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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
　　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。
　?、蹫楸苊獾刂窐?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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MicroLogix 1500/1769 System 1764-RPLTB1 REMOVABLE TERMINAL BLOCK KIT (17 PT)

PLC-5/1771 System 1784-CP5 CABLE ASSY, 10FT/3.20M, 1784-KTK1 (15-PIN D-SHELL)

Distributed I/O 1797-TCAP CONTROLNET EX TAP (DUMMY) TERMINATOR (5 PIECES)

Communications D5000-6.6.1 PI DATA TALBE LIBRARY INSTALLATION & CONFIGURATION

Support 9321-L5160R SUPT REINSTATEMENT CONTRACT FOR 9321L5160

Support 9358-EP60S SUPT RENEWAL CONTRACT FOR 9358BEPNT60ENE

Support F1771-VHSCSERB FIRMWARE UPGRADE FOR 1771VHSC I/O MODULE

RSI Software Products 9324-RLD2U7PTE RSLOGIX 5000 MINI TO PRO UPGRADE, PORTUGUESE

RSI Software Products 9304-WVPD300DU2R UPGRADE: OUT-SUPT: WINVW 256 TO WINVW PRO DEV 3000

RSI Software Products 9358-PLTM2500U4R UPGRADE: OUT-SUPT: PLANTMETRICS 50 TO 100 WORKCELL

Motion Control 8720SM-063S5QAS4 63 KW/117.5 AMP, 750 VDC, MOTOR W/SNS60,+MPL

A06B-0033-B175#7008 B3/3000 Servo Motor, Holding Brake, 32K Serial Encoder

IC200TBX223 Tool box, 23 point, (IC200UAL006) 24VDC In/Relay Out, requires 120VAC Power, VersaMax SE (IC200SET001) with all software, cables (IC640VPS002)and manuals.

IC698PSA350 RX7i PLC Power Supply, 85 to 264 VAC at 47 to 63 Hz Input, 350 Watt output

MTR-1350-E-D-E-0RR Stepping Motor Nema34 Encoder

ZA06B-0078-B503#0100 B12/3000is Servo Motor with Straight Shaft, Key, Brake and IP67 Sealing

20BD248A3AYNANC0 PowerFlex 700 AC Drive 20B

20G11RD3P4AA0NNNNN PowerFlex 755 AC Packaged Drive

25-FAN1-FE PowerFlex 520 Frame E Fan Kit

140XCP40200 Quantum 10槽本版安裝架, 20MM

FRN7.5F1S-4C 12KVA 16.5 A 7.5 KW 3相AC380V/50Hz/60Hz

Z-15GD-B 觸點(diǎn):1開/1閉,10A 250VAC機(jī)械壽命:1000萬次?彈簧式短按鈕型

ATV-31H037M2A 0.37

SCXI-1193

445-0719443

CONTEC SMC-4DL-PE

6ES7612 -2QH00-0AB4

AIMB-766G2

ZM500-RS

1492-RCDA4C63 Residual Current Device 63 A

有源導(dǎo)軌 6ES7195-1GF30-0XA0 有源導(dǎo)軌/530mm

2098-DSD-HV150-DN Ultra 3000 Servo Drive

GA647IFCLNTCDV GCA iFIX iClient Dev

GP-0602NT-F8 GagePort LVDT NT (Full Bridge for Sangamo A6G1, Standard E4-8030)

IC5005CAC0001 PanelClient 15 inch with iFIX Terminal Service License

IC647HSTAE2000KM Alarm and Events Option for Historian - Standard Server 2,000,000 Points (M4 Key)

IC647SPT001 Scheduler Proficy Plant Apps Adapter

IC693MDL733RR 12/24 Vdc Output, 05 Amp, Negative Logic (8 Points)

IC756HDV001K-99 DV Development - HP/UX Op Sys Addt'l User, Korean, Version 9.9

Pico Controllers 1760-L12AWA-NC 12 I/O PICO CONTROLLER, AC

PLC-5/1771 System 1771-IN INPUT MODULE, 24V AC, 8 INPUT

Distributed I/O 1791D-4B0 DNET 24VDC CBLOCK I/O, 4 IN SINK (NOT EXPANDABLE)

Communications 1784-PCM6 1784-PCMK DH+COMMUNICATION CABLE(8 PIN DIN)

Operator Interface 2706-P44R INVIEW MESSAGE DISPLAY. 1 OR 2 LINE

Support 9305-RSVADSJPS SUPT RENEWAL CONTRACT FOR 9305RSVADSJP

Support 9515-RSMCLT010S SUPT RENEWAL CONTRACT FOR 9515RSMCLT010EN

EtherNet/IP Products 2711-K10G20 PV1000 GRAYSCALE KEY, ENET & RS232 PRINT

RSI Software Products 9301-2SE340DEU1R RSVIEW32 RUNTIME 1500-32K UPGRADE OUT-SUPT (DE)

