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[转帖]DCS典型故障原因分析与防范对策

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绚烂之星 发表于 2008-6-19 15:54:27 | 只看该作者 回帖奖励 |倒序浏览 |阅读模式
<table class="MsoNormalTable" cellspacing="0" cellpadding="0" width="100%" border="0" style="WIDTH: 100%; mso-cellspacing: 0cm; mso-padding-alt: 0cm 0cm 0cm 0cm;"><tbody><tr style="HEIGHT: 22.5pt; mso-yfti-irow: 1;"><td style="ADDING-RIGHT: 0cm; PADDING-LEFT: 0cm; BORDER-LEFT-COLOR: #ece9d8; BORDER-BOTTOM-COLOR: #ece9d8; PADDING-BOTTOM: 0cm; BORDER-TOP-COLOR: #ece9d8; PADDING-TOP: 0cm; HEIGHT: 22.5pt; BACKGROUND-COLOR: transparent; BORDER-RIGHT-COLOR: #ece9d8;"></td></tr><tr style="HEIGHT: 106.5pt; mso-yfti-irow: 2; mso-yfti-lastrow: yes;"><td valign="top" style="ADDING-RIGHT: 0cm; PADDING-LEFT: 0cm; BORDER-LEFT-COLOR: #ece9d8; BORDER-BOTTOM-COLOR: #ece9d8; PADDING-BOTTOM: 0cm; BORDER-TOP-COLOR: #ece9d8; PADDING-TOP: 0cm; HEIGHT: 106.5pt; BACKGROUND-COLOR: transparent; BORDER-RIGHT-COLOR: #ece9d8;"><p class="MsoNormal" align="left" style="MARGIN: 0cm 0cm 0pt; TEXT-ALIGN: left; mso-pagination: widow-orphan;"><span style="FONT-SIZE: 12pt; FONT-FAMILY: 宋体; mso-font-kerning: 0pt; mso-bidi-font-family: 宋体;">一、前<span lang="EN-US">&nbsp;</span>言<span lang="EN-US"><br/>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;DCS</span>在国内大型火力发电机组上应用始于上世纪八十年代后期,到目前为止只有十几年的运行经验。华能国际电力股份有限公司整套引进<span lang="EN-US">350MW</span>机组,投资建设的南通、上安、大连、福州电厂是国内最早应用<span lang="EN-US">DCS</span>的电厂。<span lang="EN-US"><br/>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;</span>随着火力发电机组自动化水平的不断提高,单元机组<span lang="EN-US">DCS</span>系统的功能范围不断扩大。近两年新建和改造机组的单元控制室内除用于紧急停机、停炉用的后备手操外,其余操作全部依赖于<span lang="EN-US">DCS</span>。因而,由于<span lang="EN-US">DCS</span>本身故障引起的跳机现象时有发生。所以,如何提高<span lang="EN-US">DCS</span>的可靠性作为一个重要课题摆在了从事热工自动化工作的各位人士的面前。<span lang="EN-US"><br/>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;</span>由于工作关系,有机会到过三十多家火电厂收资、交流或验收,接触到应用<span lang="EN-US">DCS</span>的<span lang="EN-US">100</span>~<span lang="EN-US">700MW</span>单元机组近八十台,几乎覆盖了国内应用过的所有类型的<span lang="EN-US">DCS</span>,对各种类型的<span lang="EN-US">DCS</span>发生的故障有较多的了解,无论是进口<span lang="EN-US">DCS</span>,还是国产<span lang="EN-US">DCS</span>,尽管在原理、结构上迥异,包含的子系统也不一样多,但都或多或少地出现过一些相类似的故障,通过对典型故障进行深入细致地分析,找出故障的真正原因,举一反三,制定出防范措施,并正确地实施,可以很好地防止此类<span lang="EN-US">DCS</span>故障的重复发生。本文列举了几个典型的<span lang="EN-US">DCS</span>故障案例,供从事热工技术管理及检修人员参考。