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文章通過(guò)對(duì) DCS系統(tǒng)在火電廠運(yùn)行中常見(jiàn)的故障及發(fā)生故障原因的分析，有針對(duì)性地提出了故障出現(xiàn)時(shí)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(dòng)化設(shè)備DCS系統(tǒng)，近年來(lái)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(guò)程中經(jīng)常會(huì)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(jì)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(jiàn)的故障
　　隨著工業(yè)生產(chǎn)自動(dòng)化的不斷興起、過(guò)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(duì)DCS系統(tǒng)的應(yīng)用水平的限制，系統(tǒng)在運(yùn)行過(guò)程中難免會(huì)出現(xiàn)故障。常見(jiàn)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(gè)系統(tǒng)會(huì)停止運(yùn)行，而且還會(huì)導(dǎo)致機(jī)組的跳閘，造成非計(jì)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(wèn)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(shí)也會(huì)出現(xiàn)瞬間失電，導(dǎo)致機(jī)組跳閘;二是保險(xiǎn)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(dòng)引起保護(hù)誤動(dòng)及接插頭接觸不良導(dǎo)致穩(wěn)壓電源無(wú)輸出;四是有的系統(tǒng)整個(gè)機(jī)柜通過(guò)一路保險(xiǎn)供所有輸入信號(hào)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(wú)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(dòng)。第四是對(duì)電源實(shí)行壽命管理，該更換的時(shí)候必須更換，絕對(duì)不允許等到電源出現(xiàn)了故障的時(shí)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(jiàn)的故障部位為過(guò)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
　　①過(guò)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(zhǎng)時(shí)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(huì)報(bào)警;第二個(gè)方面是連接線松動(dòng)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(huì)馬上做出反應(yīng)，出現(xiàn)報(bào)警;第三個(gè)方面是外界強(qiáng)電信號(hào)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(pán)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(zhǎng)時(shí)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(hào)不能改變過(guò)程通道的狀態(tài)，有三種可能：其一可能是過(guò)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(guò)多地打開(kāi)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(pán)工作不正常的原因有：鍵盤(pán)組態(tài)出現(xiàn)錯(cuò)誤、接觸不良、連接電纜松動(dòng)或者在啟動(dòng)主機(jī)時(shí)誤動(dòng)了鍵盤(pán)，造成啟動(dòng)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(guò)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(kāi)機(jī)柜，并應(yīng)禁止在其附近使用大功率的無(wú)線設(shè)備，諸如禁打手機(jī)和禁止使用對(duì)講機(jī);保持工作電壓的穩(wěn)定;對(duì)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(jiǎn)單，那就是使用正版軟件，但切記要及時(shí)升級(jí)。
　　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(cuò)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(shí)，都會(huì)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(guò)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(dòng)而影響生產(chǎn)過(guò)程。另外，總線本身也會(huì)因種種原因造成通信故障。
　?、鄣刂窐?biāo)識(shí)的錯(cuò)誤。不論是就地組件還是總線接口，一旦其地址標(biāo)識(shí)錯(cuò)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(shí)，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(shí)，就地總線最好是采用雙路冗余配置，以提高通信的可靠性。
　?、蹫楸苊獾刂窐?biāo)識(shí)的錯(cuò)誤的發(fā)生，主要是要防止人為的誤動(dòng)、誤改。
　　2、結(jié)語(yǔ)
　　DCS系統(tǒng)可以有效滿足電廠各系統(tǒng)控制的需要，通過(guò)對(duì)實(shí)際應(yīng)用中不斷暴露出的一些主要故障的分析，及時(shí)加以總結(jié)，便于今后相關(guān)儀控維護(hù)人員及時(shí)發(fā)現(xiàn)問(wèn)題并作出準(zhǔn)確的判斷，采取正確的對(duì)策。
 

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Industrial Computers 6189V-DCPS DC POWER SUPPLY ATX STANDARD.

Application-specific products 1403-CF050 50 M F LINK FOR POWERMONITOR

Operator Interface 2711-K6C10L1 PV600 COLOR KEY, DNET & RS232 PRINT

Support 9301-2SE2400R SUPT REINSTATEMENT CONTRACT FOR 93012SE2400

Support 9323-ATUNES SUPT RENEWAL CONTRACT FOR 9323ATUNEENE

DeviceNet Products 1734-OB8E 24V DC8 CHANNEL SOURCE OUTPUT MODULE

RSI Software Products 9301-2SE3100KOE RSVIEW32 RUNTIME 150 (KOREAN)

