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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
　?、龠^(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。
　　鍵盤工作不正常的原因有：鍵盤組態(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，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
　　①節(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。
　　②就地總線故障。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。
　　③地址標(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。
　　③為避免地址標(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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PS2668 22N-700AACL

iBASE IB881-R

CPL93023

CM-SG-LTIE10-PCI

1492-JDG4C GROUNDING TERM. BLOCK

1492-WD4C IEC Term Blck 8x47.6x41mm Screw

軟啟動(dòng)器 3RW44221BC36

BC646TPR700 ProServer 700 I/O Runtime Sys with Proficy GlobalCare

GC647IFPLDV00150 GCC iFIX Plus SCADA 150 I/O Dev

IC200CBL505 I/O Expansion cable, 0.5 meter long

IC646MPMU01 Logic Developer PLC Nano/Micro Upgrade

IC647IFPRSR00900C iFIX Profsnl SCADA 900 I/O Server (M1Component Part)

IC660TSA020 Terminal Assembly for IC660BBA020

IC697CPM790RR GMR Redundancy CPU, 486, 2K Triplex (voted) I/O

IC800MCUB12310XERR Stepping MotorCube 175 oz-in, Pulse/Direction, Encoder Feedback

ControlLogix/1756 System 1756-OA8 74-265 VAC 2 AMP OUTPUT 8 PTS (20 PIN)

Industrial Computers 6182H-10BRH4B VVCE 1000, KEY/TOUCH, STD MEM, ENET, AC

Process Control 9358-PBPCNT10ENE RSBATCH NT FOR PROCESLGIX PC BASED PHASES 10 UNITS

Operator Interface 2711P-RBB15 PV PLUS 1500 KEY/TOUCH REPLACEMENT BEZEL

Support 9355-RSLINXCON RSLINX OPC CLNT APP SERVICE - PER DIEM (2 DAY MIN)

Support 9351-OSFR SUPT REINSTATEMENT CONTRACT FOR 9351OSF

ControlNet Products 1786-FSB500 200 MICRON BULK CABLE 500 METERS (1640 FT)

RSI Software Products 9301-2SE2400DEU2 RSVIEW32 WORKS 300-32K UPGRADE IN-SUPT (DE)

RSI Software Products 9355-WABGWEU2R UPGRADE: OUT-SUPT: WINLINX TO RSLINX GATEWAY

Motion Control MPL-A310P-SK24AA MOTOR,SERVO,1.58 NM,5000RPM,SINGL,230V,BRK,4.2KG

Motion Control 2090-DANPT-16S04 CABLE, NON-FLEX, MTR PWR, CABLE-MTD CONN, 16AWG, 0

BC647MPS101 Logic Developer PLC Standard Edition with Cable with Proficy GlobalCare Complete and a hardware key.

IC5005TBW0000 15" Inbligence Industrial PC, Perbance Series Win2000

IC800MCUB12160XN Stepping Motor Cube, 50 oz-in with Pulse/Direction, NEMA 23

OC647IFDBPKM-50 iFIX 5.0 Optn: Database Pack

20AD022A3AYNANC0 PowerFlex 70 AC Drive 22 A at 15 Hp 20A

20DC205A3EYNAEANE PowerFlex 700S AC Drive 20D

20G1ANF046JN0NNNNN PowerFlex 755 AC Packaged Drive

25C-D6P0N104 PowerFlex 527 2.2kW (3Hp) AC Drive

280-PWRM22A-M6 ArmorConnect 6 Meter M22 Patchcord

FX1S-14MT-D 直流主機(jī)8入/6出 晶體管輸出

6ES7 340-1AH01-0AE0 點(diǎn)對(duì)點(diǎn)通訊模板,CP340-1A,帶RS232C口

cRIO-9073

PCA-6277VE

MOXA CP-118U

EC0-1815V2NAR

ACE-916A

VPM-8120X-5060

ROBO-8111VG2AR-Q77

1492-SPM2D160 MCB Supplementary Protector 16 A

軟啟動(dòng)器 3RW30471BB04

ABICTDE0000/ABD 10.5 inch Color TFT/ TCP Label/ 24VDC/ with AB DataHighway Plus/ UL/ cUL/ CE/ UL1604

GC646PCMS01 GlobalCare Complete for Change Management Electronic Signature Module (Single)

HE697BEM600 Discontinued Part. Check with GE IP on migration path.

