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文章通過對(duì) 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(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(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)常見的故障
　　隨著工業(yè)生產(chǎn)自動(dòng)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(duì)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(huì)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(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)壓電源無輸出;四是有的系統(tǒng)整個(gè)機(jī)柜通過一路保險(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
　　①過程通道故障也就是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(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(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(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(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
　　DCS系統(tǒng)可以有效滿足電廠各系統(tǒng)控制的需要，通過對(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)問題并作出準(zhǔn)確的判斷，采取正確的對(duì)策。
 

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IC300TRM006 Spring-clamp style I/O plug, 6-terminal

IC800ABK001 Battery Backup Kit, Alpha SVU Series Amplifiers

MTR-3T67-G-R-B-M-0RR Servo Motor Metric 24V Brake

20AD011A3AYYAEG1 PowerFlex 70 AC Drive 11 A at 7.5 Hp 20A

20DC043A3EYNANCNL PowerFlex 700S AC Drive 20D

20G1ANC456AA0NNNNN PowerFlex 755 AC Packaged Drive

25C-B017N104 PowerFlex 527 4kW (5Hp) AC Drive

280-MTR22-M1D Motor Cable Patchcord

FR-F740-S160K 230KVA 302A 160KW 3相AC380V/50Hz/60Hz

6ES7 291-8BA20-0XA0 電池

cFP-PG-522

AMB-2000

DRC 1000 DRC 700-1000

X8DAL-3

PCI-10S PCI-6S PCI-7S PCI-8S

SF7305 SYS71838

lnterface IBX-8501

1492-SPM2C040 MCB Supplementary Protector 4 A

軟啟動(dòng)器 3RW30261BB04

20AC3P5F0AYNANC0 PowerFlex 70 AC Drive 20A

GC646MRB075 Proficy GlobalCare Complete for Logic PC Runtime 75 I/O

HE693SRC844 PC Interface C Driver Source Code

IC610MDL175RR 115/230Vac Output Module (8 points)

IC647HSTSS150KM Historian Standard Server 150000 Points (M4 Key)

IC660BBD110 Block 115Vac Input 16 Circuits

IC695ACC400CA Conbal Coated. RX3i CPU Energy Pack. Compatible with IC695CPE305 and IC695CPE310 only. Energy Pack ships with CPE305 and CPE310.

IC756WDS000E-23 Dataviews Development Suite (All Windows Languages, Custom Editor Tool kit, Custom Datasource Toolkit, 1 yr SAFE), English, Version 2.3

CompactLogix System 1769-IQ16F 1769 16 POINT HIGH SPEED 24VDC INPUT MODULE

PLC-5/1771 System 1770-XYC LITHIUM BATTERY FOR PLC-5 PROCESSORS

Distributed I/O 1798-PFTP1 PROFIBUS FIELD TERMINATION PLUG W/ 12MM CONNECTORS

Operator Interface 2711P-K6C8D PV PLUS 600 COLOR, KEYPAD, DH+, DC PS

Support 9323-WL5300R SUPT REINSTATEMENT CONTRACT FOR 9323WL5300

Support 9358-PBBK03S SUPT RENEWAL CONTRACT FOR 9358PBBK03ENE

Support F1775-L4 FIRMWARE UPGRADE FOR 1775-L4 PLC3 PROCESSOR MODULE

RSI Software Products 9324-RLT300ENE RSLOGIX 5/500/5000 ENGLISH CD BUNDLE

RSI Software Products 9701-VWMR015ADEE RSVIEW ME STATION RT 15 DISP-WINDOWS 2000 (GERMAN)

RSI Software Products 9330-GC200U UPGRADE: IN-SUPT: RSGUARDIAN CORE 24 TO 128 NODE

Motion Control 2094-PRS4 POWER RAIL, SLIM, 230V OR 460V, 4 AXIS

A06B-6089-K250 Fuse, Alpha SVU Series Amplifier Control Power

IC200UEX209-24 Qty of 24, 28 point expansion. (16) 120VAC In, (12) Relay Out (2 at 10 amp & 10 at 2 amp), 120/240VAC Power Supply (includes Ic200CBL501)

IC752CGE102 SNP CMM cable for DataPanel 30/50

MTR-3N31-H-R-0-N-S-MODRR Servo Motor MOD=shft, label & paint

ZA06B-0147-B175#7076 A22/2000 servo motor with IP67 sealing and brake and 64k serial encoder

20BD8P0A0AYNANC0 PowerFlex 700 AC Drive 8 A 5 Hp 20B

20G14NC260JA0NNNNN PowerFlex 755 AC Packaged Drive

25-PM1-V2P5 PowerFlex 520 0.4kW (0.5Hp) Power Module

OFSCSPELU Quantum OFS LARGE Expired Subbion

FVR0.75E11S-7JE 1. 9KVA 5.0A 0.75KW 單相AC220V/50Hz/60Hz

AH30-H211(H311) 選擇開關(guān)兩(三)位1開1閉

ATV38-HD28N4 22

USB-6289

850SW 13000129-002

Nematron MB820-R

GIN-6350P R2G-6350P

HP-W460GC33

OC-B2P0-CV000

1492-RXIMTR4024-32R Mech Relay Digital Interface Module

WinCC 上位監(jiān)控軟件 6AV6381-1BS06-0DV0 "WinCC?V6.0 RC?8K （8K 外部變量）"

20AB070A0AYNANC0 PowerFlex 70 AC Drive 70 A at 25 Hp 20A

GA647IFPLSR00150 GCA iFIX Plus SCADA 150 I/O Srv

GP647IFESGCLNTCRN GCP iFIX Optn: ESig & ERec iClient Run

IC600BF832RR 115Vac Input Module (32 points)

