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文章通過(guò)對(duì) DCS系統(tǒng)在火電廠運(yùn)行中常見(jiàn)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(lái)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(guò)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(jiàn)的故障
　　隨著工業(yè)生產(chǎn)自動(dòng)化的不斷興起、過(guò)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(guò)程中難免會(huì)出現(xiàn)故障。常見(jiàn)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(wèn)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(wú)輸出;四是有的系統(tǒng)整個(gè)機(jī)柜通過(guò)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(wú)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(jiàn)的故障部位為過(guò)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(guò)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(zhǎng)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(pán)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(zhǎng)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(guò)程通道的狀態(tài)，有三種可能：其一可能是過(guò)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(guò)多地打開(kāi)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(pán)工作不正常的原因有：鍵盤(pán)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(pán)，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�機(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(guò)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(kāi)機(jī)柜，并應(yīng)禁止在其附近使用大功率的無(wú)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(jiǎn)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
　　①節(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。
　　②就地總線故障。由于其連接的設(shè)備是與生產(chǎn)過(guò)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(guò)程。另外，總線本身也會(huì)因種種原因造成通信故障。
　　③地址標(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(lèi)故障的出現(xiàn)，必須做到以下幾點(diǎn)：
　　①為避免節(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。
　　②防就地總線故障的有效方法是，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。
　　③為避免地址標(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(yǔ)
　　DCS系統(tǒng)可以有效滿足電廠各系統(tǒng)控制的需要，通過(guò)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(wèn)題并作出準(zhǔn)確的判斷，采取正確的對(duì)策。
 

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20BD248A3ANNANC1 PowerFlex 700 AC Drive 20B

20G11RD014AA0NNNNN PowerFlex 755 AC Packaged Drive

25-FAN1-FC PowerFlex 520 Frame C Fan Kit

140XCP20000 Quantum I/O 模塊標(biāo)簽

FRN3.7F1S-4C 6.8KVA 9.0A 3.7 KW 3相AC380V/50Hz/60Hz

ZC-Q2255 觸點(diǎn):1開(kāi)/1閉,10A 250VAC機(jī)械壽命:1000萬(wàn)次?方式:下壓式

NSC400K3350 NSC400K 350A 3P

SCXI-1169

MG1500E

TRENT0N 92-005932-XXX

FSC-1811V2NA

ARK-6610

H3104A-NDNBD62

1492-RCDA4C40 Residual Current Device 40 A

6ES7153-2AR02-0XA0 IM153-2 冗余組，由 2 IM153-2 基本型和一個(gè) IM153/IM153 總線模板組成

2098-DSD-HV100X-DN Ultra 3000 Servo Drive

GA646PME100 GlobalCare Assist for PCM Machine Edition Version 100 User

GP-0602NT-F7 GagePort LVDT NT (Full Bridge for Marposs)

IC5002TBX0130 PanelPC 12 inch Performance Unit Deluxe with Windows XP and Stainless Steel Bezel

IC647HSTAE1KM Alarm and Events Option for Historian - Standard Server 1000 Points (M4 Key)

IC647SPM001 Scheduler Plus Module

IC693MDL732RR 12/24 Vdc Output, 05 Amp, Positive Logic (8 Points)

IC756HDV001K-97 DV Development - HP/UX Op Sys Addt'l User, Korean, Version 9.7

MSI-SDK-5 SDK Connections 5 Pack

PLC-5/1771 System 1771-IM INPUT MODULE, 220V/240V AC/DC, 8 INPUT

Distributed I/O 1791D-16B0 DNET 24 VDC COMPACTBLOCK I/O, 16 IN SINK, BASE

Communications 1784-PCM4 1784-PCMK DH485 COMMUNICATION CABLE (RJ45)

Operator Interface 2706-P43R INVIEW MESSAGE DISPLAY. 1 LINE, 20 CHARACTERS

Support 9305-RSVADSITS SUPT RENEWAL CONTRACT FOR 9305RSVADSIT

Support 9515-RSEOL074R SUPT REINSTATEMENT CONTRACT FOR 9515RSEOL074ENE

EtherNet/IP Products 2711-K10C20 PV1000 COLOR KEY, ENET & RS232 PRINT

RSI Software Products 9301-2SE3403PTE RSVIEW32 RUNTIME 32K WITH RSLINX (PORTUGUESE)