<span lang="EN-US"><br/><br/></span>二、案例一<span lang="EN-US">&nbsp;</span>控制器重启引发机组跳闸<span lang="EN-US"><br/>2.1&nbsp;</span>事件经过<span lang="EN-US"><br/>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;2001</span>年<span lang="EN-US">11</span>月<span lang="EN-US">1</span>日,<span lang="EN-US">A</span>电厂<span lang="EN-US">4</span>号机组停机前有功负荷<span lang="EN-US">270MW</span>,无功<span lang="EN-US">96MVar</span>,<span lang="EN-US">A</span>、<span lang="EN-US">B</span>励磁调节器自动并列运行,手动<span lang="EN-US">50Hz</span>柜跟踪备用。<span lang="EN-US"><br/>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;14</span>时<span lang="EN-US">26</span>分,事故音响发出,发电机出口开关、励磁开关跳闸,<span lang="EN-US">"</span>调节器<span lang="EN-US">A</span>柜退出运行<span lang="EN-US">"</span>、<span lang="EN-US">"</span>调节器<span lang="EN-US">B</span>柜退出运行<span lang="EN-US">"</span>等报警信号发出,机组解列。对<span lang="EN-US">ECS</span>控制系统检查、试验,发现<span lang="EN-US">#14</span>控制器发生故障已离线,与之冗余的#<span lang="EN-US">34</span>控制器发生重启,更换了<span lang="EN-US">#14</span>和#<span lang="EN-US">34</span>控制器主机板后,机组重新启动,不久,发变组与系统并列。<span lang="EN-US"><br/>2.2</span>原因分析<span lang="EN-US"><br/>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;</span>根据历时数据分析,<span lang="EN-US">13</span>时<span lang="EN-US">31</span>分,<span lang="EN-US">#14</span>控制器硬件故障而离线运行,热备用的<span lang="EN-US">#34</span>控制器自动由辅控切为主控。<span lang="EN-US">14</span>时<span lang="EN-US">26</span>分,<span lang="EN-US">#34</span>控制器由于通讯阻塞引起<span lang="EN-US">"WATCHDOG"</span>误判断,致使控制器重启。由于控制器控制励磁调节器的方式为长信号,没有断点保护功能,<span lang="EN-US">#34</span>控制器重启后,不能自动回到断点前的状态,导致<span lang="EN-US">A</span>、<span lang="EN-US">B</span>调节器自动退出运行,手动<span lang="EN-US">50Hz</span>柜自动投入。由于发电机失磁,发电机端电压下降,导致厂用电源电压降低,手动<span lang="EN-US">50Hz</span>柜输出电压继续降低,手动<span lang="EN-US">50Hz</span>柜投入后发电机没有脱离失磁状态,直至切除励磁装置,造成发电机失磁保护动作,发电机出口开关跳闸。<span lang="EN-US"><br/>#14</span>控制器和<span lang="EN-US">#34</span>控制器控制发变组设备,包括厂用电切换的备自投继电器接点<span lang="EN-US">BK</span>,<span lang="EN-US">#34</span>控制器重启后,<span lang="EN-US">BK</span>自动复位,继电器接点断开,<span lang="EN-US">BK</span>投到退出位置,造成<span lang="EN-US">6KV</span>电源开关<span lang="EN-US">6410</span>、<span lang="EN-US">6420</span>开关自投不成功。<span lang="EN-US"><br/>2.3</span>防范措施<span lang="EN-US"><br/><chsdate year="1899" month="12" day="30" islunardate="False" isrocdate="False" wst="on"></chsdate><chsdate></chsdate>2.3.1<chsdate></chsdate><chsdate></chsdate></span>将故障控制器更换。后来制造厂确认这一批主板晶振存在问题,同意免费更换,利用停机机会更换<span lang="EN-US">4</span>号机组所有控制器主板。<span lang="EN-US"><br/>2.3.2</span>增加任一控制器、<span lang="EN-US">I/O</span>卡、通讯卡离线报警功能。<span lang="EN-US"><br/>2.3.3</span>程序内部<span lang="EN-US">"WATCHDOG"</span>的时间设置太短,易造成误判断,对所有控制器进行软件升级。