IC647HSTCCP10M Historian Client Connection Pack 10 Users (M4 Key)

IC647TDV950 CIMPLICITY HMI Server 5000 I/O Development and Runtime System

IC693MDR390 Mixed I/O, 24Vdc Input (8 points), Relay Output (8 points)

IC756LDV001K-98 DV Development - Inb/Linux RedHat Addt'l User, Korean, Version 9.8

Pico Controllers D1760-GR001BENP PICO CONTROLLER GETTING RESULTS MANUAL

PLC-5/1771 System 1771-OW CONTACT OUTPUT MODULE

Distributed I/O 1791-IOBW BLOCK I/O, 24V DC, 64 PT MODULE

Communications 1786-FS20 200 MICRON CABLE ASSEMBLY 20 METERS (65.6 FT)

Operator Interface 9399-2SE32GRPT RSVIEW32 GETTING RESULTS GUIDE (PORTUGUESE)

Support 9356-PRO2200R SUPT REINSTATEMENT CONTRACT FOR 9356PRO2200

Support 9324-RL0300ITS SUPT RENEWAL CONTRACT FOR 9324RL0300IT

EtherNet/IP Products 1785-L40E ETHERNET/IP PLC-5/40 CONTROLLER, 48K WORD SRAM

RSI Software Products 9301-2SE3500ESU2 RSVIEW32 RUNTIME 1500-100K UPGRADE IN-SUPT (ES)

RSI Software Products 9356-PRO2450U8R UPGRADE: OUT-SUPT: RSSQL PROF.5000 TO 32000 TAGS

Motion Control N-2304-1-F04AA SERV MTR,0.5NM,6000RPM,1000 LN ENCDR,BRK

44A730464-G20 Connector Kit, AC12, A12 & A22/2000 Motor Power

IC200ALG322 ANALOG OUTPUT 12 BIT VOLTAGE +/-10V 4CH

IC693PCM300LTMP Prog. Coproc. Mdl., 160 KB (35 KB Basic Prgm), w/Port Exp. Cbl. Modified for use by OEMs (LT)

Silver Series 6008-SV2R TWO CHANNEL RIO SCANNER FOR VME BUS BACKPLANE

VMEM/VDNC/VDOCS-DEMO Demo CD for VisualMEM, VisualDocs and VisualDNC

20BD022A3NYNACD0 PowerFlex 700 AC Drive 22 A at 15 Hp 20B

20G11FD014AA0NNNNN PowerFlex 755 AC Packaged Drive

22C-D088A103 PowerFlex 400- 45 kW (60 HP) AC Drive

MA0185100 Quantum LINE TAP/COAX CBL SYS

285-BRCF25-M12 Source Brake Cordset Flex Cable

E6A2-CW5C 12-24VDC,集電極開路輸出30VDC 30mA,2相,100P/R,200P/R

1747-KFC15 ControlNet模塊

PXI-8432/4

61-600695-000

iBASE IB500

BPS-250MA2

GVPC3

MB896F-R

1492-MW9X24 IEC 9 x 24 mm Cable Marker Card

通訊處理器CP 6ES7 341-1AH01-0AE0 CP341，標(biāo)準(zhǔn)串行通訊模塊，RS232C 接口，最高76.8kbit/s,9 針Sub-D 型接口,可加載 ModbusRTU及 DataHighway 驅(qū)動(dòng)

2094-BL02 Kinetix Line Interface Module

DEMOCD00010 Proficy FIX DEMO CD

GFK-0732 ECLiPS English Control Language Programming System for Series 90-30 PLC User's Guide

IC210BDR012 24VDC Power Source, (6) 24VDC in /(4) out (Relay 8 Amp), (2) analog bs, Expandable, without LCD/Keypad

IC647ARC999 PA Reporting Client UNL

IC647PPSOC3 Proficy Process Systems Operator Console with CIMPLICITY - 3 Pak

IC693CPU311 5-Slot Base With CPU in base (6K Bytes User Program) Battery included

IC754VBL06CTD 6 inch TFT QuickPanel View/ Loaded/ 24VDC/ Blank Label

MSI-CONNECTOR-43 Historian Connector-43

SLC/1746 System 1746-R12 REPLACEMENT COVERS FOR SLC 5/01 PROCESSOR MODULES

Distributed I/O 1734-OV2E 24V DC 2 CHANNEL SINK OUTPUT MODULE

Application-specific products 1803-EEM20E4 EEM,32 PULSES, 24V DC, NEMA 4 ENCLOSURE

Operator Interface 2711E-K10C15 PANELVIEW 1000E KEYPAD TERMINAL, 10.4" FLAT PANEL

Support 9302-BATR SUPT REINSTATEMENT CONTRACT FOR 9302BAT

Support 9381-PP2500KENS SUPPORT RENEWAL CONTRACT FOR 9381PP2500KEN

DeviceNet Products 1791D-4B4P DNET 24VDC CBLOCK I/O, 4 IN SINK 4 OUT SOURCE,BASE

RSI Software Products 9301-2SE3350ESU2 RSVIEW32 RUNTIME 300-5K UPGRADE IN-SUPT (ES)

RSI Software Products 9358-PBPCNT60ENE RSBATCH NT FOR PROCESLGIX PC BASED PHASES 60 UNITS

Motion Control MPL-B860D-SJ22AA MOTOR,SERVO,83.0NM,2000RPM,SINGL,460V

Silver Series 1398-DDM-009 DRIVE,15A PEAK, ULTRA 100

HE660BGM224 Genius BASIC Programmable Co-processor with (2) RS-232 ports

IC646TJT000 CIMPLICITY?Tracker Server-Inb