DCS系統(tǒng)調(diào)試方案設計

1、1. 編制說明為高效優(yōu)質(zhì)完成調(diào)校工作，確保工藝試車進度，并實現(xiàn)長期、安全穩(wěn)定生產(chǎn)的目標，特編制本 DCS 系統(tǒng)調(diào)試方案。2. 編制依據(jù)2.1 工程合同2.2 施工圖及產(chǎn)品說明書 2.3自動化儀表工程施工及驗收規(guī)GB50093-20023. 系統(tǒng)結(jié)構(gòu)CENTUM-KL 集散控制系統(tǒng)結(jié)構(gòu)包括：1) 操作站、操作臺2) 工程師站(帶 19”彩色 CRT 和鍵盤)3) 彩色打印機4) 彩色拷貝機5) 大容量存儲單元6) 記錄儀7) 控制站及 I/O 單元8) 雙冗余通訊系統(tǒng)(包括通訊總線及接口模件)9) 聯(lián)鎖停車操作臺10) 超級用戶(帶打印機)11) PLC(帶編程單元及打印機)4. 儀表系統(tǒng)調(diào)試程

2、序圖一為儀表系統(tǒng)調(diào)試程序方框圖。本著分層隔離、平行作業(yè)的方 法，本方案將系統(tǒng)調(diào)試分劃為經(jīng)下四個層次：4.1第一層次：DC皈輔助儀表盤儀表調(diào)試在這一層次中，通過設置斷點1、2,使DCS調(diào)試與輔助儀表 盤儀表調(diào)試相對獨立、互不干擾，從而便于實現(xiàn)對這兩個工序的 平行作業(yè)，并可避免因設備狀態(tài)不正?；蚪泳€錯誤等原因造成設 備的損壞。4.2 第二層次：控制室部系統(tǒng)調(diào)試此層次在不連接控制至現(xiàn)場電纜情況下，對 DCS 機柜、壓縮 機盤、火警盤等的系統(tǒng)調(diào)試。 對于其中的聯(lián)鎖系統(tǒng)調(diào)試能否做早、 做好、做扎實，對“消除隱患、掌握主動、贏得時間”意義重大。實用標準4.3 第三層次：全裝置儀表二次聯(lián)校根據(jù)現(xiàn)場施工及工藝

3、試車進度要求，逐點連接控制室至現(xiàn)場 電纜，通過在現(xiàn)場加信號進行回路試驗，并陸續(xù)投用。4.4 第四層次：應用軟件參數(shù)的進一步調(diào)整此為在單體試車、聯(lián)動試車之前、之中、之后，對某些儀表 參數(shù)如復雜調(diào)節(jié)系統(tǒng)的計算系數(shù)、偏置值、延遲時間、設定值及 比例度、積分、微分時間等的試驗調(diào)整，以獲得最佳運行工況。5. 調(diào)試容及方法Content and Method of testing:5.1 DC碉試現(xiàn)場調(diào)試工作主要是檢查使用系統(tǒng)軟件，并對應用軟件進行組態(tài)確認 和功能測試。Local testing mainly including: checking and applying system software

4、.Executing function approval and function test.5.1.1 通電前的檢查Inspection prior to making contact.電纜絕緣電阻符合要求（大于 5M 歐），查看電纜絕緣電阻測 試記錄，必要時抽查實測。In sulati on resista nee is more tha n 5W , check ing resista nee test record.If necessary sampling and testing.核對所有電源線、信號線、通訊總線應連接無誤。Checking all power supply line

5、s, signal lines, and communication trunk line right and identical.控制站、操作臺、工程師站等各機框插卡、適配器及其接口的 型號、位置正確無誤。For control station, operation table, engineer station, specification andsiteof all insert cards, adaptors and nozzle connection shall be correct.各插卡予設定旋鈕位置正確。Location for presetting button of ins

6、ert cards is right.扣電源單元及插卡上電源開關(guān)均處于“ OFF”位置，所有保險絲完好無損。Power unit and switch of insert card shall shut off, and fuses areundamaged and fine. 機柜所有連接螺釘均應牢固、無松動。Tightly fixing connection screw to machine and cabinet. 接地系統(tǒng)接地電阻測試：Grounding resistance testing:a) 從控制室接地板上拆除“ MG ”、“ CG”接地母線， 用接地電阻測試儀分別測量基接地電

7、阻， 應符合設計 要求(小于 10 歐)。Dismantling MG and CG, from grounding plate of control room. Measuring grounding resistance and compliance with desig n (less tha n10D)b) 用萬用表檢查各機柜接地匯流排是否分別與 “MG”、“ CG”接地板插通。Testing using multimeter whether grounding bus-bars of cabinet well connect with MG or Cg grounding plate