<span lang="EN-US"><br/>2.3.4</span>调节器<span lang="EN-US">AQK</span>、<span lang="EN-US">BQK</span>方式开关和厂用电备自投<span lang="EN-US">BK</span>开关组态图增加断点保护功能,防止控制器自启动后,励磁调节器和厂用电自投开关退出运行。<span lang="EN-US"><br/>2.3.5</span>检查<span lang="EN-US">ECS</span>系统的所有组态,对存在以上问题的逻辑进行修改。<span lang="EN-US"><br/>2.3.6</span>联系调节器厂家,使调节器内部可以作到运行状态自保持,将控制器控制调节器的方式改为短脉冲信号控制。<span lang="EN-US"><br/>2.6.7</span>在<span lang="EN-US">ECS</span>内增加手动<span lang="EN-US">50Hz</span>柜输出电压自动跟踪功能。<span lang="EN-US"><br/><br/></span>三、案例二在线传代码致使机组解列<span lang="EN-US"><br/>3.1</span>事件经过<span lang="EN-US"><br/>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;2002</span>年<span lang="EN-US">7</span>月<span lang="EN-US">12</span>日,<span lang="EN-US">B</span>电厂#<span lang="EN-US">5</span>机组监盘人员发现机组负荷从<span lang="EN-US">552MW</span>迅速下降,主汽压力突升,汽轮机调门开度,由原来的<span lang="EN-US">20%</span>关闭到<span lang="EN-US">10%</span>并继续关闭,高调门继续迅速关闭至<span lang="EN-US">0%</span>,机组负荷降低至<span lang="EN-US">5MW</span>,运行人员被迫手动紧急停炉,汽轮机跳闸,发电机解列。<span lang="EN-US"><br/>3.2</span>原因分析<span lang="EN-US"><br/>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;DCS</span>与汽轮机控制系统分别由两家国外公司制造,两系统差异较大,通讯问题没有很好地解决,存在一些难以消除的缺陷。热控人员在<span lang="EN-US">DCS</span>工程师站上向负责<span lang="EN-US">DCS</span>与汽轮机控制系统通讯的<span lang="EN-US">LC</span>传送通讯代码时,<span lang="EN-US">DCS</span>将汽轮机阀位限制由正常运行中的<span lang="EN-US">120%</span>修改为<span lang="EN-US">0.25%</span>,造成汽机<span lang="EN-US">1</span>、<span lang="EN-US">2</span>、<span lang="EN-US">3</span>号调门由<span lang="EN-US">20%</span>关闭至<span lang="EN-US">0%</span>,机组负荷由<span lang="EN-US">552MW</span>迅速降至<span lang="EN-US">5MW</span>。<span lang="EN-US"><br/>3.3&nbsp;</span>防范措施<span lang="EN-US"><br/>3.3.1</span>机组运行期间,禁止<span lang="EN-US">DCS</span>传代码工作。<span lang="EN-US"><br/>3.3.2</span>机组停运期间,<span lang="EN-US">DCS</span>传代码时,应经运行班长同意,并做好安全措施。<span lang="EN-US"><br/>3.3.2</span>将<span lang="EN-US">DCS</span>操作员站对汽轮机控制系统操作员站画面进行操作的功能闭锁,但在<span lang="EN-US">DCS</span>操作员站上仍能监视到汽轮机控制系统的信息。<span lang="EN-US"><br/><br/></span>四、案例三<span lang="EN-US">&nbsp;DCS</span>工作站时钟混乱引发<span lang="EN-US">DCS</span>失灵<span lang="EN-US"><br/>4.1</span>事件经过:<span lang="EN-US"><br/>2001</span>年<span lang="EN-US">&nbsp;8</span>月<span lang="EN-US">3</span>日,<span lang="EN-US">C</span>电厂<span lang="EN-US">2</span>号机组负荷<span lang="EN-US">200MW</span>,<span lang="EN-US">#1</span>至<span lang="EN-US">#9</span>控制器处于控制方式,<span lang="EN-US">#51</span>至<span lang="EN-US">#59</span>控制器处于备用方式。