DCS系統(tǒng)調(diào)試方案(中英)

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(jìn)度，并實現(xiàn)長期、安全穩(wěn)定生產(chǎn)的目標(biāo)，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)范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

2、程序圖一為儀表系統(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： DCS及輔助儀表盤儀表調(diào)試在這一層次中，通過設(shè)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(shè)備狀態(tài)不正?；蚪泳€錯誤等原因造成設(shè)備的損壞。4.2第二層次：控制室內(nèi)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。學(xué)習(xí)參考.4.3第三層次：全裝置儀表二次聯(lián)校根據(jù)現(xiàn)場施工及工藝試車

3、進(jìn)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(jìn)行回路試驗，并陸續(xù)投用。4.4第四層次：應(yīng)用軟件參數(shù)的進(jìn)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(fù)雜調(diào)節(jié)系統(tǒng)的計算系數(shù)、偏置值、延遲時間、設(shè)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)試內(nèi)容及方法Content and Method of testing:5.1DCS調(diào)試現(xiàn)場調(diào)試工作主要是檢查使用系統(tǒng)軟件，并對應(yīng)用軟件進(jìn)行組態(tài)確認(rèn)和功能測試。Local testing mainly including: checking and applying system software.Execu

4、ting function approval and function test.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。Insulation resistance is more than 5M, checking resistancetest record.If necessary sampling and testing.核對所有電源線、信號線、通訊總線應(yīng)連接無誤。Checkingallpowersupplylines,signallines,andcommunica

5、tion trunkline right and identical.控制站、操作臺、工程師站等各機框內(nèi)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 and siteof all insert cards, adaptors and nozzle connection shall be correct.各插卡予設(shè)定旋鈕位置正確。Location for presetting button of insert cards is right.學(xué)習(xí)參考.扣電源單元及

6、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 are undamaged and fine.機柜內(nèi)所有連接螺釘均應(yīng)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阻， 應(yīng)符合設(shè)計要求（小于 10 歐）。Dismantl

7、ingMG andCG, fromgroundingplateofcontrolroom.Measuringgroundingresistanceandcompliance with design (less than10 )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。Testingusing multimeterwhether groundingbus-barsof cabinetwell connect with MGor Cg groundingplateor not.c)測量“ MG”、“ CG”間絕緣電阻應(yīng)符合 GBJ93-86 規(guī)范要求（大于 5M歐

8、）。Insulation resistance between MG and CG shall be compliance with GBJ93 86 (more than 5M )8) UPS電源測試UPS Testing:a) 檢查電源盤內(nèi)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(yīng)為 220VAC 10%，50Hz 2%。ElectricanputUPS intouse.Measuringvoltagedeli

9、vering to instrument power panel is 220VAC 10, 50HZ 2.c) 由電氣人員作 UPS不間斷試驗。 （滿負(fù)荷投用后，重復(fù)此項試驗，蓄電池供電時間應(yīng)不小于 30 分鐘）Electrican execute UPS testing (After overloadingrunning do it again. Time of battery supplying is no less than 30 minutes.)學(xué)習(xí)參考.通電試驗Testing of making contact.逐個地將各機柜、操作臺進(jìn)行以下通電試驗：Testing every

10、cabinet, operation table one by one as follow:1) 將電源盤內(nèi)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(yīng)為 220 22VAC。The switch in power supply panel to cabinet shall be on. Measuring voltage of cabinet main power prior to closing by digital universalmeter. The range of result is 22022VAC.2) 確認(rèn)機柜內(nèi)各卡件（除電源卡件外）已拔離卡座

11、，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(yīng)符合廠商說明書要求（ 5.1 0.02V 、 -12 0.3V 、 12 0.3V 、24 VDC）。若超過允許偏差范圍，則進(jìn)行調(diào)整。Make sure allcard components shallbe pulledfrom plug.And then switch on main power switch of cabinet, powerunit, power components. Applying voltage meter to measure direct output

12、voltage, the measuring results shall becompliance with manufacture instruction. (5.1 0.02V,-12 0.3V, 12 0.3V,24+3.5VDC). Adjusting if out of deviation allowance.3) 進(jìn)行雙電源手動切換試驗Executing manual switch test with double power supply.4) 將各嵌套扇、信號變換器風(fēng)扇、硬盤驅(qū)動器風(fēng)扇、柜頂、門風(fēng)扇等電源接通，檢查各風(fēng)扇，應(yīng)運行正常。Running all ferrule fa

13、ns, signal conrertor fans , hardpand driving 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.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 en

14、gineer station學(xué)習(xí)參考.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.。各站裝載程序詳見說明書。Allloadingprocedures referto manufacture instruction.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、

15、臺等進(jìn)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)定的時間內(nèi)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 simulation default, observingthe runningof spare module withinspecifiedtime and converting.Inspectingautomatic converting is normal or no

16、t.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 spare testing.e) 打印機熱備用試驗Heatintg spare testing of printer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

17、內(nèi)容應(yīng)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：學(xué)習(xí)參考.Static display of screen testing:* 檢查標(biāo)題的位置、顏色、文字說明。Checkingtitleincludingsite,colorandworddescription.* 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(jìn)出接頭。Wid

18、th, site, color and inlet or outlet connector ofprocess pipeline.* 測量變量的符號、文字、大小、位置、顏色。Symbol, word, size, site, color of measured variables.* 儀表信號的箭頭、寬度、位置、內(nèi)容。Slope, width, site and content of instrument signal.* 頁連接符號的形狀、大小、位置、顏色、進(jìn)出箭頭。Shape, size, site, color, and inlet and outlet slope of page ne

