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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。
　　②諸如球標(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。
　　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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RSI Software Products 9301-2SE2400KOU5 RSVIEW32 WORKS 5K-32K UPGRADE IN-SUPT (KO)

RSI Software Products 9355-WABSNEU3 UPGRADE: IN-SUPT: RSLINX SINGLE NODE TO RSLINX GW

Motion Control MPL-A330P-HK22AA MOTOR,SERVO,4.18NM,5000RPM,ENCDR,230V,5.0KG

Motion Control 2090-UXBC-D1515 BREAKOUT BOARD CABLE,CN2,ULTRAX000,15M

CBL-12-MPS-20 Power Cable, MTR-1221-*-D & MTR-1231-*-D Stepping Motor with S2K, 20 Ft.

IC600PB551RR PDT Video Board

IC800SKCBVL050 Power/Brake Cable, S2K to 4.5 - 5kW S-Series Servo Motors, 5 Meters

OC647IFESGRNUNLMTC iFIX Optn: ESig & ERec Unl I/O Runtime (M1Component Part)

20AD052A3AYNACC0 PowerFlex 70 AC Drive 52 A at 40 Hp 20A

20DC5P0A0EYNANASE PowerFlex 700S AC Drive 20D

20LF1K0N0ENNKN10WA PowerFlex 700L AC Drive 20L

2707-PS220 MICROVIEW 220V AC POWER SUPPLY

280-PWRM22E-M2 ArmorConnect 3-PH Power Media drop cable

FX2N-CNV-BD RS485 通信轉(zhuǎn)換模塊

6ES7 972-0CA23-0XA0 PC MPI電纜

ExpressCard-8421/2

104-1812CLD2N

ELEC30-03A

MPB#100056

ZC-YS0303.C

HS6237

BUS-PAC(PCI)

1492-SPM3B100-N MCB Supplementary Protector 10 A

軟啟動(dòng)器 3RW40271BB14

AT-8624FC-10_1 Proficy Process Systems Switch with One Multi-mode Fiber Module from Allied-Telesis

GC646TDV700 Proficy GlobalCare Complete for 700 I/O Point Runtime / Development System.

HMI-AGO-202 ANTI-GLARE OVERLAY 10.5 inch/ 5 per pack

IC640WDD401 Cable, IBM-PC/XT class computers to Series Six CCM 9 Pin Connector

IC647HSTSSEO5KM eSignature Option for Historian - Standard Server 5000 Points (M4 Key)

IC660BSM120 Bus Switching Module 115Vac/125Vdc

IC695DEM008 Fieldbus Demo Case: RX3i and Fieldbus

IC756WRE024E-27 Runtime License Windows 1-24 Users English v2.7

FlexLogix System

PLC-5/1771 System D1771-6.5.57 FAST MILLIVOLT ANALOG INPUT MODULE(1771-IFM)MNL

Process Control 1757-PLXNT ALARM PAGER

Operator Interface 2711P-RDK7C PV PLUS 700, KEYPAD DISPLAY MODULE

Support 6620-NMUS 6620-NMU SOFTWARE SUPPORT RENEWAL

Support 8100-HSRASR SUPT REINSTATEMENT CONTRACT FOR 8100HSRAS

Support F1785-L20BSERD FIRMWARE UPGRADE FOR 1785-L20B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE220ESU1R RSVIEW32 WORKS 150-300 UPGRADE OUT-SUPT (ES)

RSI Software Products 9701-VWSB100AJPE RSVIEW SE STATION 100 DISPLAY (JAPANESE)

RSI Software Products 9399-HDWAREREFES HARDWARE INTERFACE CONFIG. USER GUIDE (SPANISH)

Motion Control 2098-DSD-HV050X-DN HIGH VOLTAGE DRIVE, 11A/22A, ULTRA3000 W/DNET,INDE

BC5105KAX0000 Panel C Industrial Computer 15" Bundled with WIN XP

IC300DIQ616 8 DC Inputs (12/24vdc, pos/neg logic), 8 DC Outputs (5/12/24vdc, 0.5A, pos logic)

IC752FPY001 Mature. Industrial Floppy Drive for the Datapanel 320T

MTR-3S46-G-R-B-E-0RR Servo Motor 24V Brake

ZA06B-6110-K201#XYM CZ6 regenerative discharge resistor connector kit for BSVM1-40i Beta i series amplifier

20BP140A0ANNANC0 PowerFlex 700 AC Drive 20B

20G14TF415JN0NNNNN PowerFlex 755 AC Packaged Drive

25A-B011N104 PowerFlex 523 2.2kW (3Hp) AC Drive

2711P-T12C4D8K PanelView Plus Terminal

OPC-G11S-AIO(模擬量接口卡)

AHX144 指示燈泡24V/1W

ATS48C21Q 210A

SCC-SG03

TAHOMA TECH 10118B

INTERFACE PCI 8521S

100-79-0810-00

SC I486

MK620-MCT01

1492-SPM1B400 MCB Supplementary Protector 40 A

直流電源 6EP1436-3BA00 3 相 400-500VAC 輸入，24VDC/20A 輸出

20AC022A0AYYANC0 PowerFlex 70 AC Drive 22 A at 11 kW 20A

GA647TRT075 Proficy GlobalCare Assist for CIMPLICITY HMI Server 75 I/O Runtime System

GP647IFSTRN00900 GCP iFIX Std HMI 900 I/O Run

IC600CB536RR Communications Control Module Type 2

IC647HSTCSEO10000KM eSignature Option for Historian - Enterprise Corporate Server 10,000,000 Points (M4 Key)

IC647WATERINFOCENTER Water InfoCenter Solution Pack - Hist, iFIX, IGS, WebSpace, Water SP (M4 Key)

IC693UDR005RR 28 pt DC In/Relay Out/DC Out, AC Power Supply

IC756RDV001J-97 DV Development - Irix Op Sys Addt'l User, Japanese, Version 9.7

MicroLogix 1200 System 1762-L40AWA MICROLOGIX 1200, 40 PT.