<span lang="EN-US">8</span>时<span lang="EN-US">23</span>分,各控制器依次发<span lang="EN-US">NTP</span>报警,历史站报警窗口显示如下:<span lang="EN-US"><br/>Aug&nbsp;3&nbsp;08</span>:<span lang="EN-US">23</span>:<span lang="EN-US">50&nbsp;drop7&nbsp;</span><<span lang="EN-US">7</span>><span lang="EN-US">&nbsp;NTP</span>:<span lang="EN-US">too&nbsp;many&nbsp;recvbufs&nbsp;allocated</span>(<span lang="EN-US">30</span>)<span lang="EN-US"><br/>Aug&nbsp;3&nbsp;08</span>:<span lang="EN-US">23</span>:<span lang="EN-US">50&nbsp;drop4&nbsp;</span><<span lang="EN-US">7</span>><span lang="EN-US">&nbsp;NTP</span>:<span lang="EN-US">too&nbsp;many&nbsp;recvbufs&nbsp;allocated</span>(<span lang="EN-US">30</span>)<span lang="EN-US"><br/>………<br/>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;8</span>时<span lang="EN-US">26</span>分,<span lang="EN-US">#2</span>控制器脱网,<span lang="EN-US">#52</span>控制器切为主控;<span lang="EN-US">11</span>时<span lang="EN-US">05</span>分,<span lang="EN-US">#52</span>控制器脱网;<span lang="EN-US">13</span>时<span lang="EN-US">39</span>分,<span lang="EN-US">#7</span>控制器脱网,<span lang="EN-US">#57</span>控制器切为主控,在<span lang="EN-US">#7</span>控制器向<span lang="EN-US">#57</span>控制器切换瞬间,由该控制器控制的<span lang="EN-US">A</span>、<span lang="EN-US">B</span>磨煤机跳闸;<span lang="EN-US">15</span>时<span lang="EN-US">11</span>分,<span lang="EN-US">#9</span>控制器脱网,<span lang="EN-US">#59</span>控制器切为主控,在<span lang="EN-US">#9</span>控制器向<span lang="EN-US">#59</span>控制器切换瞬间,由该控制器控制的<span lang="EN-US">E</span>磨煤机跳闸;<span lang="EN-US">15</span>时<span lang="EN-US">51</span>分,<span lang="EN-US">#1</span>控制器脱网,<span lang="EN-US">#51</span>控制器切为主控,在<span lang="EN-US">#1</span>控制器向<span lang="EN-US">#51</span>控制器切换瞬间,由该控制器控制的<span lang="EN-US">A</span>引风机动叶被强制关闭。<span lang="EN-US"><br/>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;15</span>时<span lang="EN-US">22</span>分,重启操作员站<span lang="EN-US">drop213</span>(备用时钟站),<span lang="EN-US">NTP</span>报警未消失;<span lang="EN-US">15</span>时<span lang="EN-US">35</span>分,重启历史站,<span lang="EN-US">NTP</span>报警未消失;<span lang="EN-US">15</span>时<span lang="EN-US">59</span>分,重启工程师站(主时钟站),<span lang="EN-US">NTP</span>报警基本消失;<span lang="EN-US">16</span>时<span lang="EN-US">09</span>分,重启历史站,<span lang="EN-US">16</span>时<span lang="EN-US">30</span>分,系统恢复正常。<span lang="EN-US"><br/>4.2</span>原因分析<span lang="EN-US"><br/>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;NTP</span>软件的作用就是维持网络时钟的统一,主时钟设置在工程师站上,备用时钟设置在操作员站上。控制器脱网原因为主时钟与备用时钟不同步造成系统时钟紊乱,从而造成<span lang="EN-US">NTP</span>报警导致控制器脱网。