RSI Software Products 9356-PRO2200U2R UPGRADE: OUT-SUPT: RSSQL STD.300 TO PROF.300 TAG

Motion Control 1326AB-B720E-S2K7L MOTOR,SERVO,460V,30.9NM,3500RPM,SINGL,BRK,IP67

4161-6-5 BCD To 7 SEG Display . 6 Digit, 5VDC. Dust Seal

HMI-CCT-303 BACKLIGHT TUBE 6" STN or MONOCHROME LCD QPK3 Series QPK-3xxxx-Sxx or Lxx)

IC693CPU323 10-Slot Base With Turbo CPU in base (.6 msec) 12K bytes User Program

SFW-TGTP-1.2 Target Program Flash Memory Card Rev 1.2

TRM-21006678 4 point screw terminal motor power or ac power connector for IMC-200 ampless controller

20BD011A0AYNACD1 PowerFlex 700 AC Drive 20B

20F1ANF212JN0NNNNN PowerFlex 753 AC Packaged Drive

22B-E6P6H204 PowerFlex 40 4 kW (5 Hp) AC Drive

140EHC20200C Quantum 高速計數(shù)模塊, 24 VDC, 500Hz, 2通道, CC

284G-FVD2P3S-10-RRG-CBG-DB1-EMI ArmorStart 284 Controller

E2K-F10MC1 10mm,電容式,三線,常開 200mA NPN電源:10-30VDC扁型50×20×10mm

1746-IV8 24VDC 8點(diǎn)輸入模塊 源流

PXI-6250

PCI-14P12

FSC-1713VNA (B)

AP-56HP-A

TEKNOR T936 IBAAB

PCA-6194VG

1492-MS5X9H11-20 Connection Products

1495-N71 3/4 in. Hub

行程開關(guān) 3SE53120SG13

CP6B-0WPB-0070-AZ Power cable for B22/2000is motor. 7 meters

GF-AU10V Connecting FlashCable to Analog Unipolar +10 V (No connector),

IC200UEX014 14 point Exp (8) 24VDC In, (6)24V DC Out, 24VDC Power Supply (includes IC200CBL501)

IC647AEC002 PA Efficiency Client 2 Pak

IC647PCM050 Proficy Change Management Server - 50 Concurrent Users

IC693CBL329 Cable, Left Side, Two - 24 Pin 90 Degree Connectors, 1 Meter

IC754BEZ12GAS Replacement Gasket for 12In SSteel Bezel

IMC-31CP-2-DRR IMC-D Series Servo Motor Controller, Enhanced, DeviceNet, 12 Amp

SLC/1746 System 9399-RSRGR RSRULES GETTING STARTED GUIDE

Distributed I/O 1732D-8CFGM12 DEVICENET 24VDC 8 SELECTABLE POINTS W/M12

Application-specific products 1404-M805B-000 MASTER MODULE-PQ-24V P/S

Operator Interface 2711-K10G9 PV1000 GRAYSCALE KEY, RS232 (DH485) & RS232 PRINT

Support 9301-2SE3400DER SUPT REINSTATEMENT CONTRACT FOR 93012SE3400DE

Support 9381-P500ENS SUPT RENEWAL CONTRACT FOR 9381P500EN

DeviceNet Products 1790-8BV8BX LDX I/O, 24VDC, 8 UNIV IN/8 SRCE OUT EXPAN D-SHELL

RSI Software Products 9301-2SE3300PTU1 RSVIEW32 RUNTIME 300-1500 UPGRADE IN-SUPT (PT)

RSI Software Products 9358-EPBKY03ENE RSBIZWARE EPROCEDURE BACKUP KEY 3 UNITS

Motion Control MPL-B520K-MJ22AA MOTOR,SERVO,10.7 NM,4000RPM,MULTI,460V,11.3KG

Motion Control 9101-0403 CONNECTOR KIT, MOTOR BRAKE, F/H, 90 DEG

GQPJ2D100S2P QUICKPANEL JR. COLOR 5" STN GE LABEL

IC646MRC700 Logic PC & View 700 Tag Runtime System

MTR-3T21-G-R-B-M-S MTR-Series Servo Motor, Resolver, Metric, 24 Brake, Seal

SNAP 10C5 PC Port is 9-pin male and port on CNC is 9-pin female. This is for Xo n/Xoff communications.

20BC056A3AYNAEC1 PowerFlex 700 AC Drive 56 A 30 kW 20B

20F11NE032AA0NNNNN PowerFlex 753 AC Packaged Drive

22-RFD180 PowerFlex EMC Filter

140CPU43412A Quantum CPU 486,2M用戶邏輯,2MB,1MB+

281D-F12Z-10C-CR ArmorStart Direct Online RVSG Starter

C200H-OA221 輸出單元, 8點(diǎn), 可控硅 1A 200VAC

PCI-1760 8ch繼電器輸出及8ch光隔DI卡，PCI總線

PCI-8513