IC630MDL366RR Analog Output Module, 4-20mA (2 channels)

IC647HSTSS5KM Historian Standard Server 5000 Points (M4 Key)

IC660BLC001 Cable w/Connectors Alpha 9823 15 In (Qty 3)

IC695ALG728 Analog Output HART Module, 8 channels,that is configurable for voltage, current, current/HART configured for Current: 0 to 20mA, 4 to 20mA; Voltage: +/- 10VDC, 0 to 10VDC per channel non isolated. Up to 16 bit resolution. Requires high capacity ter

IC756WDV009K-23 DV Development Sys Visual Basic, Korean, Version 2.3

CompactLogix System 1769-CLL1 1 FT (305 MM) LEFT-TO-LEFT BUS EXPANSION CABLE

PLC-5/1771 System 9399-RL53GRDE RSLOGIX 5 GETTING RESULTS GUIDE(GERMAN)

Distributed I/O D1794-6.5.3 FLEX I/O REMOTE I/O ADAPTER MOD. USER MANUAL

Operator Interface 2711P-T6M5A PV PLUS 600 GRAYSCALE, TOUCH, RS232, AC PS

Support 6404-DDMCS SUPT RENEWAL CONTRACT FOR 6404DDMC

Support 9358-PLTM2100R SUPT REINSTATEMENT CONTRACT FOR 9358PLTM2100ENE

Support F1784-CPCIDS FIRMWARE UPGRADE FOR 1784-CPCIDS COMMUNICATION MOD

RSI Software Products 9301-2SE2200DEU1 RSVIEW32 WORKS 150-300 UPGRADE IN-SUPT (DE)

RSI Software Products 9701-VWSB000AJPE RSVIEW SE STATION UNLIMITED DISPLAY (JAPANESE)

RSI Software Products 9399-APSIE SLC 500 APS IMPORT/EXPORT UTILITY USER MANUAL

Motion Control 2098-DSD-HV220 HIGH VOLTAGE DRIVE, 47A/94A, ULTRA3000

ABK3D200C2P/DVN QUICKPANEL 6" TFT W/DVN

IC220TBK123 I/O TERMINAL STRIP, 12 POSITION SPRING STYLE W/COLOR, OUTPUT, QTY 10

IC752DPH000RR Datapanel H, 640x200 LCD with CCFT backlight. Text, bitmaps, bar graphs, real time clock. Includes integrated keypad. No touch capability.

MTR-3S33-G-R-B-E-S MTR series servo motor with resolver and brake and shaft seal

ZA06B-6050-K120 Motor encoder connector kit for B0.5/3000 motor

20BE052A3AYNAND0 PowerFlex 700 AC Drive 52 A 50 Hp 20B

20G14NF050JA0NNNNN PowerFlex 755 AC Packaged Drive

25-RF011-AL PowerFlex 520 10.7A 230V EMC Filter Kit

2711P-RTBAC3 PanelView Plus Accessory

FRN75G11S-4CX 114KVA 150A 75KW 3相AC380V/50Hz/60Hz

AH22-SZR(G,Y,W,C,O)M 方30×30mm指示燈自帶變壓器AC220V-6.3V,顏色同上

ATV-58HD12M2 5.5

USB-9421

6GK1541-2BA00

DPS-350NB-1

SUN 375-3536

PCISA-C400R-RS-R20

TPC-1261H-A1E

1492-SPM1B030-N MCB Supplementary Protector 3 A

6ED1052-1HB00-0BA5 LOGO!24RC 24VAC/DC 8DI/4DO,繼電器輸出，實(shí)時(shí)時(shí)鐘

20AC011A3AYNANC0 PowerFlex 70 AC Drive 20A

GA647IFSTRNUNLMT GCA iFIX Std HMI Unlmt Run

GP647IFPLSR00150 GCP iFIX Plus SCADA 150 I/O Srv

IC600BF942RR -10Vdc to +10Vdc Analog Output Module (4 channels)