<span lang="EN-US"><br/>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;NTP</span>故障的原因有两种可能,一种是主频为<span lang="EN-US">400MHz</span>工作站,不同于<span lang="EN-US">1</span>号机组的<span lang="EN-US">270MHz(SUN</span>公司在<span lang="EN-US">400MHz</span>工作站上对操作系统有较大改进<span lang="EN-US">)</span>工作站,<span lang="EN-US">2</span>号机组所用的<span lang="EN-US">1.1</span>版本软件在<span lang="EN-US">400MHz</span>工作站上未测试过,不能确保<span lang="EN-US">1.1</span>版本软件在此配置上不出问题。另一种是主时钟与备用时钟不同步,在<span lang="EN-US">8</span>月<span lang="EN-US">3</span>日控制器脱网后,曾发现<span lang="EN-US">Drop214</span>的时钟比其它站快了<span lang="EN-US">2</span>秒<span lang="EN-US">,&nbsp;</span>当时<span lang="EN-US">Drop214</span>的画面调用速度较慢,经重启后正常,并且<span lang="EN-US">NTP</span>时钟报警是在系统运行<span lang="EN-US">73-75</span>天左右才出现的,估计是系统时钟偏差积累到一定程度后导致主、备时钟不同步,而引起系统时钟紊乱,最终导致控制器脱网。<span lang="EN-US"><br/>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;NTP</span>时钟故障使控制器脱网,处理不及时会使报警的控制器依次脱网,从而导致整个控制系统瘫痪。<span lang="EN-US"><br/>4.3</span>防范措施<span lang="EN-US"><br/>4.3.1</span>根据本次故障现象,制造商将软件由<span lang="EN-US">1.1</span>版本升级为<span lang="EN-US">1.2</span>版本。<span lang="EN-US"><br/>4.3.2</span>为确保控制系统可靠运行,定期重启主时钟和备用时钟站。<span lang="EN-US"><br/>4.4&nbsp;D</span>电厂<span lang="EN-US">5</span>号机组在<span lang="EN-US">2002</span>年试运期间曾发生<span lang="EN-US">DCS</span>时钟与<span lang="EN-US">GPS</span>时钟不同步,引发<span lang="EN-US">DCS</span>操作员站失灵事件。由于网<span lang="EN-US">&nbsp;</span>上传送的数据均带时间标签,时钟紊乱后会给运行机组带来严重后果,基本情况与<span lang="EN-US">C</span>电厂<span lang="EN-US">2</span>号机组类似。采取的措施是暂时断开<span lang="EN-US">GPS</span>时钟,待软件升级和问题得到根本解决后,再恢复<span lang="EN-US">GPS</span>时钟。<span lang="EN-US"><br/><br/></span>五、案例四<span lang="EN-US">&nbsp;CABLETRON</span>集线器总通讯板故障导致<span lang="EN-US">MFT</span>误动<span lang="EN-US"><br/>5.1</span>事件经过<span lang="EN-US"><br/>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;2002</span>年<span lang="EN-US">&nbsp;1</span>月<span lang="EN-US">1</span>日,<span lang="EN-US">E</span>电厂<span lang="EN-US">1</span>号机组负荷<span lang="EN-US">250MW</span>,<span lang="EN-US">#51</span>至<span lang="EN-US">#59</span>控制器处于控制方式,<span lang="EN-US">#1</span>至<span lang="EN-US">#9</span>控制器处于备用方式,<span lang="EN-US">A</span>、<span lang="EN-US">B</span>、<span lang="EN-US">C</span>、<span lang="EN-US">E</span>、<span lang="EN-US">F</span>磨煤机运行。<span lang="EN-US">18</span>时<span lang="EN-US">57</span>分,所有磨煤机跳闸(直吹炉),<span lang="EN-US">MFT</span>动作,机组跳闸。