PLC-5/1771 System 1771-ES SERVO ENCODER FEEDBACK EXPANDER

Distributed I/O 1794-IB16XOB16P 24 VDC COMBO MODULE, 32 POINTS

Communications 9355-WABJBENE RSLINX OEM/RSJUNCTIONBOX BUNDLE

Operator Interface D6195-6.5.1IT CONTROLVIEW 300 INSTALLATION MANUAL (ITALIAN)

Support 9358-BEPB10R SUPT REINSTATEMENT CONTRACT FOR 9358BEPB10ENE

Support F1747-SDNSERB FIRMWARE UPGRADE FOR 1747-SDN MODULE

RSI Software Products 9324-RL0300ENE RSLOGIX 500 STANDARD CD-ROM

RSI Software Products 9301-2SE3503JPE RSVIEW32 RUNTIME 100K WITH RSLINX (JAPANESE)

RSI Software Products 9358-HSTS2200U1R UPGRADE: OUT-SUPT: HISTORIAN 150 TO 300 TAG

Motion Control W-3016-N-H00AA MOTOR,SERVO,WASHDOWN,AF,1.7 NM,3000RPM,6.4KG

5412-128 Greyline Micro MC. 4 Lines, (20) 5MM Chars. VFD. Quick Connect. 128K Memory. NEMA 4

IC200ERM001 EXPANSION RECEIVER ISOLATED

IC695DEM002 RX3i type 2 demo case. Demo includes CPU, power supply, Ethernet, bsimulator, output, high speed counter, analog combo, Universal analog, and digital servo modules. Demo also includes QuickPanel control/view

MTR-1216-N-D-E-0 MTR series NEMA 23 stepping motor. Winding connection type is determined by cable

VSPCSE-REPTS VISUALSPC SECURE EDITION REPORTS

20BD077A0ANNACC1 PowerFlex 700 AC Drive 77 A 60 Hp 20B

20G11LF710JN0NNNNN PowerFlex 755 AC Packaged Drive

22F-A2P5N113 PowerFlex 4M- 0.4 kW (0.5 HP) AC Drive

490NAA27102 Quantum MODBUS PLUS電纜,500'

291E-FAZ-G1-3FR Direct Online Reversing Starte

PYF08A-E 導(dǎo)軌安裝型，MY2J，MY2NJ

1756-IM16I 220VAC 16點(diǎn)輸入模塊（每路單獨(dú)隔離）

PXIe-5160

PCL-832

SOM-4486

DC2405M

PEAK 600VL

IBM X3250M3

1492-PD3C263 350 A Power Distribution Block

中央處理單元 6ES7414-4HJ04-0AB0 CPU414-4H,1.4MB RAM，60ns，電源 24VDC，MPI/PROFIBUS-DP 主站接口

2097-V31PR2 Kinetix 300 Servo Drive

ENP2335M020 Male Standard/Male Standard, 2 meters

GFK-1866 S2K Series Brushless Servo Amplifier User's Manual

IC220DEM012 VERSAPOINT STATIC DEMO, PROFIBUS NIU

IC647CSPR002 Proficy Cause+ for Inbligent HMI/SCADA Runtime Server - 2X monitored KPIs

IC647PSC300 Proficy Process Systems 3000 I/O with CIMPLICITY

IC693MDL230LT 120 Vac Isolated Input (8 Points) (LT)

IC756CDV000E-97 DV Development - Compaq True64 Op Sys, English, Version 9.7

MSI-MGMT-25-43 Production Management Clients 25 Pack

PLC-5/1771 System 1785-L26B PROTECTED PLC-5/20 CONTROLLER, 16K WORD SRAM

Distributed I/O 1738-IJM23 5 VDC INCREMENTAL ENCODER

Communications 1787-PCABL PROBE CABLE FOR 1770KFD

Operator Interface 2711-NM13 2 MBYTE PC FLASH MEMORY CARD FOR PANELVIEW E TERMS

Support 9304-WTD300S SUPT RENEWAL CONTRACT FOR 9304WTD300

Support 9324-RLD200S SUPT RENEWAL CONTRACT FOR 9324RLD200ENE

DeviceNet Products 2711-B5A10L1 PV550 MONO KEY&TOUCH, DNET & RS232 PRINT

RSI Software Products 9301-2SE335JPU3R RSVIEW32 RUNTIME 1500-5K UPGRADE OUT-SUPT (JP)

RSI Software Products 9371-EDESI1 RSWIRE DESIGNER/IEC STANDALONE

Motion Control MPG-B010-091M24 MOTOR,SERVO,GEAR RATIO 91,35NM,71RPM,MULTI,BRK

Silver Series 2711-K14C3 PV1400 COLOR KEY, DH485 & RS232 PRINT

HE693STG883 8 channel +/-20mV, +/-25mV, +/-30mV strain gage b module for Series 90-30 with 16-bit resolution and weighing functions.

IC670CHS002 I/O Base, Box Style