8、 or not.c) 測量“ MG”、“ CG”間絕緣電阻應符合 GBJ93-86 規(guī)要求(大于 5M 歐)。Insulation resistance between MG and CG shall be complia nee with GBJ93 86 (more than 5M Q)8) UPS電源測試UPS Testing:a) 檢查電源盤和電源開關(guān)均處于“ OFF”位置。Make sure power panel switch and power switch shall shut off.b) 由電氣人員將 UPS 投運，測量送至儀表電源盤主電 源開關(guān)前電壓應為 220VAC&#

9、177;10%， 50Hz±2%。Electrican put UPS into use. Measuring voltage delivering to in strume nt power panel is 220VAC土 10%o, 50HZ 土 2%o.c) 由電氣人員作 UPS 不間斷試驗。(滿負荷投用后， 重復此項試驗，蓄電池供電時間應不小于 30分鐘)Electrican execute UPS testing (After overloading running do it again. Time of batterysupplying is no less than

10、 30 minutes.)5.1.2 通電試驗Testing of making contact.逐個地將各機柜、操作臺進行以下通電試驗：Testing every cabinet, operationtable one by one as follow:1) 將電源盤去機柜電源開關(guān)置于“ ON ”位置用數(shù)字萬用表 檢查機柜主電源開關(guān)前電壓，應為 220± 22VAC 。The switch in power supply panel to cabinet shall be on. Measuring voltage of cabinet main power prior to cl

11、osing by digital universalmeter. The range of result is 220± 22VAC.2) 確認機柜各卡件(除電源卡件外)已拔離卡座，然后依次 將機柜主電源開關(guān)、 電源單元、電源卡件上電源開關(guān)置于“ON”，用數(shù)字電壓表測量各直流電壓輸出，應符合廠商說明書要求(5.1 土 0.02V、-12 土 0.3V、12土 0.3V、24VDC )。若超過允許偏差圍，則進行調(diào)整。Make sure all card components shall be pulled from plug. And then switch on main power

12、 switch of cabinet, power unit, power components. Applying voltage meter to measure direct output voltage, the measuring results shall be compliance with manufacture instruction. (5.1 ± 0.02V,-12 ± 0.3V, 12 ± 0.3V,24+3.5VDC). Adjusting if out of deviation allowance.3) 進行雙電源手動切換試驗Execu

13、ting manual switch test with double power supply.4) 將各嵌套扇、信號變換器風扇、硬盤驅(qū)動器風扇、柜頂、 門風扇等電源接通，檢查各風扇，應運行正常。Running all ferrule fans, signal conrertor fans , hardpanddriving fans,top cabinet, door fans, and checking whether they are normal or not.5) 檢查電源報警電路是否起作用。Checking the reaction of power alarm circuit.

14、5.1.3 系統(tǒng)啟動、裝載System starting up and loading.工程師站起動程序。 Starting procedure of engineer station 操作站起動程序。 Starting procedure of engineer station 控制站起動：通電后，調(diào)出系統(tǒng)狀態(tài)畫面，確診狀態(tài)正常。Control station starting: After making contact, selecting system status screen ans making sure it normal.裝載操作Loading operation.。 各站裝載

15、程序詳見說明書。All loading procedures refer to manufacture instruction.5.1.4 系統(tǒng)診斷及冗余試驗System diagnosis and redundancy testing.調(diào)出系統(tǒng)診斷畫面，對各站、臺等進行診斷檢查。Selecting system diagnosis screen, and checking. 對系統(tǒng)的各種冗余模件，人為地模擬故障(通過切斷電源；拔 掉電源插頭、插卡等方法)，觀察備用模件能否在規(guī)定的時間運 行，并在操作臺上觀察切換過程，觀察自動切換過程是否正常。Under the term of man sim

16、ulation default, observing the running of spare module within specified time and converting. Inspecting automatic converting is normal or not.a) 電源冗余試驗Power supply spare testing.b) 通訊冗余試驗Communication spare testing.c) 雙重化控制器冗余試驗Spare testing of double control controller.d) 操作站冗余試驗Operating station s

17、pare testing.e) 打印機熱備用試驗Heatintg spare testing of printer5.1.5 畫面測試Screen Testing:1) 流程圖畫面測試：Screen testing of flowprocess.a) 流程畫面以 P&I 圖形式顯示，頁數(shù)及畫面容應符合組 態(tài)要求。Showing flow, in from of PI.Page and content shall be compliance with function requirement.b) 畫面靜態(tài)顯示檢查：Static display of screen testing:* 檢