<span lang="EN-US"><br/>5.2</span>原因分析<span lang="EN-US"><br/>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;</span>经分析,确认是<span lang="EN-US">DCS</span>集线器的总通讯板故障,导致连在其上的所有控制器同时发生切换,在控制器向备用控制器切换过程中,<span lang="EN-US">#57</span>、<span lang="EN-US">#58</span>、<span lang="EN-US">#59</span>控制器<span lang="EN-US">K</span>键信号误发(这三个控制器属<span lang="EN-US">FSSS</span>系统),即<span lang="EN-US">CRT</span>上<span lang="EN-US">"</span>磨煤机跳闸按钮<span lang="EN-US">"</span>的跳闸和确认指令同时发出,使所有磨煤机跳闸,导致<span lang="EN-US">MFT</span>动作。<span lang="EN-US"><br/>5.3</span>防范措施<span lang="EN-US"><br/>CABLETRON</span>集线器属于早期产品,目前在市场上购买备件已比较困难,采用<span lang="EN-US">CISCO</span>集线器来取代<span lang="EN-US">CABLETRON</span>集线器。<span lang="EN-US"><br/><br/></span>六、案例五<span lang="EN-US">&nbsp;</span>冗余控制器失灵造成机组跳闸<span lang="EN-US"><br/>6.1</span>事件经过<span lang="EN-US"><br/>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;2003</span>年<span lang="EN-US">3</span>月<span lang="EN-US">23</span>日,<span lang="EN-US">F</span>电厂#<span lang="EN-US">3</span>机组停机前电负荷<span lang="EN-US">115MW</span>,炉侧主汽压<span lang="EN-US">9.55MPa</span>,主汽温<span lang="EN-US">537℃</span>,主给水调节门开度<span lang="EN-US">43%</span>,旁路给水调节门开度<span lang="EN-US">47%</span>(每一条给水管道均能满足<span lang="EN-US">100%</span>负荷的供水),汽包水位正常;其它各参数无异常变化。<span lang="EN-US"><br/>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;</span>监盘人员发现锅炉侧部分参数显示异常,各项操作均不能进行,同时炉侧<span lang="EN-US">CRT</span>画面显示各项自动已处于解除状态。调自检画面发现<span lang="EN-US">#3</span>控制器离线,<span lang="EN-US">#23</span>控制器处于主控状态。运行人员立即联系热工人员处理,同时借助汽机侧<span lang="EN-US">CRT</span>画面监视主汽压、主汽温,并对汽包电接点水位计和水位<span lang="EN-US">TV</span>加强监视,主汽压在<span lang="EN-US">9.0</span>~<span lang="EN-US">9.6MPa</span>波动、主汽温在<span lang="EN-US">510</span>~<span lang="EN-US">540℃</span>波动、汽包水位在<span lang="EN-US">+75</span>~<span lang="EN-US">-50mm</span>波动,维持运行。<span lang="EN-US"><br/>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;</span>几分钟后,热工人员赶到现场,发现<span lang="EN-US">#3</span>控制器离线、<span lang="EN-US">#23</span>控制器为主控状态,但<span lang="EN-US">#23</span>控制器主控下的<span lang="EN-US">I/O</span>点(汽包水位、主汽温、主汽压、给水压力、等)均为坏点,自动控制手操失灵。经过多次重启,<span lang="EN-US">#3</span>控制器恢复升为主控状态。在释放强制的<span lang="EN-US">I/O</span>点时,监盘人员发现汽包水位急剧下降,就地检查发现旁路给水调节门在关闭状态,手动摇起三次均自动关闭,汽包水位<span lang="EN-US">TV</span>和显示表监视不到水位,手动停炉、停机。<span lang="EN-US"><br/>6.2</span>原因分析<span lang="EN-US"><br/>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;</span>根据能追忆到的历史记录分析,可以推断<span lang="EN-US">#3</span>控制器(主控)故障前,<span lang="EN-US">#23</span>控制器(辅控)因硬件故障或通讯阻塞,已经同<span lang="EN-US">I/O</span>总线失去了通讯。