RSI Software Products 9358-BNTK60ENE RSBATCH BACK-UP KEY 60 UNITS

Motion Control MPL-B420P-MK22AA MOTOR,SERVO,4.74 NM,5000RPM,MULTI,460V

Motion Control 2090-UXBK-D1501 BREAKOUT BOARD KIT,MTR FDBK,CN2,ULTRA X000,1M

GFK-0777 SS-90 Analog-100 Brushless Servo Amplifier Instruction Manual

IC646MDA159 View 1500 Tag Runtime & Development System

MSC-V-V 0-10 V in / 0-10 V out

PSPC-MONITOR100 Prof Shop Floor SPC Monitor 100 User

20BC022A0AYNANA0 PowerFlex 700 AC Drive 22 A at 11 kW 20B

20F11GC015JA0NNNNN PowerFlex 753 AC Packaged Drive

2198-P208 Kinetix 5700 DC Bus Supply

2711P-RDB10C PanelView Plus Display Module

280D-F12S-10C-CR ArmorStart Direct Online Starter

CQM1-AD042 4路模擬量輸入單元(無(wú)需供電單元)

FPM-3150 15“TFT

PCI-6143

VTC 2000

NTLX22AA

超微 C2SBE

BPP-14-8I4P

FASTCOM:4W-GT

1492-L2T-B IEC Term Blck 3.5x63x29.5mm Spr Clp

1492-XIMTR4024-32R 40-Pin Relay IFM 24V DC 32 Relays

軟啟動(dòng)器 3RW44253BC44

BC647MRA159 View Runtime 1500 I/O with Proficy GlobalCare Complete with USB Hardware key

GC647IFUBSTS GCC iFIX iClientTS User Base Support

IC200CPUE05CA Conbal coated CPU with built-in Ethernet 10Mbits, one RS 232 and one RS 485 port.

IC646NCN010 HMI for CNC Option

IC647IFSTRNUNLMTC iFIX Standard HMI Unlimited Runtime (M1Component Part)

IC670MDL233RR 120VAC 8 pt. Isolated Input

IC697MDL241 240 Vac Isolated Input (16 Points)

IC800SLCBV100 Power/brake cable for SLM100 or SLM250 S-series servo motor with brake. 10 meters

ControlLogix/1756 System 1756-DMAF 2-RE PMI FIBER OPTIC CABLE ADAPTERS

Industrial Computers 6182H-12BRH6D VVCE 1250, KEY/TOUCH, STD MEM, RIO/DH, DC

Process Control 1757-PFBEXP035 PROFIBUS INTERFACE MODULE EXPANSION

Operator Interface 2711P-RN6 PV PLUS DH+/RIO/DH-485 COMMUNICATION MODULE

Support 9357-ANETMD3R SUPT REINSTATEMENT CONTRACT FOR 9357ANETMD3E

Support 9361-DATAOCXS SUPT RENEWAL CONTRACT FOR 9361DATAOCX

ControlNet Products 1734-OB2E 24V DC 2 CHANNEL SOURCE OUTPUT MODULE

RSI Software Products 9301-2SE2400U4 UPGRADE: IN-SUPT: WINVIEW TO RSVIEW32 WORKS 32K

RSI Software Products 9357-DNETMD3E RSNETWORX FOR DEVICENET PLUS MAINT. AND DIAGS

Motion Control MPL-A420P-HJ24AA MOTOR,SERVO,4.74NM,5000RPM,ENCR,230V,BRK,6.8KG

Motion Control 2090-UXNFBMP-S15 CABLE,ULGRF50ON-FLEX,MOTOR FEEDBACK,MP,15M

CBL-13-ED-20 Encoder Cable, MTR-1235, 13xx, 14xx & 1N Series Stepping Motors to IMC-D or S2K, 20 Ft.

IC600WD100 I/O Cable, 100 feet (30m)

IC800SKCPV100 Power Cable, S2K to 1-2.5kW S-Series Servo Motors, 10 Meters

OC647IFESGSRUNLMTM iFIX Optn: ESig & ERec Unl I/O Server (M4 Part)

20AD065A3AYNANG0 PowerFlex 70 AC Drive 65 A at 50 Hp 20A

20DC820A0ENNBNANE PowerFlex 700S AC Drive 820 A 450 kW 20D

20P21AD073RA0NNN PowerFlex 73 A DC Drive

2711-ND3CNM PanelView ND3CN MED Accessory

280-PWRM22G-M025 ArmorStart Three-Phase Power Media

34 FX-EEPROM-4 EEPROM存儲(chǔ)卡4K/步,適用FX2N 490.-

6AV6 545-0CC10 TP270-10 觸摸屏 10.4寸彩色顯示

GPIB-RS485/422

EC3-1544CLD3N

SHT-8B/PCI

NC-537-32

研域工控G41DM

SET 5132-B

XL-F130-20123

1492-SPM3B300 MCB Supplementary Protector 30 A

軟啟動(dòng)器 3RW40261BB04

BC646EXI365 Solution Provider additional iSuite License

GC646TRT700 Proficy GlobalCare Complete for Server 700 I/O Runtime System

HMI-CAB-C100 CABLE SIMATIC TI TI545-1102

IC641GBE647 PCIM Driver Software

IC647IFCLNTCDVK iFIX iClient Development (M1 Kit Part)

IC660EBA023RR Thermocouple, 24/48Vdc Power, Electronic Assembly

IC695LRE001CA RX3i Local Serial Expansion Conbal Coated.