18、查標題的位置、顏色、文字說明。Checking title including site, color and word description.* 圖形的形狀、大小、位置、顏色。Shape, size, site and color of picture.* 工藝管線的寬度、位置、顏色及進出接頭。Width, site, color and inlet or outlet connector of process pipeline.文檔大全實用標準* 測量變量的符號、文字、大小、位置、顏色。Symbol, word, size, site, color of measured variabl

19、es.* 儀表信號的箭頭、寬度、位置、容。Slope, width, site and content of instrument signal.* 頁連接符號的形狀、大小、位置、顏色、進出箭頭。Shape, size, site, color, and inlet and outlet slope of page nexto page.* 工程測量單位符合設計要求。Engineering measurement unit shall comply with design.c) 畫面動態(tài)顯示檢查：Active display of screen testing.* 測量變量的變化值應在系統(tǒng)可識

20、別的精度圍。Variable range shall be within the pricision recognized by system.* 閥、泵運行狀態(tài)的顏色變化。Color change of running status of pump or valve.* 報警狀態(tài)變化，且應是正確的優(yōu)先級別。Change of alarm status, which are right priority level.d) 從流程畫面選擇回路， 進行調(diào)整設定值、 控制模式(自 動 / 手動)和手動輸出的試驗。Selecting loop from flow screen and regulati

21、ng set data, control model (Auto/ manual ) and manual output.2) 總貌畫面測試Genera appearance screen testing:a) 確認總貌畫面已按組態(tài)數(shù)據(jù)表組態(tài)。Making sure general appearance functioned according to function data.b) 檢查總貌畫面每個區(qū)組和單元的正確組態(tài)。Examining correct function of each unit and group of general appearance.3) 組畫面調(diào)試Groupsc

22、reen Testing:a) 確認組畫面中回路，與總貌畫面中描述的組一致。Affirming loops of group screen corresponding with those of general appearance screen.b) 各測量值、 設定值、模擬和數(shù)字形式的輸出均正確組 態(tài)。Measuring data, specified data, simulation and digital output are identical.c) 進行改變設定值、控制模式和輸出試驗。Testing of changing set data, control module and

23、output.d) 對數(shù)字或程序回路的組畫面， 通過改變其狀態(tài)，觀察塊的顏色或狀態(tài)顯示信息的變化應符合組態(tài)要求。For groupscreen of digital or procedure loop, color of observation block or change of indication result shall meet function requirement by changing its status.e) 確認對可選擇功能Selection function: 高低限報警、 偏差報警、輸出限制、 調(diào)整參數(shù)、電源故障 重新啟動模式、 串級或前饋回路信息、 濾波器參數(shù)以及

24、其 它與回路或數(shù)字程序有關(guān)的信息的組態(tài)。Functioning of high or low limit alarm, deviation alarm, output restict, modulating parameter, restarting pattern of power default, loop of series or prefeedback, filter para. And other messages related to loop or number procedure.4) 回路畫面測試Loop screen testing:a) 鍵入位號，調(diào)出回路畫面，確認回路類

25、型組態(tài)正確。In putting tag No. and finding loop screen.Making sure function of loop type is right.b) 確認測量值、設定值、輸出等正確組態(tài)。Making sure correct functions such as measured data, set date , and output.c) 進行改變設定值、控制模式和輸出的試驗。Testing of changing specified data, control moclule and output.d) 確認可選擇的功能已按設計正確組態(tài)。Ensure

26、Selection function:e) 用工程師鍵盤在此畫面上進行修改組態(tài)參數(shù)， 如在線 改變調(diào)整參數(shù)、組態(tài)信息的定義、算法選擇等試驗。Modifying function parameter using engineer keyboard on the screen. Such as, changing regulation para, on line, concept of function, selection of caculation method.5) 歷史趨勢畫面測試Testing of history trend screen:a) 確認該畫面已按組態(tài)數(shù)據(jù)表組態(tài)。Afirm

27、ing screen functioned on basis of function data.b) 時間基準變更試驗(可從 30分鐘到 12 小時變更) Altering test of time basis (from 30 minutes to 12 hours)c) 通過輸入信號， 觀察畫面能按實時信息自動更新，對 設計指定的變量進行歷史趨勢系統(tǒng)儲存時間檢查， 應 能保存 20-30 天。Observe screen can renew automaticly according to actual information through inputting signal. Stora

