Description
GE DS200SLCCF1AZZ module
Contact: Mr. Lai
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Research on common faults and countermeasures of DCS system
DCS system is a distributed control system. It is a modern high-tech technology combining computer, display, communication, continuous monitoring, alarm and programmable control. It has comprehensive functions, convenient operation, flexible configuration, and stable and reliable. The practice has proved that the application of DCS system to large and medium-sized production enterprises not only contributes to daily production maintenance and reliable and stable operation, but also saves costs for enterprises, thus reducing costs and improving core competitiveness of enterprises.
1 Common faults of DCS system
1.1 Communication failure
DCS system network topology and communication protocols are various, but most of the DCS systems of different brands in the market are divided into two levels in the network organization structure: one is to the central processor and its expansion sub-station (lower computer), the other is the human-computer interface, such as operators, servers, various stations of operator stations (upper computer). Communication failures usually take the following forms: system crash, network disconnection, communication interruption, etc. There are three common reasons for communication failure: first, the operation of the DCS system communication function is mostly completed by asking data from one node to another node. If the other node does not have the data, it will ask again and again until it reads the data. If there is no such data on the network, the network will be blocked and the communication will not be able to proceed normally. Secondly, DCS configuration is deficient, and its application software has been increasing with the development of science and technology, but it is not actually connected with I/O points. Therefore, even if the CPU reads data, it is very effective, which brings considerable load to the CPU and easily causes network congestion. Finally, network communication media problems, hardware upgrade drivers can not keep up, and the operating environment temperature is too high, and other factors may hinder communication.
1.2 Hardware failure
The hardware failure is generally manifested in the process control layer, mainly because the modules in the whole system, especially I/O, are damaged. Hardware failure can be very obvious, so it is easy to detect. The impact of it is usually only local. The unchanged parameter display is the manifestation of hardware damage. Hardware damage is mostly caused by the aging of the original due to improper use or too long use. If the surrounding environment of DCS is dusty and high temperature, it will seriously shorten its service life. In view of this, it is best to ensure that the civil engineering and decoration works have been completed before installing the DCS control system. If it is in summer, it is also necessary to pay attention to timely start the air conditioning, or focus on the protection level of complex environment when selecting the DCS system products. At present, many brands of DCS products in the market have developed the self-diagnosis function of hardware, which can directly reflect the location of the faulty hardware on the upper computer, and can also specify which channel has failed, which also brings a lot of convenience to eliminate the hardware failure.
In addition to the channel fault, there are also human-machine interface faults in the hardware fault. The specific manifestations of human-machine interface faults are: the mouse can not operate normally, because of the failure, so it is very inconvenient for operators to use. The reason for this situation may be that the USB interface is unstable, or there may be a problem with the computer motherboard. The crash may be due to defects in the DCS system software itself, or it may be caused by too much CPU load. When this happens, be patient to analyze the cause. The operation of the function keyboard fails. Sometimes the key contact is poor. At this time, the keyboard operation is abnormal.
1.3 Software fault
Software failures are usually caused by the defects of the DCS system itself, and most of them occur at the early stage of the DCS software upgrade stage. The software is the most complex part of the DCS system. The program is complex, and the configuration workers are mostly cross-working. In this way, once the communication is not in place, there will be loopholes, and software errors are inevitable. The modification of DCS system software shall be carried out in strict accordance with the regulations, and the modification shall be backed up. In case of data loss, the backup can be used for repair. There are three main types of software failures: the configuration information of the master CPU and the slave CPU is inconsistent, which makes the CPU unable to complete initialization; The network communication pressure is too large, resulting in system chaos; After a component is updated, the relevant parameters do not change accordingly.
1.4 Power failure GE DS200SLCCF1AZZ
Power failure will directly lead to the failure of DCS system control functions, stop operation and cause economic losses. The control power supply is literally the “lifeline” of DCS system. If some particularly important power supply fails, it will directly affect the orderly and stable operation of the protection logic and other control logic, and even lead to the misoperation of some interlocking driving elements, causing serious production accidents. Common faults of the power supply include: (1) the connector is not firmly crimped or connected stably, resulting in poor contact; (2) The CPU has a problem or the insurance configuration is unreasonable, so that the power supply is cut off; (3) The power line wiring is not scientific and is too close to the facilities with strong magnetic interference; (4) Various reasons lead to module damage.
