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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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Motion Control 2090-UXNPBMP-8S15 CABLE,460V,NON-FLEX,MOTOR POWER,MP,8 GAUGE,15M

CBL-3T-MP-20 Power Cable, MTR-3T4x, MTR-3T5x & MTR-3T6x Series Servo Motors, 20 Ft.`

IC641CTL993 OEM Evaluation Kit

IC800SLM350M2KE25 3500W, 230 VAC SL Servo Motor, 2.5K Quad Encoder

OC647TSSNET000 Proficy Troubleshooter Connector: .NET Wrapper Read & Write

20AE1P7A0AYNNNC0 PowerFlex 70 AC Drive 1.7 A at 1 Hp 20A

20DD156A0EYNANANE PowerFlex 700S AC Drive 20D

20P41AE1K6RA0NNN PowerFlex DC Drive 1688 A

2711P-B4C20D8 PanelView Plus 6 Graphic Terminal

280-PWRM35A-M20 3 Phase Power Media Patchcord M35 20M

CPM1A-30CDR-A-V1 30點(diǎn)主機(jī) AC100-220V 18點(diǎn)入，12點(diǎn)繼電器輸出

3VU1340-0MJ00 2.4~4A

NI 9381

PSC-586

ADAM-4068

AOM-TPM-9655V

NORCO-730V

DMC5410 DMC3410

1492-J35-Y IEC 1-Ckt Feed-Through Blk 35mm

1492-SPM3D130 MCB Supplementary Protector 13 A

軟啟動(dòng)器 3RW40381TB05

BC646MSS101 Logic Developer State Standard with Programming Cable with Proficy GlobalCare Complete

GC647AUR001 GC PA Universal Reporting Client

IC200ACC402 VersaMax Micro 14, 20, 23 and 28 spare Removable Terminal Strips, 10 per pack

IC646CSPC050 Proficy Cause+ for Intelligent HMI/SCADA Client Enabler - 50X CALs

IC647IFPLRNUNLMTK iFIX Plus SCADA Unlimited Runtime (M1 Kit Part)

IC660MLA100 Label for IC660BBA100 (Qty 100)

IC697ALG440 Analog Input Expander, Current, 16 Channels

IC758WMM005 iGlobalCare Complete 1-5 Users (same site): DataViews for Windows

FlexLogix System 1794-PS3 120/230VAC TO 24VDC @3A

GuardPLC Systems 1755-IF8 GUARDPLC 2000 - ANALOG INPUT MODULE

Process Control 1757-UPGSIFV UPGRADE ASEA CONTROLLER QUICKBUILDER INTERFACE

Operator Interface 2711P-T12C4D2 PV PLUS 1250, TOUCH, RIO/DH, DC PS, EXT MEM

Support 9220-TAR SUPT REINSTATEMENT CONTRACT FOR 9220TA

Support 2755-ASNFRS SUPT RENEWAL CONTRACT FOR 2755ASNF

Support F1785-LTSERB FIRMWARE UPGRADE FOR 1785-LT PLC5 PROCESSOR MODULE

RSI Software Products 9301-2SE2350JPU2 RSVIEW32 WORKS 300-5K UPGRADE IN-SUPT (JP)

RSI Software Products 9701-VWSTFRU1 RSVIEW STUDIO FOR ME - ENT SERIES UPGRADE (FRENCH)

RSI Software Products 9399-WAB32UGPT RSLINX USERS GUIDE (PORTUGUESE)

Motion Control 8720MC -D180-AA- 180 AMP D CHASSIS DRIVE, ENCLOSURE, LESS OPTIONS

BC646MRB150 Logic PC Runtime 150 I/O

IC300OSW001 Cscape PDA Software with Handspring Visor/Visor Deluxe/Prism Cable

IC754ACC12GAS Gasket for 12 QuickPanel View & Control"

MTR-3T45-H-R-B-M-0 MTR series metric servo motor with resolver and brake

20AC8P7A3AYNAEC0 PowerFlex 70 AC Drive 8.7 A at 4 kW 20A

20DC022A0EYNANANE PowerFlex 700S AC Drive 20D

20G1ALF460AN2NNNNN PowerFlex 755 AC Packaged Drive

25B-D2P3N114 PowerFlex 525 0.75kW (1Hp) AC Drive

2715-T10CD PanelView 5500 10.4 in. Graphic Terminal

FR-A740-5.5K 9.1 KVA 12A 5.5KW

CTT120/480-0 120A 耐壓480V

cDAQ-9179

EPIA-PX10000G

PCL-849

EPE-1815VNA-H61

SKYNET ADT-925C

PCA-6002VE

Q965 18204010

1492-SPM1D500 MCB Supplementary Protector 50 A

變頻器選件 6SE6 400-0BE00-0AA0 BOP2 操作面板 430

20AC2P1C0AYNANC0 PowerFlex 70 AC Drive 20A

GC646MPM001 Proficy GlobalCare Complete for Logic Developer - PLC Nano/Micro

HE693OIU177 Compact VF OIU powered by 24VDC with Numeric Keypad

IC609SJR121RR Series One Junior 24Vdc Src In/Rly Out, 115Vac Power

IC647HSTSC150KM Server to Server Collector for Historian - Standard Server 150000 Points (M4 Key)

IC660BBA026 Block 24/48Vdc Analog Current Source 6 Inputs

IC694MDL741 Output module 12/24 VDC 0.5 amps 16 points, negative logic.

IC756WDJ009E-22 DV Development Sys VB and Java, English, Version 2.2

MicroLogix 1500/1769 System 1769-ECL LEFT END CAP/TERMINATOR

PLC-5/1771 System 1771-CD 1771I/O CHASSIS CABLE FOR 177-P2 POWER SUPPLY

Distributed I/O 1797-OE8H EX HART ANALOG OUTPUT MODULE, 13 BIT, 8PT., S.E.

