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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(zhuǎn)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(nèi)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(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
　?、龠^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。
　　②諸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?qū)Υ蛴C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(guān)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。
　?、诰偷乜偩€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。
　　③地址標識的錯誤。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：
　　①為避免節(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(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(jié)，便于今后相關(guān)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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CBL-13-ED-20 Encoder Cable, MTR-1235, 13xx, 14xx & 1N Series Stepping Motors to IMC-D or S2K, 20 Ft.

IC600WD100 I/O Cable, 100 feet (30m)

IC800SKCPV100 Power Cable, S2K to 1-2.5kW S-Series Servo Motors, 10 Meters

OC647IFESGSRUNLMTM iFIX Optn: ESig & ERec Unl I/O Server (M4 Part)

20AD065A3AYNANG0 PowerFlex 70 AC Drive 65 A at 50 Hp 20A

20DC820A0ENNBNANE PowerFlex 700S AC Drive 820 A 450 kW 20D

20P21AD073RA0NNN PowerFlex 73 A DC Drive

2711-ND3CNM PanelView ND3CN MED Accessory

280-PWRM22G-M025 ArmorStart Three-Phase Power Media

34 FX-EEPROM-4 EEPROM存儲卡4K/步,適用FX2N 490.-

6AV6 545-0CC10 TP270-10 觸摸屏 10.4寸彩色顯示

GPIB-RS485/422

EC3-1544CLD3N

SHT-8B/PCI

NC-537-32

研域工控G41DM

SET 5132-B

XL-F130-20123

1492-SPM3B300 MCB Supplementary Protector 30 A

軟啟動器 3RW40261BB04

BC646EXI365 Solution Provider additional iSuite License

GC646TRT700 Proficy GlobalCare Complete for Server 700 I/O Runtime System

HMI-CAB-C100 CABLE SIMATIC TI TI545-1102

IC641GBE647 PCIM Driver Software

IC647IFCLNTCDVK iFIX iClient Development (M1 Kit Part)

IC660EBA023RR Thermocouple, 24/48Vdc Power, Electronic Assembly

IC695LRE001CA RX3i Local Serial Expansion Conbal Coated.

IC756WRE024K-97 DataViews Runtime for Windows 1-24, Per User, Korean, Version 9.7

FlexLogix System 1794-IA16 85-132V AC INPUT MODULE, 16 POINT

PLC-5/1771 System D1771-6.5.90 ANALOG INPUT MODULE USER MANUAL

Process Control 1757-PLXSIFA PLX AB INTEGRATION QUICKBUILDER INTERFACE

Operator Interface 2711P-T7C6B2 PV PLUS 700, TOUCH, RIO/DH, AC PS, EXT MEM

Support 9307-RSP32RENR SUPT REINSTATEMENT CONTRACT FOR 9307RSP32REN

Support GML-DMS SUPT RENEWAL CONTRACT FOR GMLDM

Support F1785-L26BSERA FIRMWARE UPGRADE FOR 1785-L26B PLC5 PROCESSOR MODU

RSI Software Products 9301-2SE2300ESE RSVIEW32 WORKS 1500 (SPANISH)

RSI Software Products 9701-VWSB250AFRE RSVIEW SE STATION 250 DISPLAY (FRENCH)

RSI Software Products 9399-INTVMSUG INTERCHANGE FOR OPEN VMS USER GUIDE

Motion Control 2098-IPD-075-DN DRIVE, 35A/75A, ULTRA5000, DEVICENET

BC646MBTS99 CIM Machine Edition Traditional Development Suite - Site Licenses w/1yr.SAFE

IC300DQM306 16 DC Outputs (5/12/24vdc, 0.5A pos logic with ESCP)

IC752PBI100 PC/104 Profibus Card for models 160/240E

MTR-3S65-G-R-0-E-SRR Servo Motor with Seal

ZA06B-6114-K220#E Motor power and brake power right angle connector for B2/4000is or B4/4000is motor

20C-316051-C01 MOV ASSY, 460V, 700A, 40J, M6 LUGS

20G1ABC750AN0NNNNN PowerFlex 755 AC Packaged Drive

25A-CTMFC1 PowerFlex 523 Control Module Front Cover

2711P-T15C22D9P PanelView Plus 7 Graphic Terminal

6SE6440-2UC13-7AA1 0.37KW

SC-N3 380VAC/65A 30KW 110V . 220V AC 2NO+2NC

UG221H-LR4 5.7寸 STN 單色 320*240 SRAM/時鐘

SCC-AI06

SEED-PCIDRV 7.820.014

PCI-3163

CERAVAC Transmitters CTR 100 / CTR 91

158637-0001

FSB-945G

1492-SPM1C030 MCB Supplementary Protector 3 A

通用型變頻器 6SE6 420-2UC25-5CA1 "5.5 KW，185 x 245 x 195"

20AC022F0AYNANC0 PowerFlex 70 AC Drive 22 A at 11 kW 20A

GC-8450-SW-CF CONFIG SW WITH CABLE

GPA-602-H LVDT Expansion Unit (Half Bridge), includes G-0602 connecting cable.

IC600CP625RR 19 inch Series Six Plus CPU 125Vdc Power Supply (11 Slots)

IC647HSTCSEO40KM eSignature Option for Historian - Enterprise Corporate Server 40000 Points (M4 Key)

IC647WFLCWSP Proficy Workflow - Cityworks Service Provider

IC694ALG222CA Conbal Coated Analog Voltage Input module 16 channels single ended/ 8channels differential

IC756RDV010K-97 DV Draw Development on IRIX Op Sys, Korean, Version 9.7

MicroLogix 1200 System 1762-OB16 16 POINT 24 VDC SOURCE OUTPUT MODULE

PLC-5/1771 System 1771-PD PID CONTROL MODULE, 2 LOOPS

Distributed I/O 1794-OB16P 24V DC SOURCE OUTPUT MODULE (PROTECTED), 16 POINT

Communications 9399-INTHPUG INTERCHANGE FOR HP-UX USERS GUIDE

Support

Support 9358-BIZ1C0PS SUPT RENEWAL CONTRACT FOR 9358BIZ1C0PENE

Support F1771-ASBSERB FIRMWARE UPGRADE FOR 1771-ASB I/O MODULE

RSI Software Products 9324-RL5300NXENE RSLGX 5/RSNTWRX STD. BUNDLE, ENU

RSI Software Products 9301-2SE350ESU4R RSVIEW32 RUNTIME 150-100K UPGRADE OUT-SUPT (ES)

RSI Software Products 9358-HSTS2350U3R UPGRADE: OUT-SUPT: HISTORIAN 1500 TO 5K TAG

Motion Control 0041-5074 TEFLON SHAFT SEAL KIT FOR USE ABOVE FOOD LINES

78004653 Target Empty Rack Assembly

IC200MDD846LT MIXED OUTPUT RELAY 2.0A PER PT ISOLATED 8PT / INPUT 120VAC GRP 8PT (LT)