IC647HSTCR50KM Collector Redundancy Option for Historian - Standard Server 50000 Points (M4 Key)

IC647TPR935 CIMPLICITY HMI ProServer 35,000 I/O Runtime System

IC693PTM100CA Conbal Coated Power Transducer Module

IC756MDV001J-97 DV Development - Alpha OpenVMS Addt'l User, Japanese, Version 9.7

MicroLogix 1000/1761 System 1761-NET-DNI DEVICENET INTERFACE (DNI)

PLC-5/1771 System 1771-NBV1 HIGH RESOLUTION ISOLATED ANALOG MODULE

Distributed I/O 1792D-CB18JP MAXUM ROUND MEDIA 18MM BASE, PASSTHRU FOR DNET

Communications 9351-HPUSRT INTERCHANGE FOR HP-UX RUNTIME

Operator Interface D6190-6.5.25 CONTROLVIEW AND CONTROLVIEW 300 INSTALLATION MNL

Support 9358-B03R SUPT REINSTATEMENT CONTRACT FOR 9358B03ENE

Support 9392-CDRSFRU UPGRADE TO ENGLISH/FRENCH BUNDLE

RSI Software Products 9323-L2300DUR UPGRADE: OUT-SUPT: 6200-2 BOTH TO AI-2 BOTH

RSI Software Products 9301-2SE3500PTE RSVIEW32 RUNTIME 100K (PORTUGUESE)

RSI Software Products 9356-SQLSAPALENE RSSQL FOR SAP SOLUTIONS SERVER PREMIUM

Motion Control TL-A230P-BJ34AA MOTOR, SERVO, 1.3NM, 5000RPM, 17BIT SERIAL FEEDBAC

44A739462 Series 90-30 State Logic CSE311 Upgrade to latest revision

IC200CHS003 I/O CARRIER CONNECTOR STYLE

IC694MDL390 OUTPUT MODULE 120/240 VAC 2AMPS 5 POINT ISOLATED

MSI-UNIV-WEB-25-43 Univ Web(RTIP/Dash/Web/Excel) 25 Pak-43

VSPC32-OPCOPEN OPC Client Option includes VisualSPC Importer (licensing is per client PC), Support for unlimited Points/Tags.

20BD040A0AYNAND0 PowerFlex 700 AC Drive 40 A at 30 Hp 20B

20G11JC1K4JN0NNNNN PowerFlex 755 AC Packaged Drive

22D-D012F104 PowerFlex 40P 5.5 kW (7.5 Hp) AC Drive

140NOE77101C Quantum TSX Quantum Ethernet 10/100 Option Modul

290E-FAP-G1 Direct Online Starter

E53-AZ03 NEW RS485通訊板

1761-NET-ENI Ethernet 網(wǎng)絡(luò)接口模塊

PXIe-2575

OMRON XM2C-0912

C79040-A6420-C849-03-85

PCLTA-20

MATROX METEOR2/4 750-03

PCM-9371

1492-NM16 TERM BLCK End Barrier

前連接器 6ES7392-1AJ00-0AA0 20 針前連接器，螺釘型

2094-SE02F-M00-S0 Kinetix 6200/6500 Control Module

DT1008 RoboMount (Articulating DuraTouch and Keyboard Mounting Bracket)

GFK-1056 Series 90-30 State Logic Control System User's Manual

IC210NDR012 24VDC Power Source, (6) 24VDC in /(4) out (Relay 8 Amp), (2) analog bs. Not expandable,no LCD/Keypad, no cover. .