28、ge time of specified variability history trend shall be checked and preserved 20-30days.6) 報警匯總畫面測試Testing of alarm collective screen:a) 檢查報警畫面應按各報警發(fā)生時間先后順序排列， 且 報警畫面一旦被調(diào)用，即在畫面頂部顯示最新的報 警。Inspecting alarm screen according to alarming time sequence. If selected and used, latest alarm shall be showed a

29、t the top of screen.b) 確認每個報警的操作組號、 說明文字、優(yōu)先級別等正 確，且不同優(yōu)先級別的報警的聲光區(qū)分正確。Making sure operation No, instruction words, priority level is correct. Sound and light classification of different priority level alarm is true.c) 確認任一操作臺上消聲操作均能關(guān)閉所有的蜂鳴器。Affirming soundabsorption plant of every operation table can

30、close all sounders.7) 系統(tǒng)狀態(tài)畫面測試Testing of system status screen:a) 調(diào)出系統(tǒng)狀態(tài)畫面，檢查連接在通訊系統(tǒng)上的各節(jié)點 已正確組態(tài)。Finding system status screen. Checking all joints connecting with communication system have been correctly functioned.b) 當其中任一節(jié)點發(fā)生故障時，應能發(fā)出報警信號。 Alarming if each joint is wrong.5.1.6 操作鍵盤功能試驗 Keyboard Funct

31、ion testing:1) 確認由操作員直接操作的功能鍵操作正常， 能調(diào)出各種顯 示，操作每個回路(包括控制模式、設定值、設定串級、 輸出信號調(diào)整等)，報警確認，執(zhí)行打印機的各種功能。實用標準Operating keyboard directty operated by operator is normal. Finding all indications and operating every loop (including control module, set data, setting serieslevel, output signal ). Alarming and Execut

32、ing all functions.2) 確認由鍵鎖或口令啟動的操作員鍵盤功能操作正常， 能改 變測量圍，報警值及輸出信號限制等。Making sure keyboard function locked by key or password is normal. It can change measuring range, alarming data, and output signal restrict.5.1.7 打印機、拷貝機用報表測試Testing chart for printer and copier.1) 檢查打印機能將操作站規(guī)定的信息進行打印。Checking printer

33、can print information specified by operation station.2) 確認報警打印自動發(fā)生，排列順序與報警匯總畫面一致。Affirmingalarmprintingautomatically. Sequence keepcompliance with alarm collection screen.3) 檢查“確認”或“恢復”時間的打印與實際發(fā)生時間相同。Keep printing time of verifying and resuming identical with actual time.4) 檢查如報警發(fā)生數(shù)量比打印速度快，報警打印不會丟失C

34、hecking alarm printing can not lose if alarming speed is faster than printing speed.5) 檢查如打印機發(fā)生故障， 修復后仍能將這段時間的報警點 正確打印。If printer is wrong, alarming spot can be correctly printed during default time after repairation.6) 確認由 PLC 來的聯(lián)鎖報警在規(guī)定的組(整個聯(lián)鎖被劃分 為組)中具有第一信號顯示，并具有300ms的分辨率。Verify interlock alarm sig

35、nal PLC. In specified group has prior indication, and precision of 300ms.7) 確認拷貝機能對各臺 CRT 屏幕顯示的任何畫面進行硬拷 貝，測試時每臺 CRT 至少各拷貝一個畫面。Affirm all screens from every CRT indicating screen shall be hard copied by copier. At least copying a picture to each CRT.8) 確認報表能按組態(tài)的格式打印。實用標準Affiring chart can print accor

36、ding to function format.9）檢查小時報表、 班報表、日報表、月報表的自動打印功能。Checking automatic printing function of hour chart, daychart , monthly month.10）檢查報表數(shù)據(jù)可是瞬時值、 平均值、前 30 小時累計值（且 含有小時平均值）Checking chart data such as movent value, average value, and 30 hours acculation value （including hour coverage value5.1.8 系統(tǒng)記錄儀測

37、試System recorder testing:確認記錄儀已編程，功能符合設計要求。Making sure recorder has been complied. Function is compliance with design.給每臺記錄儀（ 3 筆）至少加一個輸入信號，檢查能否經(jīng)已組 態(tài)的通道記錄。Adding an input signal at least to every recorder. Checking wherher pass functioned access recorder or not.5.1.9 DC通道測試Testing of DCS Access:經(jīng)上述對

38、 DCS 組態(tài)及功能測試后， 進行 100%通道測試，即從 I/O 輸入端加信號，在操作站 CRT 上觀察指示值， 從操作站輸出信號， 在 I/O 輸出端測量輸出值，其偏差應符合精度要求（ 0.2 級）。After testing function, enecuting access-testing completely. Inputing signal from I/O end, observing indication value on operating station CRT, and outputting signal from measuring value. Output dev