IC756WRE024K-97 DataViews Runtime for Windows 1-24, Per User, Korean, Version 9.7

FlexLogix System 1794-IA16 85-132V AC INPUT MODULE, 16 POINT

PLC-5/1771 System D1771-6.5.90 ANALOG INPUT MODULE USER MANUAL

Process Control 1757-PLXSIFA PLX AB INTEGRATION QUICKBUILDER INTERFACE

Operator Interface 2711P-T7C6B2 PV PLUS 700, TOUCH, RIO/DH, AC PS, EXT MEM

Support 9307-RSP32RENR SUPT REINSTATEMENT CONTRACT FOR 9307RSP32REN

Support GML-DMS SUPT RENEWAL CONTRACT FOR GMLDM

Support F1785-L26BSERA FIRMWARE UPGRADE FOR 1785-L26B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2300ESE RSVIEW32 WORKS 1500 (SPANISH)

RSI Software Products 9701-VWSB250AFRE RSVIEW SE STATION 250 DISPLAY (FRENCH)

RSI Software Products 9399-INTVMSUG INTERCHANGE FOR OPEN VMS USER GUIDE

Motion Control 2098-IPD-075-DN DRIVE, 35A/75A, ULTRA5000, DEVICENET

BC646MBTS99 CIM Machine Edition Traditional Development Suite - Site Licenses w/1yr.SAFE

IC300DQM306 16 DC Outputs (5/12/24vdc, 0.5A pos logic with ESCP)

IC752PBI100 PC/104 Profibus Card for models 160/240E

MTR-3S65-G-R-0-E-SRR Servo Motor with Seal

ZA06B-6114-K220#E Motor power and brake power right angle connector for B2/4000is or B4/4000is motor

20C-316051-C01 MOV ASSY, 460V, 700A, 40J, M6 LUGS

20G1ABC750AN0NNNNN PowerFlex 755 AC Packaged Drive

25A-CTMFC1 PowerFlex 523 Control Module Front Cover

2711P-T15C22D9P PanelView Plus 7 Graphic Terminal

6SE6440-2UC13-7AA1 0.37KW

SC-N3 380VAC/65A 30KW 110V . 220V AC 2NO+2NC

UG221H-LR4 5.7寸 STN 單色 320*240 SRAM/時(shí)鐘

SCC-AI06

SEED-PCIDRV 7.820.014

PCI-3163

CERAVAC Transmitters CTR 100 / CTR 91

158637-0001

FSB-945G

1492-SPM1C030 MCB Supplementary Protector 3 A

通用型變頻器 6SE6 420-2UC25-5CA1 "5.5 KW，185 x 245 x 195"

20AC022F0AYNANC0 PowerFlex 70 AC Drive 22 A at 11 kW 20A

GC-8450-SW-CF CONFIG SW WITH CABLE

GPA-602-H LVDT Expansion Unit (Half Bridge), includes G-0602 connecting cable.

IC600CP625RR 19 inch Series Six Plus CPU 125Vdc Power Supply (11 Slots)

IC647HSTCSEO40KM eSignature Option for Historian - Enterprise Corporate Server 40000 Points (M4 Key)

IC647WFLCWSP Proficy Workflow - Cityworks Service Provider

IC694ALG222CA Conbal Coated Analog Voltage Input module 16 channels single ended/ 8channels differential

IC756RDV010K-97 DV Draw Development on IRIX Op Sys, Korean, Version 9.7

MicroLogix 1200 System 1762-OB16 16 POINT 24 VDC SOURCE OUTPUT MODULE

PLC-5/1771 System 1771-PD PID CONTROL MODULE, 2 LOOPS

Distributed I/O 1794-OB16P 24V DC SOURCE OUTPUT MODULE (PROTECTED), 16 POINT

Communications 9399-INTHPUG INTERCHANGE FOR HP-UX USERS GUIDE

Support

Support 9358-BIZ1C0PS SUPT RENEWAL CONTRACT FOR 9358BIZ1C0PENE

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

RSI Software Products 9324-RL5300NXENE RSLGX 5/RSNTWRX STD. BUNDLE, ENU

RSI Software Products 9301-2SE350ESU4R RSVIEW32 RUNTIME 150-100K UPGRADE OUT-SUPT (ES)

RSI Software Products 9358-HSTS2350U3R UPGRADE: OUT-SUPT: HISTORIAN 1500 TO 5K TAG

Motion Control 0041-5074 TEFLON SHAFT SEAL KIT FOR USE ABOVE FOOD LINES

78004653 Target Empty Rack Assembly

IC200MDD846LT MIXED OUTPUT RELAY 2.0A PER PT ISOLATED 8PT / INPUT 120VAC GRP 8PT (LT)