RSI Software Products 9356-PRO2200U1R UPGRADE: OUT-SUPT: RSSQL STD.150 TO PROF.300 TAG

Motion Control 1326AB-B720E-M2K7L MOTOR,SERVO,460V,30.9NM,3500RPM,MULTI,BRK,IP67

4161-6-24-N12 BCD TO 7 SEG DISPLAY. 6 DIGIT. 24 VDC. NEMA 12

HMI-CCT-301 BACKLIGHT TUBE 10.5" STN QPI3 Series (QPI-3xxxx-Sxx)

IC693CPU313 5-Slot Base With Turbo CPU in base (.6 msec), 1K Registers, (12K Bytes User Program)

SFW-CCSD-6-0.2 CCS for Windows Software v6.0 CD-ROM

TRM-21006676 IMC controller I/O connector

20BD-DB1-2 PowerFlex 700 Dynamic Brake Resistor Kit

20F1ANF212AN0NNNNN PowerFlex 753 AC Packaged Drive

22B-E6P6C104 PowerFlex 40 4 kW (5 Hp) AC Drive

140EHC10500 Quantum 高速計(jì)數(shù)模塊, 35kHz@5 VDC, 5通道

284G-FVD2P3D-10-RRG-CBG-DB1-EMI ArmorStart 284 Controller

E2K-C25ME1 25mm,電容式,三線,常開(kāi) 200mA NPN電源:10-30VDC圓M34

1746-IB16 24VDC 16點(diǎn)輸入模塊 匯流

PXI-6225

IPC-6114P12

MDP3MP-P00-OE5F

4BW00166C1X10

A-822PGH/A-822PGL

IMBA-H61A

1492-MS5X9 IEC 5 x 9 mm Marker Card

1495-N67 Protective Fuse Cover

行程開(kāi)關(guān) 3SE53120SG11

CP6B-0WEB-0070-AZ Shielded motor power cable for B22is motor (straight connector). 7 meters

GF-AB.01V Connecting FlashCable to Analog Bipolar +/-.01 V (No connector).

IC200UEX012-24 Qty of 24, 14 point expansion. (8) 24VDC In, (6) Relay Out, 24VDC Pow er Supply (includes IC200CBL501)

IC647ADMM "ADM:Azonix uMAC 1050, 1060, 6000"

IC647PCM010 Proficy Change Management Server - 10 Concurrent Users

IC693CBL328 Cable, Right Side, One - 24 Pin 90 Degree Connector, 3 Meter

IC754BEZ06GAS Replacement Gasket for 6-In SSteel Bezel

IMC-31CE-2-MODRR IMC-D Series Servo Motor Controller, Enhanced, 12 Amp

SLC/1746 System 9399-RL50GRPT RSLOGIX 500 GETTING RESULTS GUIDE (PORTUGUESE)

Distributed I/O

Application-specific products 1404-M805A-RIO-02 MASTER MODULE-PQ RIO COM-120/240V P/S-CLASS0.2

Operator Interface 2711-K10G8L1 PV1000 GRAYSCALE KEY, DH+ & RS232 PRINT

Support 9301-2SE3350S SUPT RENEWAL CONTRACT FOR 93012SE3350

Support 9381-P500ENR SUPT REINSTATEMENT CONTRACT FOR 9381P500EN

DeviceNet Products 1790-7CMCBL LDX I/O REPLACEMENT RIBBON CABLE, 7CM (LOTS OF 5)

RSI Software Products 9301-2SE3300PTE RSVIEW32 RUNTIME 1500 (PORTUGUESE)