2 Preventive measures
2.1 Anti-signal interference
Even slight signal interference may cause communication failure, affect the system operation, cause system paralysis, or signal interference directly interferes with the signal entering the DCS, resulting in misoperation and so on, which will cause huge losses. How to better resist signal interference can prevent the following measures: First, before painting the walls around the central control room, it is necessary to install a layer of dense steel wire mesh, Then connect with PE grounding system, so as to effectively avoid the huge interference of strong electromagnetic field. Second, the power equipment should not be grounded in series, and the power equipment should be kept as far away from the grounding wire as possible. Thirdly, the dual-circuit redundant power supply system is used to supply power to the DCS, and the UPS is always supplied without interval, so as to improve the overall anti-interference level of power supply and circuit. Fourth, all analog signals entering the DCS system must be connected with shielded cables. The shielding layer must be specially grounded and its resistance to ground must be less than 1 Ω. Fifth, shield the radio around the DCS system as much as possible.
2.2 UPS power supply maintenance
Regularly measure the actual temperature of the key terminals with the help of infrared thermometer, and record it in detail at the same time. Pay special attention if there is temperature rise; Measure the power supply voltage with the help of a multimeter and record the data. Pay special attention if there is any fluctuation; At the maintenance or shutdown stage of the DCS system, the switch test shall be carried out in time to monitor whether the redundant CPU can automatically switch and be in normal working condition; Check I/O modules, and replace some aging and corroded electrical connectors in time; Charge or discharge the battery in strict accordance with the battery use rules; Check the fan and clean it if necessary to make the air duct unblocked.GE DS200SLCCF1AZZ
2.3 DCS software and hardware system operation and management
2.3.1 Operation management. The so-called operation management refers to daily patrol inspection, software management, spare parts management, etc. The software is the core of the DCS system, and the program is complex. Its configuration and modification must be carried out according to the regulations. At the same time, the modification information should be backed up to prevent the failure caused by data loss; If there is a problem with the DCS device, it is necessary to replace it with spare parts. Before installation and use, it is necessary to have a comprehensive test of its function to avoid the recurrence of the whole system failure.
2.3.2 Maintenance management. Maintenance management attaches importance to the maintenance process and procedures. In order to ensure the stable operation quality of the DCS system and ensure the normal operation for a long time, major maintenance must be carried out regularly, such as software backup, power cleaning, parts cleaning, etc.
With the development of science and technology, the DCS control system is becoming more mature and more widely used in various industrial production fields. It has become an indispensable automatic control equipment. The powerful function of DCS has brought huge economic benefits to industrial production.
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Company advantage service:
1.Has been engaged in industrial control industry for a long time, with a large number of inventories.
2.Industry leading, price advantage, quality assurance
3.Diversified models and products, and all kinds of rare and discontinued products
4.15 days free replacement for quality problems
1.Has been engaged in industrial control industry for a long time, with a large number of inventories.
