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文章通過對 DCS系統(tǒng)在火電廠運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)的運行和操作人員在實際工作中應用提供借鑒。
　　作為火電廠安全經(jīng)濟運行主導因素的熱控自動化設備DCS系統(tǒng)，近年來得到了普遍應用，為火電廠機組安全、穩(wěn)定的運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)，導致了發(fā)電機組的非計劃停運，給發(fā)電企業(yè)造成不應有的損失。
　　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雜，一種綜合控制系統(tǒng)――DCS系統(tǒng)應用而生了。由于目前各火電廠對DCS系統(tǒng)的應用水平的限制，系統(tǒng)在運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)會停止運行，而且還會導致機組的跳閘，造成非計劃停運。
　　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，但在轉換時也會出現(xiàn)瞬間失電，導致機組跳閘;二是保險配置不合理及DPU電源內部故障等造成電源中斷，導致系統(tǒng)運行的停止;三是穩(wěn)壓電源波動引起保護誤動及接插頭接觸不良導致穩(wěn)壓電源無輸出;四是有的系統(tǒng)整個機柜通過一路保險供所有輸入信號或一路電源外接負載很大，導致模件的損壞;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致部分I/O模件與主機的通信中斷，在這種情況下，系統(tǒng)會馬上做出反應，出現(xiàn)報警;第三個方面是外界強電信號竄入形成干擾而導致通道故障的發(fā)生。
　?、谥T如球標和控制操作出現(xiàn)失靈和實效以及操作員站出現(xiàn)死機、鍵盤和打印機出現(xiàn)工作不正常的現(xiàn)象都屬于人機接口故障。
　　球標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，致使觸點不能實現(xiàn)自行通斷，也或是電纜插頭接觸不良造成與主機的通信斷路。
　　控制操作實效的主要原因是因球標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;其三是設備超負荷或者過多地打開窗口，導致不響應。
　　操作員站死機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時誤動了鍵盤，造成啟動缺失。
　　打印機出現(xiàn)工作不正常的原因：或者是配置不合理，或者是因對打印機實施屏蔽而造成的。
　1.2.2硬件(模件)故障應采取的防范措施：
　　在DCS系統(tǒng)的運行過程中，為了減少硬件(模件)故障的發(fā)生，需要注意以下幾點：嚴格按照相關標準和規(guī)定為硬件提供良好的運行環(huán)境;主機和從機的DPU不得隨意進行人為切換;接地要良好;避免靜電感應;在工作狀態(tài)下，不應隨意打開機柜，并應禁止在其附近使用大功率的無線設備，諸如禁打手機和禁止使用對講機;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)絡系統(tǒng)故障
　　通信網(wǎng)絡是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)點總線和就地總線，也可能是因為地標錯誤所造成。
　　1.4.1通信網(wǎng)絡系統(tǒng)發(fā)生故障的主要原因
　?、俟?jié)點總線故障。當總線的干線任一處中斷時，都會導致該總線上所有站及其子設備通信故障。
　　②就地總線故障。由于其連接的設備是與生產(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。
　?、鄣刂窐俗R的錯誤。不論是就地組件還是總線接口，一旦其地址標識錯誤，必然造成通信網(wǎng)絡的紊亂。
　　1.4.2通信網(wǎng)絡系統(tǒng)故障應采取的防范措施
　　要防止通信網(wǎng)絡類故障的出現(xiàn)，必須做到以下幾點：
　?、贋楸苊夤?jié)點總線故障的發(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備的聯(lián)接點進行妥善處理，拆裝設備時，不得影響總線的正常運行，總線分支應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。
　?、蹫楸苊獾刂窐俗R的錯誤的發(fā)生，主要是要防止人為的誤動、誤改。
　　2、結語
　　DCS系統(tǒng)可以有效滿足電廠各系統(tǒng)控制的需要，通過對實際應用中不斷暴露出的一些主要故障的分析，及時加以總結，便于今后相關儀控維護人員及時發(fā)現(xiàn)問題并作出準確的判斷，采取正確的對策。
 

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PWS-1K41P-1R

TLA7334-02

IPM-8540D

1492-PBC9 Power Distribution Block Accessory

中央機架 6ES7400-2JA00-0AA0 UR2-H 機架用于分段的中央機架，18 槽

2097-F1 Kinetix 300/350 24.0 A Line EMI Filter

EDS-308-S-SC-T C1 D2 7-port 10/100, 1 port single-mode SC fiber (-40 to 75 deg C op temp)

GFK-1464 DSM302 Motion Controller for Series 90-30 User's Manual

IC220ACC105 MOTOR CIRCUIT CONNECTOR-QTY 10

IC647BWI255 Batch Opt: WorkInstruction Large Server Pak (255 Units)

IC647PRTORAC Proficy Portal Oracle Connector (M1 Key)

IC693DNS201 DeviceNet Slave Module

IC756ADV001J-98 DV Development - AIX Op Sys Addt'l User, Japanese, Version 9.8

MSI-ELECTRONICSIG-43 Electronic Signature-43 25% of total package price

SLC/1746 System 1746-RT32 REPLACEMENT TERMINAL BLOCK

Distributed I/O 1738-OB2EPM12 24VDC 2 SOURCING OUTPUTS WITH M12 CONNECTORS

Communications 1784-CP10 CABLE ASSY, 10FT/3.20M, IBM AT OR COMPATIBLE CMPTR

Operator Interface 2711-NMCE MEMORY CARD RETAINER PV300, PV600 TOUCH

Support 9302-RTR SUPT REINSTATEMENT CONTRACT FOR 9302RT

Support 9324-RL5300FRR SUPT REINSTATEMENT CONTRACT FOR 9324RL5300FR

DeviceNet Products 2706-P43C INVIEW MESSAGE DISPLAY. 1 LINE, 20 CHARACTERS

RSI Software Products 9301-2SE3353ZHE RSVIEW32 RUNTIME 5K WITH RSLINX (CHINESE)