RSI Software Products 9358-EPBKY01ENE RSBIZWARE EPROCEDURE BACKUP KEY 1 UNIT

Motion Control MPL-B4540F-SK24AA MOTOR,SERVO,10.2NM,3000RPM,SINGL,460V,BRK

Motion Control 9101-0402 CONNECTOR KIT, MOTOR ENCODER, F/H, 90 DEG

GQPJ2D100L2P/S QUICKPANEL JR. MONO 5" WITH ADHESIVE GE LABEL

IC646MRC300 Logic PC & View 300 Tag Runtime System

MTR-3T21-G-R-0-M-S MTR-Series Servo Motor, Resolver, Metric, Seal

SFW-TGTP-1.22 Target series flash memory card version 1.22

20BC056A3AYNAEC0 PowerFlex 700 AC Drive 56 A 30 kW 20B

20F11NE022AA0NNNNN PowerFlex 753 AC Packaged Drive

22-RFD100 PowerFlex EMC Filter

140CPU31110 Quantum Unity Quantum 31110 CPU

281D-F12Z-10B-CRW ArmorStart Direct Online RVSG Starter

C200H-OD211 輸出單元,12點(diǎn), 晶體管 0.3A 12-48VDC

PCI-1761 8ch隔離數(shù)字量輸入，8ch繼電器輸出

PCI-8512

HiCORE-i6420

IPC-6108P3(B)

LWT-50H-522

PCN-6351

PCM-9579

1492-LS2-3 IEC Sensor Blck 5.1x68x38.5mm Sprng Clip

1494G-EF3J6 NEMA 1494G Enclosed Disconnect

軟啟動(dòng)器 3RW44432BC45

BC647SPK5M4 Solution Provider 5-pack M4 Keys includes 5 physcial M4 keys

GC647PPSOCC Global Care for Proficy Process Systems Operator Console with CIMPLICITY

IC200MDL640 Input 24VDC POS/NEG logic (2 groups of 8) 16 points

IC646PCM025 Proficy Change Management 25 user pack

IC647MPP005 Logic Developer PLC Professional 5 Pack with USB Hardware key

IC676CBLPWF050 IP67 Power Cordset - 5 Meters - Female Connector w/Leads

IC697PCM712RR VME Programmable Coprocessor

IC800SSI107P2RR 7.2A, 115/230V, Profibus S2K Servo Controller for S-Series Motors

SLC/1746 System

Industrial Computers 6189-RDK7C VVCE 700, KEYPAD DISPLAY MODULE

Process Control 9399-RSBREUG RSBATCH RECIPE EDITOR USER'S GUIDE

Operator Interface 2711-B5A20L1 PV550 MONO KEY&TOUCH, ENET & RS232 PRINT

Support 9303-3CS0E01UR DRIVEPANEL TO DRIVEPANEL32 UPGRADE:OUT-OF-SUPPORT

Support 9371-EWLI3S SUPT RENEWAL CONTRACT FOR 9371EWLI3

ControlNet Products 2706-P44C INVIEW MESSAGE DISPLAY. 1 OR 2 LINE

RSI Software Products 9301-2SE2500FRU5 RSVIEW32 WORKS 5K-100K UPGRADE IN-SUPT (FR)

RSI Software Products 9358-BBBKY10ENE RSBIZWARE BATCH, EPRO BUNDLE BACKUP KEY 10 UNITS

Motion Control MPL-A4530F-SK22AA MOTOR,SERVO,8.36 NM,2800RPM,SINGL,230V,8.2KG

Motion Control 2090-UXNPBMP-8S09 CABLE, 460V,NON-FLEX,MOTOR POWER,MP,8 GAUGE,9M

CBL-3T-MP-10 Power Cable, MTR-3T4x, MTR-3T5x & MTR-3T6x Series Servo Motors, 10 Ft.

IC641CTL992 Distributor Demonstration Kit

IC800SLM250M2XE25 2500W, 230 VAC SL Servo Motor, Holding Brake, 2.5K Quad Encoder

OC647TSSINSQL000 Proficy Troubleshooter Connector: InSQL Source

20AE0P9A0AYNNNC0 PowerFlex 70 AC Drive 20A

20DD156A0ENNANANE PowerFlex 700S AC Drive 20D

20P41AE1K3RA0NNN PowerFlex 575V AC 1000 HP DC Drive

2711P-B4C20A8 PanelView Plus 6 Graphic Terminal

280-PWRM35A-M2 ArmorConnect 2 Meter M35 Patchcord

CPM1A-20CDT-D-V1 20點(diǎn)主機(jī) DC24V 12點(diǎn)入，8 點(diǎn)晶體管輸出.漏型

3VU1340-0NH00 2~3.2A

NI 9375

IEI SAGP-865EV

Agilent E6473B E6473-60008

DSXFX/INT Y7131-02

EC4-1811LD2NA

ASI-10M

1492-J35-B IEC 1-CKT FEED-THROUGH BLK