当<span lang="EN-US">#3</span>控制器因主机卡故障离线后,<span lang="EN-US">#23</span>控制器升为主控,但无法读取<span lang="EN-US">I/O</span>数据,造成参与汽水系统控制的一对冗余控制器同时失灵,给水自动控制系统失控,汽包水位保护失灵。在新更换的#<span lang="EN-US">3</span>控制器重启成功后释放强制点的过程中,<span lang="EN-US">DCS</span>将旁路给水调节门指令置零(逻辑如此设计是为了在控制器故障时,运行机组向更安全的方向发展),关闭旁路调节门。而旁路调节门为老型号的阀门,相当于解除了自保持的电动门(接受脉冲量信号),切手动时不能做到电气脱扣,因此,紧急情况下不能顺利打开,造成汽包缺水。<span lang="EN-US"><br/>6.3</span>防范措施<span lang="EN-US"><br/>6.3.1</span>更换<span lang="EN-US">#3</span>、<span lang="EN-US">#23</span>控制器主机板,同时考虑增加主机板的备品储备。<span lang="EN-US"><br/>6.3.2</span>增加通讯卡,使控制器与<span lang="EN-US">I/O</span>卡之间的通讯为冗余的。<span lang="EN-US"><br/>6.3.3</span>对所有控制器、<span lang="EN-US">I/O</span>卡、<span lang="EN-US">BC</span>卡的通讯进行监测,增加脱网逻辑判断功能,生成报警点并进行历史记录。一旦控制器工作异常,可及时报警并处理。<span lang="EN-US"><br/>6.3.4</span>增加控制器超温报警功能,在控制器出现故障之前可以采取措施,将事故消灭在萌芽之中。<span lang="EN-US"><br/>6.3.5</span>汽包水位等重要调节、保护系统的输入信号,一般应为三路相互独立的信号,通过分流器将这三路信号变成六路信号,分别进六块端子板和<span lang="EN-US">AI</span>卡件,送入两对控制器,一对控制器用于调节、保护,另一对控制器只参与保护。这样可以很好地解决一对冗余的控制器同时故障时,重要保护失灵的问题。<span lang="EN-US"><br/>6.3.6</span>更换重要自动调节系统的执行机构,使之具有完善的操作功能。<span lang="EN-US"><br/>6.3.7&nbsp;DCS</span>失灵时,若主要后备硬手操或监视仪表不能维持正常运行,运行人员应立即停机、停炉。<span lang="EN-US"><br/>6.3.8</span>关闭<span lang="EN-US">MIS</span>系统接口站中的所有硬盘共享功能,确保<span lang="EN-US">DCS</span>系统同<span lang="EN-US">MIS</span>系统只具备单向通讯功能。<span lang="EN-US"><br/><br/></span>七、结<span lang="EN-US">&nbsp;</span>束<span lang="EN-US">&nbsp;</span>语<span lang="EN-US"><br/>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;</span>以上案例只是在一定范围内发生的<span lang="EN-US">DCS</span>故障的几个比较典型案例,即使将这些案例的反措全部应用到每套<span lang="EN-US">DCS</span>中去,也不能避免<span lang="EN-US">DCS</span>故障的再次发生。在更大范围内,由<span lang="EN-US">DCS</span>故障引发的停机事件也不会太少,有些事件肯定会涉及到控制器负荷率高、网络通讯负荷率高等问题,由于目前还没有有效的手段监测控制器负荷率和网络通讯负荷率,找出这类事件的根本原因还有一定的难度,因此,消除这类缺陷也比较困难。<span lang="EN-US"><br/>&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;</span>要防止各类事故的发生,必须从源头<span lang="EN-US">-DCS</span>的设计和制造抓起,将国内应用的各种类型的<span lang="EN-US">DCS</span>发生过的故障情况反馈到有关部门,由有关部门召集专家进行分析研究,制定出相应的标准、制度和反措,强制执行,并形成一个大的闭环质量控制体系,长期良性循环。<span lang="EN-US">
                                                                <p></p></span></span></p><p></p><p></p><p></p><p></p></td></tr></tbody></table><p class="MsoNormal" style="MARGIN: 0cm 0cm 0pt;"><span lang="EN-US"><p><font face="Times New Roman">&nbsp;</font></p></span></p><p><font face="Times New Roman">&nbsp;</font></p>
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追风无痕 发表于 2008-7-7 09:50:06 | 只看该作者
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