39、iation allowance shall be compliance with accuracy requirement. （0.2 level）測試方法：根據(jù)回路圖，將輸入輸出信號按模擬量、數(shù)字量、 熱電偶、熱電阻等類型分組調(diào)試。Testing method: According to loop drawing, testing input and output signal on the base of classification such as sinullation signal, digital signal, thermocaple and RTD.調(diào)試過程中， 注意回路的分

40、支、 指示、記錄、報警等同時試驗。 Testing loop branch, indication, record, alarming simulltanously.每完成一個回路（或其中一部分）調(diào)試后，用色筆在回路一作 出標記，并及時填寫調(diào)試記錄。實用標準Making sign on the loop using color pen and filling testing record on time after testing.對順序及聯(lián)鎖回路試驗：根據(jù)邏輯圖、輸入信號檢查順序及聯(lián) 鎖動作應符合設計要求。若不符，檢查順序表組態(tài)。Sequence and interlock loop tes

41、ting:According to logic drawing and input signal, checking action of sequence and interlock compliant with design. If no , checking function of sequence table/schedule5.2 其它層次調(diào)試Other grade testing.由于本方案主要述及 DCS 調(diào)試。圖 3 儀表系統(tǒng)調(diào)試程序方框圖中的第一層 次調(diào)試(工序 2)及第二、三、四層次調(diào)試均為常規(guī)調(diào)試。故本方案僅作 簡要敘述，其中有關(guān) PLC 聯(lián)鎖系統(tǒng)調(diào)試方案另行編制。The

42、scheme has mainly introduced the testing for DCS. The testing work process in the pane -chart (chart 3) is gen eral test ing so brief in troduce in here. relevant testing for PLC has other scheme.5.2.1 輔助儀表盤儀表調(diào)試Testing of auxiliary instrument panel: 對其中的壓縮機盤主要是調(diào)速器、軸瓦溫度監(jiān)視器、機組 PLC 調(diào) 試。至于振動、位移監(jiān)視器調(diào)試，需待現(xiàn)

43、場電纜連接后作探頭特 性曲線測試后進行。Compressor panel testing mainly includes acculator axle temperature monitor, PLC group. After connection of local cable and testing of detector charactertistic contour , testing vibration and sitechange monitor.對火警和可燃氣體檢測系統(tǒng)，在不連接現(xiàn)場電纜的情況下，通過 接模擬負載進行聲光報警試驗。For fire alarm and gas det

44、ector system, under the condition of nonconnection local cable, executing sound and lightalarm test by pulsing simulation loading.5.2.2 控制室部系統(tǒng)調(diào)試CR system testing:這一層次調(diào)試檢查 DCS 與輔助儀表盤間的所有串行信號模擬 及聯(lián)鎖報警信號等，它與第一層次一起，構(gòu)成了裝置調(diào)試的核心。Checking all series simulation signal and interlock alarming signal 文檔大全實用標準bet

45、ween DCS and auxiliary instrument panel. It and first level test is the heart of plant testing.確認接口組態(tài)正確，檢查串行信號符合設計要求。keeping connector function correct and seriesline signal compliant with design.各機柜間所有模擬、數(shù)字（報警聯(lián)鎖）信號傳遞正確，動作可 靠，符合設計要求。All simulation and digital signal conveying between machine and cab

46、inet is right reliable, and compliance with design.5.2.3 二次聯(lián)校Secondary intertesting: 二次聯(lián)校是裝置開車前，設計、施工、建設單位對儀表調(diào) 試工作的全面檢查與確認，尤其是對聯(lián)鎖系統(tǒng)要組織電氣及工藝 專業(yè)人員共同確認。It is entire inspection and affirmation of instrument testing before starting up with shared participation of client, designer and contractor. For inte

47、rlock system. It shall be approved by electrican and process technican.1）首先要對回路電纜進行絕緣和導通試驗，然后在現(xiàn)場變送 器、發(fā)訊開關(guān)處加模擬工藝信號。First, executing insulation and conductivity test for loop cable. Then, pulsing simulation signal at place of local transmitter and output switch.2） 在二次聯(lián)校過程中，對檢測系統(tǒng)要進一步核對信號的量 程、工程單位、報警上下限等，對調(diào)節(jié)系統(tǒng)要檢查設定置、比例、 積分、微分時間預設定、輸出正反作用及調(diào)節(jié)閥氣開氣閉是否正 確，During the course of intertesting, checking signal range, unit upper a