Operator Interface 2711P-B6C1A PV PLUS 600 COLOR, KEY/TOUCH, SRIO, AC PS

Support 9323-PA1FS SUPT RENEWAL CONTRACT FOR 9323PA1F

Support 9358-HSTS2400R SUPT REINSTATEMENT CONTRACT FOR 9358HSTS2400

Support F1772-LWSERC FIRMWARE UPGRADE FOR 1772-LW PLC2 PROCESSOR MODULE

RSI Software Products 9324-RLD3U7DEE RSLOGIX 5000 STD. TO PRO UPGRADE, GERMAN

RSI Software Products 9305-ADSGWENE RSVIEW32 ACTIVE DISPLAY SERVER WITH RSLINX GATEWAY

RSI Software Products 9358-PLTMCLTENE RSBIZ PLNTMET RED ONLY CL

Motion Control 2092-DA1 DRIVE, 1.4A/3.4A, ULTRA1500 DIGITAL SERVO DRIVE

A06B-0128-B675#7076 A6/3000 Servo Motor, IP67 Sealing, Holding Brake, 64K Serial Encoder

IC200UAR028 28 point PLC,(16) 120VAC In, (12) Relay Out (2 at 10 amp and 10 at 2 amp) 120V/240AC Power Supply. Battery (IC200ACC403) is required for data retention. Battery not included.

IC752BTS450 Display Station 1085 - 10.4" active matrix VGA (640x480) resistive touch screen with integrated keypad, Pentium 133, 32MB, 2 Gig hard drive, expansion slots, Ethernet, with CIMPLICITY HMI and Win NT

MTR-1362-E-A-E-SRR Stepping Motor Nema34 Encoder Splashproof

ZA06B-0113-B075#7008 B0.5/3000 servo motor with 32k serial encoder

20BD3P4A0AYNANC0 PowerFlex 700 AC Drive 3.4 A at 2 Hp 20B

20G11TC770JN0NNNNN PowerFlex 755 AC Packaged Drive

25-PM1-B011 PowerFlex 520 2.2kW (3Hp) Power Module

990XTS00300 Quantum B200 轉(zhuǎn)換接頭

FRN 2. 2E1S-4C 4. 1KVA 5.5A 2.2KW 3相AC380V/50Hz/60Hz

61F-G2 自動(dòng)供水和排水控制，水位異常高報(bào)警 電源:110/220VAC

ATV-31HU30M3XA 3

USB-232/4

PCI-7432

ARCNET PCI20-CXB

INTEK PLUS V3.3

PCI-9111

DAQ-PCI64C

1492-RIFM20F-2 Connection Products

總線插頭 6GK1500-0FC00 RS485 總線插頭， 12MBd180? ，連接 OP 及 OLM

2099-BM10-S Kinetix 7000 Servo Drive

GA647IFESGCLNTCRN GCA iFIX Optn: ESig & ERec iClient Run

GP-2102NT/FOWSB GagePort Digital NT 2-port input (Fowler OEM) - Sales BOM.

IC5007TAX0030 PanelPC 17 inch Standard Unit Deluxe with Windows XP

IC647HSTAE75KM Alarm and Events Option for Historian - Standard Server 75000 Points (M4 Key)

IC647SSM005 Scheduler Shop Floor Server 5 users

IC693MDL742 12/24 Vdc Output, 1 Amp, Positive Logic (16 Points), Fused

IC756LDV000E-925 "DataViews Development on Intel Linux/Red Hat Op Sys, English v9.25"

Pico Controllers 1760-IA12XOW6I 18 I/O EXPANSION MODULE, AC

PLC-5/1771 System 1771-OAN OUTPUT MODULE, 120V AC, 32 OUTPUTS

Distributed I/O 1791P-16B0 PROFIBUS 24VDC CBLOCK I/O, 16 IN SINKING, BASE

Communications 2760-RB FLEXIBLE INTERFACE MODULE, 2-SLOT, 1771 I/O RACK

Operator Interface 2706-PDH485P DH-485 COMMUNICATION MODULE FOR 2706-P22R

Support 9701-VWSB000AR SUPT REINSTATEMENT CONTRACT FOR 9701VWSB000AENE

Support 9515-RSNHS250S SUPT RENEWAL CONTRACT FOR 9515RSNHS250ENE

EtherNet/IP Products 2711P-K7C4B2 PV PLUS 700, KEYPAD, ENET, AC PS, EXT MEM

RSI Software Products 9301-2SE340ITU2R RSVIEW32 RUNTIME 300-32K UPGRADE OUT-SUPT (IT)

RSI Software Products 9356-PRO2300U6R UPGRADE: OUT-SUPT: RSSQL PROF.300 TO 1500 TAG

Motion Control 1326AB-B740C-S2L MOTOR,SERVO,460V,53.0NM,2200RPM,SINGL,IP67

4162-L-6 4162 CONTINUOUS LENS KIT. FOR (6) 4162s

HMI-KPN-302 QUICKPANEL KEYPAD FOR 10.5"

IC693CPU360RR CPU 360 Module (240K Bytes configurable user memory, 4K I/O, 8 racks), no built-in Serial Ports

SPS-24W-2 24 VDC PS, 1.0A, 85-265 VAC INPUT

TRM-JAUX-10 S2K auxiliary I/O screw terminal breakout board with 10 foot cable

20BD014A0AYNAND0 PowerFlex 700 AC Drive 14 A at 10 Hp 20B

20G11BD1K2AN0NNNNN PowerFlex 755 AC Packaged Drive

22C-B012N103 PowerFlex 400- 2.2 kW (3 HP) AC Drive

140XBP00400C Quantum 背板, 4槽, CC