(yùn)行環(huán)境;主機(jī)和從機(jī)的DPU不得隨意進(jìn)行人為切換;接地要良好;避免靜電感應(yīng);在工作狀態(tài)下，不應(yīng)隨意打開機(jī)柜，并應(yīng)禁止在其附近使用大功率的無線設(shè)備，諸如禁打手機(jī)和禁止使用對講機(jī);保持工作電壓的穩(wěn)定;對于重要的硬件(模件)要由足夠的冗余配置。
　　1.3軟件故障
　　1.3.1軟件發(fā)生故障的主要原因
　　一般情況下，軟件故障發(fā)生的原因很單純，軟件本身的不完善是故障的主因。
　　1.3.2軟件故障應(yīng)采取的防范措施
　　由于軟件故障的原因單純，那么，防范軟件故障的方法也很簡單，那就是使用正版軟件，但切記要及時升級。
　　1.4通信網(wǎng)絡(luò)系統(tǒng)故障
　　通信網(wǎng)絡(luò)是DCS系統(tǒng)與生產(chǎn)一線連接的紐帶，其故障一般發(fā)生在節(jié)點(diǎn)總線和就地總線，也可能是因?yàn)榈貥?biāo)錯誤所造成。
　　1.4.1通信網(wǎng)絡(luò)系統(tǒng)發(fā)生故障的主要原因
　?、俟?jié)點(diǎn)總線故障。當(dāng)總線的干線任一處中斷時，都會導(dǎo)致該總線上所有站及其子設(shè)備通信故障。
　?、诰偷乜偩€故障。由于其連接的設(shè)備是與生產(chǎn)過程直接發(fā)生聯(lián)系的一次元件或控制設(shè)備，所以工作環(huán)境惡劣，故障率高，容易受到檢修人員的誤動而影響生產(chǎn)過程。另外，總線本身也會因種種原因造成通信故障。
　?、鄣刂窐?biāo)識的錯誤。不論是就地組件還是總線接口，一旦其地址標(biāo)識錯誤，必然造成通信網(wǎng)絡(luò)的紊亂。
　　1.4.2通信網(wǎng)絡(luò)系統(tǒng)故障應(yīng)采取的防范措施
　　要防止通信網(wǎng)絡(luò)類故障的出現(xiàn)，必須做到以下幾點(diǎn)：
　?、贋楸苊夤?jié)點(diǎn)總線故障的發(fā)生，最有效的方法是采用雙路冗余配置的方式，避免因一路總線發(fā)生故障而影響全局。
　?、诜谰偷乜偩€故障的有效方法是，要將就地總線與就地設(shè)備的聯(lián)接點(diǎn)進(jìn)行妥善處理，拆裝設(shè)備時，不得影響總線的正常運(yùn)行，總線分支應(yīng)安裝在不易碰觸的地方。同時，就地總線最好是采用雙路冗余配置，以提高通信的可靠性。
　　③為避免地址標(biāo)識的錯誤的發(fā)生，主要是要防止人為的誤動、誤改。
　　2、結(jié)語
　　DCS系統(tǒng)可以有效滿足電廠各系統(tǒng)控制的需要，通過對實(shí)際應(yīng)用中不斷暴露出的一些主要故障的分析，及時加以總結(jié)，便于今后相關(guān)儀控維護(hù)人員及時發(fā)現(xiàn)問題并作出準(zhǔn)確的判斷，采取正確的對策。
 

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BC646EXO365 Solution Provider additional OP License

GC646TRT935 Proficy GlobalCare Complete for Server 35,000 I/O Runtime System

HMI-CAB-C102 CABLE MODICON 984 MICRO

IC641GTE666 Diagnostics/Configuration Disk for IBM-PS/2 Class Computers

IC647IFCLNTCRNC iFIX iClient Runtime (M1Component Part)

IC660EBA024RR Current Source Analog, 24/48Vdc, Electronic Assembly

IC695MDL765 Smart Digital Output Module 24/125 volt DC, ESCP 1A Positive Logic 16 Points. Module does not ship with terminal block. IC694TBB032 or IC694TBSx032 terminal block is required.

