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LR03565,

LR03565

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文章通过对 DCS系统在火电厂运行中常见的故障及发生故障原因的分析，有针对性地提出了故障出现时的处理措施，可为火电厂在DCS系统的运行和操作人员在实际工作中应用提供借鉴。
　　作为火电厂安全经济运行主导因素的热控自动化设备DCS系统，近年来得到了普遍应用，为火电厂机组安全、稳定的运行起到了积极的作用。但是，DCS系统的安全性和可靠性还有待提高，在运行过程中经常会出现这样或那样的故障，这些故障的出现，导致了发电机组的非计划停运，给发电企业造成不应有的损失。
　　1、DCS系统常见的故障
　　随着工业生产自动化的不断兴起、过程控制要求的日益复杂，一种综合控制系统――DCS系统应用而生了。由于目前各火电厂对DCS系统的应用水平的限制，系统在运行过程中难免会出现故障。常见的DCS系统故障有：电源系统故障、硬件(模件)故障、系统软件故障和通信网络系统故障。
　　1.1电源系统故障
　　电源故障是DCS系统的致命故障，一旦电源出现故障，不仅整个系统会停止运行，而且还会导致机组的跳闸，造成非计划停运。
　　1.1.1电源系统出现故障的主要原因
　　电源方面的问题比较多，一是备用电源不能自投，虽采用UPS和APS双路互为备用的供电方式，但在转换时也会出现瞬间失电，导致机组跳闸;二是保险配置不合理及DPU电源内部故障等造成电源中断，导致系统运行的停止;三是稳压电源波动引起保护误动及接插头接触不良导致稳压电源无输出;四是有的系统整个机柜通过一路保险供所有输入信号或一路电源外接负载很大，导致模件的损坏;五是系统电源未采用UPS供电，冗余备用就更无从谈起。
　　1.1.2电源系统故障应采取的防范措施
　　要保证DCS系统的安全、稳定，首先要具备合理的电源布置，其次要选用高质量的电源模块，并要保证较高的冗余率。再次是注意观察电源的输出电压，防止出现波动。第四是对电源实行寿命管理，该更换的时候必须更换，绝对不允许等到电源出现了故障的时候才更换。
　　1.2硬件(模件)故障
　　DCS系统的硬件(模件)卡件可分为处理器模件、I/O模件及通讯模件三大部分，这三大模件的功能各自不同，常见的故障部位为过程通道和人机接口。
　　1.2.1硬件(模件)出现故障的主要原因
　　①过程通道故障也就是I/O卡件故障。引起I/O卡件发生故障的第一方面的原因是卡件因长时间工作而出现老化和损坏，这种工作的发生，一般是隐藏性的，只有参数出现异常，系统才会报警;第二个方面是连接线松动导致部分I/O模件与主机的通信中断，在这种情况下，系统会马上做出反应，出现报警;第三个方面是外界强电信号窜入形成干扰而导致通道故障的发生。
　　②诸如球标和控制操作出现失灵和实效以及操作员站出现死机、键盘和打印机出现工作不正常的现象都属于人机接口故障。
　　球标操作失灵的原因有装置因长时间工作发生老化或者被浮尘或油腻污染，致使触点不能实现自行通断，也或是电缆插头接触不良造成与主机的通信断路。
　　控制操作实效的主要原因是因球标的操作信号不能改变过程通道的状态，有三种可能：其一可能是过程通道硬件发生故障;其二可能是操作员站所用软件的缺陷;其三是设备超负荷或者过多地打开窗口，导致不响应。
　　操作员站死机的原因基本与控制操作失效的原因相同。
　　键盘工作不正常的原因有：键盘组态出现错误、接触不良、连接电缆松动或者在启动主机时误动了键盘，造成启动缺失。
　　打印机出现工作不正常的原因：或者是配置不合理，或者是因对打印机实施屏蔽而造成的。
　1.2.2硬件(模件)故障应采取的防范措施：
　　在DCS系统的运行过程中，为了减少硬件(模件)故障的发生，需要注意以下几点：严格按照相关标准和规定为硬件提供良好的运行环境;主机和从机的DPU不得随意进行人为切换;接地要良好;避免静电感应;在工作状态下，不应随意打开机柜，并应禁止在其附近使用大功率的无线设备，诸如禁打手机和禁止使用对讲机;保持工作电压的稳定;对于重要的硬件(模件)要由足够的冗余配置。
　　1.3软件故障
　　1.3.1软件发生故障的主要原因
　　一般情况下，软件故障发生的原因很单纯，软件本身的不完善是故障的主因。
　　1.3.2软件故障应采取的防范措施
　　由于软件故障的原因单纯，那么，防范软件故障的方法也很简单，那就是使用正版软件，但切记要及时升级。
　　1.4通信网络系统故障
　　通信网络是DCS系统与生产一线连接的纽带，其故障一般发生在节点总线和就地总线，也可能是因为地标错误所造成。
　　1.4.1通信网络系统发生故障的主要原因
　　①节点总线故障。当总线的干线任一处中断时，都会导致该总线上所有站及其子设备通信故障。
　　②就地总线故障。由于其连接的设备是与生产过程直接发生联系的一次元件或控制设备，所以工作环境恶劣，故障率高，容易受到检修人员的误动而影响生产过程。另外，总线本身也会因种种原因造成通信故障。
　　③地址标识的错误。不论是就地组件还是总线接口，一旦其地址标识错误，必然造成通信网络的紊乱。
　　1.4.2通信网络系统故障应采取的防范措施
　　要防止通信网络类故障的出现，必须做到以下几点：
　　①为避免节点总线故障的发生，最有效的方法是采用双路冗余配置的方式，避免因一路总线发生故障而影响全局。
　　②防就地总线故障的有效方法是，要将就地总线与就地设备的联接点进行妥善处理，拆装设备时，不得影响总线的正常运行，总线分支应安装在不易碰触的地方。同时，就地总线最好是采用双路冗余配置，以提高通信的可靠性。
　　③为避免地址标识的错误的发生，主要是要防止人为的误动、误改。
　　2、结语
　　DCS系统可以有效满足电厂各系统控制的需要，通过对实际应用中不断暴露出的一些主要故障的分析，及时加以总结，便于今后相关仪控维护人员及时发现问题并作出准确的判断，采取正确的对策。
 

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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电缆,500'

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

PYF08A-E 导轨安装型，MY2J，MY2NJ

1756-IM16I 220VAC 16点输入模块（每路单独隔离）

PXIe-5160

PCL-832

SOM-4486

DC2405M

PEAK 600VL

IBM X3250M3

1492-PD3C263 350 A Power Distribution Block

中央处理单元 6ES7414-4HJ04-0AB0 CPU414-4H,1.4MB RAM，60ns，电源 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 Intelligent 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 input module for Series 90-30 with 16-bit resolution and weighing functions.

IC670CHS002 I/O Base, Box Style