RSI Software Products 9326-AD5USENE RSAUTOMATION DESKTOP 5 USER W/ SQL SERVER

Motion Control MPG-A010-091S22 MOTOR,SERVO,GEAR RATIO 91,35NM,65RPM,SINGL,230V

Silver Series 1785-V40B VME PLC-5/40 CONTROLLER, 48K WORD SRAM

HE693PBS106 Profibus DP slave module

IC660BRD020 Genius 24/48Vdc Source Block for Redundancy "T" Output Configurations

QPI-ABR-201 MODULE AB REMOTE I/O

ST-5231 STXi Serial Interface module RS-485, 1 Channel

20BC1P3A3AYNAEC0 PowerFlex 700 AC Drive 20B

20F1AGF212JN0NNNNN PowerFlex 753 AC Packaged Drive

22B-A5P0F104 PowerFlex 40 0.75 kW (1 Hp) AC Drive

140DDI35310C Quantum 開關量DC輸入32點24V,4組隔離,負邏輯,CC

284D-FVD4P0B-10-RR-3-DB-SB-EMI DeviceNet Variable Frequency Drive

E3JM-DS70M4T 70cm,擴散反射式,觸點輸出3A帶ON/OFF延時?電源同上

ADAM-5000/485 基于RS-485的分布式數(shù)據(jù)采集控制系統(tǒng)

PXI-2544

W26361-W10-Z2-02-36

Hivertec HPCI-CPD534A

PCI-1756

FI-RBXAT-PEL02Z/4 FI-RBXAT-PEL02/3

PCI-9016

1492-MCAA220 20 A UL489 Miniature Circuit Breaker

1494U-LA36 1494U 30A-60A Aluminum Lugs

軟啟動器 3RW44552BC45

CBL-30-BT-10 Brake cable for MTR-3S or MTR-3N series servo motors with brake. 10 feet

GF-0200/MTI Connecting FlashCable to Chicago Dial Indicator Logic Series, Zipper c ompatible.

IC200TBX140 Tool box, Micro 40 and software. Includes (IC200UDR140) 24VDC In/Relay Out, requires 120/240VAC power, (IC200USB001) RS-232 option board with (2) 0 -10VDC analog in with Proficy software, manuals and cables (IC646MPM101)

IC646TBSPMPS400 Smart Process Monitoring Process+ server 400 loops

IC647NSE000 CIMPLICITY HMI SMARTEYE Driver

IC693ACC330 Base is discontiued. Use generic TBQC base IC693ACC329.

IC752BUU000 WinCfg & DataPanel Software Upgrade

IC800VMCP100 Power cable for 100 W to 750 W VersaMotion servo motors- 10 meter

SLC/1746 System 1746-OW16 RELAY OUTPUT MODULE FOR PROGRAMMABLE CONTROLLER

Industrial Computers 6189V-35HDD 3.5" HARD DISK DRIVE STANDARD

Application-specific products 1400-PD51A POWERMONITOR DISPLAY MODULE

Operator Interface 2711-B6C20L1 PV600 COLOR KEY&TOUCH, ENET & RS232 PRINT

Support 9301-2SE2400DER SUPT REINSTATEMENT CONTRACT FOR 93012SE2400DE

Support 9307-EM83PXS SUPT RENEWAL CONTRACT FOR 9307EM83PXENE

DeviceNet Products 1734D-IB8XOW8S 24 VDC 8 SINK IN 8 RELAY OUT, DNET COMMS, SPRING

RSI Software Products 9301-2SE250PTU5R RSVIEW32 WORKS 5K-100K UPGRADE OUT-SUPT (PT)

RSI Software Products 9358-BNT60U2 UPGRADE: IN-SUPT: RSBATCH 10 TO 60

Motion Control MPL-B330P-MK22AA MOTOR,SERVO,4.18 NM,5000RPM,MULTI,460V

Motion Control 2090-U3BB2-DM44 BREAKOUT BOARD, CN1, ULTRA3000 DRIVE MOUNTED

GFK-0646 C Programmer's Toolkit for Series 90-70 User's Manual

IC646CCW000 CIMPLICITY Client for Microsoft Windows

MSCPX-21280698 Marathon Exp CPU - 333 MHz AMD CPU, 128M, 6G, Win98, 2 ISA and 2 PCI/ISA expansion slots

PSPC-DC50-220L Prof Shop Floor SPC DC 50 User 220v

20BC015A0AYYANC0 PowerFlex 700 AC Drive 20B

20F11FC043JA0NNNNN PowerFlex 753 AC Packaged Drive

2198-KITCON-DSL CONNECTOR KIT, K5500, DSL

2711P-RBK10 PanelView Plus Accessory

280-PWRM35H-M35 ArmorConnect 3-PH Power Media trnk cable

CQM1-ID214 輸入32點. 24V DC

IPC-610P/250-14 PC總線工控機箱，9-ISA/1-CPU/4-PCI槽底板，帶250瓦電源?。4U高度

PCI-6035E

Am5X86-P75-S

IPC-610H PCA-6006

ASUS華碩P5E64