IC756WRE049E-23 DataViews Runtime for Windows 25-49, Per User, English, Version 2.3

FlexLogix System 1794-IA8I 85-132VAC INPUT MOD(ISOL)

PLC-5/1771 System D1771-6.5.92 1771-BIM BASIC MODULE USER MANUAL

Process Control 1757-PLXSIFD PLX HW S9000 ETHERNET QUICKBUILDER INTERFACE

Operator Interface 2711P-T7C6D2 PV PLUS 700, TOUCH, RIO/DH, DC PS, EXT MEM

Support 9307-RSP32WENR SUPT REINSTATEMENT CONTRACT FOR 9307RSP32WEN

Support GML-DSS SUPT RENEWAL CONTRACT FOR GMLDS

Support F1785-L26BSERD FIRMWARE UPGRADE FOR 1785-L26B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2300ESU2 RSVIEW32 WORKS 150-1500 UPGRADE IN-SUPT (ES)

RSI Software Products 9701-VWSB250DEU1 RSV SE STATION 25 - 250 DISPLAY UPGRADE (GERMAN)

RSI Software Products 9399-INTWINUG INTERCHANGE FOR WINDOWS USER GUIDE

Motion Control 2098-IPD-HV030-DN HIGH VOLTAGE DRIVE, 7A/14A, ULTRA5000 DEVICENET

BC646MDA000 View Development/Runtime 8,000 I/O

IC300DQM902 20 Relay Outputs (250vac, 30vdc, 2.0A)

IC752PBMU11 Profibus Master/Scanner for ControlStation CE Iix

MTR-3S65-G-R-B-E-SRR Servo Motor 24V Brake, Seal

ZA06B-6114-K230#E Motor power right angle connector for B0.4/5000is or B0.5/5000is or B1/5000is or BM0.5/4000 or BM1/4000 motor

20C-DA1-A PowerFlex 700H 24V DC Control IO Board

20G1ABC770AN0NNNNN PowerFlex 755 AC Packaged Drive

25A-D010N114 PowerFlex 523 4kW (5Hp) AC Drive

2711P-T15C4A8 PanelView Plus Terminal

6SE6440-2UC17-5AA1 0.75KW

SC-N4 380VAC/80A 40KW 110V . 220V AC 2NO+2NC

UG221H-SR4 5.7寸 STN 16色 320*240 24VDC

SCC-AI14

VG4C-RT4

ULTICOM XH0303-4

JAPMC-MC2100T1

PenMount PM6200

PREAMP 8001-4107

1492-SPM1C030-N MCB Supplementary Protector 3 A

通用型變頻器 6SE6 420-2UD13-7AA1 0.37 KW，73 x 173 x 149

20AC030A0AYNANC0 PowerFlex 70 AC Drive 30 A at 15 kW 20A

GC-8451-SW-CF MTL8000 CONFIG. SOFTWARE

GPA-602-H1 LVDT Expansion Unit (Half Bridge H1 Blocks), includes G-0602 connectin g cable.

IC600CR610RR 13 inch Series Six Plus CPU Rack w/o Power Supply (8 Slots)

IC647HSTCSEO5000KM eSignature Option for Historian - Enterprise Corporate Server 5,000,000 Points (M4 Key)

IC647WFLESOP Proficy Workflow - eSOP Operating Procedures Templates and Reports

IC694ALG223 Input module, analog 16 point single ended, current.

IC756RDV010K-98 DV Draw Development on IRIX Op Sys, Korean, Version 9.8

MicroLogix 1200 System 1762-OB8 8 POINT 24 VDC SOURCE OUTPUT

PLC-5/1771 System 1771-PM CLUTCK/BRAKE MODULE, (USED IN PAIRS)

Distributed I/O 1794-OB16PK CONFORMAL COAT, 24VDC SOURCE OUT PROTECTED,16 PT

Communications 9399-INTOSFUG INTERCHANGE FOR DIGITAL UNIX USER GUIDE

Support 6200-AGA3R SUPT REINSTATEMENT CONTRACT FOR 6200AGA3

Support 9358-BIZDME1R SUPT REINSTATEMENT CONTRACT FOR 9358BIZDME1

Support F1771-ASBSERC FIRMWARE UPGRADE FOR 1771-ASB I/O MODULE

RSI Software Products 9324-RL5350ENE RSLOGIX 5/RSLOGIX EMULATE 5 BUNDLE, CD

RSI Software Products 9301-2SE350ESU5R RSVIEW32 RUNTIME 5K-100K UPGRADE OUT-SUPT (ES)

RSI Software Products 9358-HSTS2400 RSBIZWARE HISTORIAN SERVER - 32K TAG LIMIT

Motion Control 0041-5075 VITON SHAFT SEAL KIT FOR USE BELOW FOOD LINES,

78004654 Target Replacement Power Supply

IC200MDD847 MIXED OUTPUT RELAY 2.0A PER PT ISOLATED 8PT / INPUT 240VAC GRP 8PT

IC697ACC800 Fiber Optic Cable for Reflective Memory module (IC697VRM015). Five feet long.