2.Industry leading, price advantage, quality assurance
3.Diversified models and products, and all kinds of rare and discontinued products
4.15 days free replacement for quality problems
All kinds of module card driver controller servo motor servo motor embedded card wires and cables Power module control module is applicable to steel, hydropower, nuclear power, power generation, glass factory, tire factory, rubber, thermal power, paper making, shipping, navigation, etc
ABB — AC 800M controller, Bailey, PM866 controller, IGCT silicon controlled 5SHY 3BHB01 3BHE00 3HNA00 DSQC series
BENTLY — 3500 system/proximitor, front and rear card, sensor, probe, cable 3500/20 3500/61 3500/05-01-02-00-001 3500/40M 176449-01 3500/22M 138607-01
Emerson — modbus card, power panel, controller, power supply, base, power module, switch 1C31,5X00, CE400, A6500-UM, SE3008,1B300,1X00,
EPRO — PR6423 PR6424 PR6425 PR6426 PR9376 PR9268 Data acquisition module, probe, speed sensor, vibration sensor
FOXBORO — FCP270 FCP280 FCM10EF FBM207 P0914TD CP40B FBI10E FBM02 FBM202 FBM207B P0400HE Thermal resistance input/output module, power module, communication module, cable, controller, switch
GE —- IS200/215/220/230/420 DS200/215 IC693/695/697/698 VMICPCI VMIVME 369-HI-R-M-0-0-E 469 module, air switch, I/O module, display, CPU module, power module, converter, CPU board, Ethernet module, integrated protection device, power module, gas turbine card
HIMA — F3 AIO 8/4 01 F3231 F8627X Z7116 F8621A 984862160 F3236 F6217 F7553 DI module, processor module, AI card, pulse encoder
Honeywell — Secure digital output card, program module, analog input card, CPU module, FIM card
MOOG — D136-001-007 Servo valve, controller, module
NI — SCXI-1100 PCI – PXIE – PCIE – SBRIO – CFP-AO-210 USB-6525 Information Acquisition Card, PXI Module, Card
Westinghouse — RTD thermal resistance input module, AI/AO/DI/DO module, power module, control module, base module
Woodward — 9907-164 5466-258 8200-1300 9907-149 9907-838 EASYGEN-3500-5/P2 8440-2145 Regulator, module, controller, governor
YOKOGAWA – Servo module, control cabinet node unit
Main products:
PLC, DCS, CPU module, communication module, input/output module (AI/AO/DI/DO), power module, silicon controlled module, terminal module, PXI module, servo drive, servo motor, industrial display screen, industrial keyboard, controller, encoder, regulator, sensor, I/O board, counting board, optical fiber interface board, acquisition card, gas turbine card, FIM card and other automatic spare parts
ABB — AC 800M controller, Bailey, PM866 controller, IGCT silicon controlled 5SHY 3BHB01 3BHE00 3HNA00 DSQC series
BENTLY — 3500 system/proximitor, front and rear card, sensor, probe, cable 3500/20 3500/61 3500/05-01-02-00-001 3500/40M 176449-01 3500/22M 138607-01
Emerson — modbus card, power panel, controller, power supply, base, power module, switch 1C31,5X00, CE400, A6500-UM, SE3008,1B300,1X00,
EPRO — PR6423 PR6424 PR6425 PR6426 PR9376 PR9268 Data acquisition module, probe, speed sensor, vibration sensor
FOXBORO — FCP270 FCP280 FCM10EF FBM207 P0914TD CP40B FBI10E FBM02 FBM202 FBM207B P0400HE Thermal resistance input/output module, power module, communication module, cable, controller, switch
GE —- IS200/215/220/230/420 DS200/215 IC693/695/697/698 VMICPCI VMIVME 369-HI-R-M-0-0-E 469 module, air switch, I/O module, display, CPU module, power module, converter, CPU board, Ethernet module, integrated protection device, power module, gas turbine card
HIMA — F3 AIO 8/4 01 F3231 F8627X Z7116 F8621A 984862160 F3236 F6217 F7553 DI module, processor module, AI card, pulse encoder
Honeywell — Secure digital output card, program module, analog input card, CPU module, FIM card
MOOG — D136-001-007 Servo valve, controller, module
NI — SCXI-1100 PCI – PXIE – PCIE – SBRIO – CFP-AO-210 USB-6525 Information Acquisition Card, PXI Module, Card
Westinghouse — RTD thermal resistance input module, AI/AO/DI/DO module, power module, control module, base module
Woodward — 9907-164 5466-258 8200-1300 9907-149 9907-838 EASYGEN-3500-5/P2 8440-2145 Regulator, module, controller, governor
YOKOGAWA – Servo module, control cabinet node unit
Main products:
PLC, DCS, CPU module, communication module, input/output module (AI/AO/DI/DO), power module, silicon controlled module, terminal module, PXI module, servo drive, servo motor, industrial display screen, industrial keyboard, controller, encoder, regulator, sensor, I/O board, counting board, optical fiber interface board, acquisition card, gas turbine card, FIM card and other automatic spare parts