MTR-1231-N-D-E-0 MTR series NEMA 23 stepping motor. Winding connection type is determined by cable

Z44A730464-G26 "Connector for brake power for all Alpha or Beta motors (except B0.5, Bis or BHVis) or fan power for A40/2000 motor "

20BD077A3ANNAND0 PowerFlex 700 AC Drive 77 A 60 Hp 20B

20G11NC043AA0NNNNN PowerFlex 755 AC Packaged Drive

22F-D013N104 PowerFlex 4M- 5.5 kW (7.5 HP) AC Drive

990NAD21810 Quantum MBUS+ DROP CABLE 8' LFT-HD DEC

294D-FD1P5Z-G2 Variable Frequency Drive

PYC-A1 MY/LY系列安裝卡子（100個/包）

1756-OX8I 8點(diǎn)繼電器輸出模塊（每路單獨(dú)隔離）

PXIe-6356

PCI-2726CL

MPC03-LH

臺聯(lián)E1-4CB TAINET模塊 DCS 4E1

PCI-V504

MSC-486SSD

1492-PDEC4 Power Distribution Block Accessory

數(shù)字量輸入/輸出模塊 6ES7422-7BL00-0AB0 DO/32 24V DC, 光隔離，0.5A

2097-V33PR5-LM Kinetix 350 2.0kW Servo Drive

ET-GT-5ES-4ST 3 RJ45 Ports, 2 Multimode Fiber Port Ethernet Switch

GFK-2056 VMIC - Analog Input User's Manual - IC697VAL216/232/264

IC220MDL644 INPUT, 24VDC POSITIVE LOGIC, 16PT (REQUIRES 4 IC220TBK122)

IC647DMC005 DataMart 5 Reporting Clients

IC647PWRV00 Proficy Power SCADA Additional Viewer License

IC693MDL250 120 Vac Isolated Input (16 points). Module requires a terminal block IC694TBBx32 or IC693TBSx32).

IC756CDV001J-98 DV Development - Compaq True64 Op Sys Addt'l User, Japanese, Version 9 .8

MSI-PROD-100 Product Management Clients 100 Pack

PLC-5/1771 System 1785-L86B PROTECTED PLC-5/80 CONTROLLER, 100K WORD SRAM

Distributed I/O 1738-FPD FIELD POTENTIAL DISTRIBUTOR

Communications 1784-PCICS CONTROLNET PCI BUS SCANNER & MESSAGING CARD WITH

Operator Interface 2711E-NF2 FUNCTION KEY LEGEND INSERTS, PV1400E KEYPAD

Support 9304-WVR256R SUPT REINSTATEMENT CONTRACT FOR 9304WVR256

Support 9324-RLD25U7PTE RSLOGIX 5000 LITE PORTUGUESE TO PRO UPGRADE

DeviceNet Products 2711-K10C10 PV1000 COLOR KEY, DNET & RS232 PRINT

RSI Software Products 9301-2SE3400DEU2 RSVIEW32 RUNTIME 300-32K UPGRADE IN-SUPT (DE)

RSI Software Products 9371-EDETJSA RSWIRE DETAILER/JIC WIN STANDALONE

Motion Control MPF-A430H-SJ22BA MOTOR,SERVO,FDGRADE,6.55NM,3500RPM,SINGL

2024-128-C Greyline OS, 2 Line, (20) 5MM Chars, LCD, Quick Connect, 128K Memory W/Clock/Date NEMA 4

HE693THM409 4 ch. J, K, N, T, E, R, S, 0.5 癈 resolution, 癈/癋 engr. units

IC670MDL730 24VDC 2.0A Output Pos. Logic, 8pt Electronic Short Circuit Protection Module

QPJ-COS-201 MODULE CANOpen