19、xto page.* 工程測量單位符合設(shè)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(yīng)在系統(tǒng)可識別的精度范圍內(nèi)。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(yīng)是正確的優(yōu)先級別。Chan

20、ge of alarm status, which are right priority level.d) 從流程畫面選擇回路， 進(jìn)行調(diào)整設(shè)定值、控制模式（自動 / 手動）和手動輸出的試驗。Selecting loop from flow screen and regulating setdata, controlmodel (Auto/manual ) and manual output.2) 總貌畫面測試Genera appearance screen testing:a) 確認(rèn)總貌畫面已按組態(tài)數(shù)據(jù)表組態(tài)。Making sure general appearance functioned

21、according to function data.學(xué)習(xí)參考.b) 檢查總貌畫面每個區(qū)內(nèi)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Group screen Testing:a) 確認(rèn)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(shè)定值、模擬和數(shù)字形式的輸出均正確組態(tài)。Measu

22、ring data, specified data, simulation and digital output are identical.c) 進(jìn)行改變設(shè)定值、控制模式和輸出試驗。Testing of changing set data, control module and 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(yīng)符合組態(tài)要求。For group screen of digital or procedure loop, color of observation block or change of indication resul

23、tshall meet function requirement by changing its status.e) 確認(rèn)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, deviationalarm,outputrestict,modulatingparameter,restarting pattern of power default, loop of seriesor

24、 pre feedback, 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(rèn)回路類型組態(tài)正確。In putting tag No. and finding loop screen.Making sure function of loop type is right.b) 確認(rèn)測量值、設(shè)定值、輸出等正確組態(tài)。Making sure correctfunctionssuch as measured data,學(xué)習(xí)參考.

25、set date , and output.c) 進(jìn)行改變設(shè)定值、控制模式和輸出的試驗。Testing of changing specified data, control moclule and output.d) 確認(rèn)可選擇的功能已按設(shè)計正確組態(tài)。Ensure Selection function:e) 用工程師鍵盤在此畫面上進(jìn)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

26、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(rèn)該畫面已按組態(tài)數(shù)據(jù)表組態(tài)。Afirmingscreen functionedon basis of functiondata.b) 時間基準(zhǔn)變更試驗（可從 30 分鐘到 12 小時變更）Altering test of time basis (from 30 minutes to 12hours)c) 通過輸入信號， 觀察畫面能按實時信息自動更新，對設(shè)計指定的變量進(jìn)行

27、歷史趨勢系統(tǒng)儲存時間檢查， 應(yīng)能保存 20-30 天。Observe screen can renew automaticly according toactualinformationthrough inputtingsignal.Storagetime of specifiedvariabilityhistorytrendshallbechecked 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(yīng)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。

28、Inspecting alarm screen according to alarming time sequence. If selected and used, latest alarm shall be showed at the top of screen.b) 確認(rèn)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。MakingsureoperationNo,instructionwords,priorityleveliscorrect.Soundandlight學(xué)習(xí)參考.classification of different priority lev

29、el alarm is true.c) 確認(rèn)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 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 jointsconnecting with communication system have been correc

30、tly functioned.b) 當(dāng)其中任一節(jié)點發(fā)生故障時，應(yīng)能發(fā)出報警信號。Alarming if each joint is wrong.操作鍵盤功能試驗 Keyboard Function testing:1) 確認(rèn)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(shè)定值、設(shè)定串級、輸出信號調(diào)整等），報警確認(rèn)，執(zhí)行打印機的各種功能。Operating keyboard directty operated by operator is normal. Finding all indications and operating everyloop(includ

31、ingcontrolmodule,setdata,settingseries level, output signal ). Alarming and Executing all functions.2) 確認(rèn)由鍵鎖或口令啟動的操作員鍵盤功能操作正常， 能改變測量范圍，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.打印機、拷貝機用報表測試T

32、esting chart for printer and copier.1) 檢查打印機能將操作站規(guī)定的信息進(jìn)行打印。Checking printer can print information specified by operation station.2) 確認(rèn)報警打印自動發(fā)生，排列順序與報警匯總畫面一致。Affirming alarm printing automatically. Sequence keep compliance with alarm collection screen.學(xué)習(xí)參考.3) 檢查“確認(rèn)” 或“恢復(fù)”時間的打印與實際發(fā)生時間相同。Keep printing

33、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Checking alarm printing can not lose if alarming speedis faster than printing speed.5) 檢查如打印機發(fā)生故障， 修復(fù)后仍能將這段時間內(nèi)的報警點正確打印。If printer is wrong, alarming spot can be correctly printed during default time after repairatio

34、n.6) 確認(rèn)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。Verifyinterlockalarm signalPLC. In specifiedgroup hasprior indication, and precision of 300ms.7) 確認(rèn)拷貝機能對各臺 CRT 屏幕顯示的任何畫面進(jìn)行硬拷貝，測試時每臺CRT至少各拷貝一個畫面。Affirmallscreens from every CRTindicatingscreen shallbe hard copied by copier.At leastcopyinga pic

35、turetoeach CRT.8)確認(rèn)報表能按組態(tài)的格式打印。Affiring chart can print according 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 printingfunction 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

36、acculation value (including hour coveragevalue系統(tǒng)記錄儀測試System recorder testing:確認(rèn)記錄儀已編程，功能符合設(shè)計要求。Makingsurerecorderhasbeencomplied.Functioniscompliance 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 inputsignal at least to every recorder. Checking學(xué)習(xí)參考.wherher pass functioned access recorder

37、 or not.DCS通道測試Testing of DCS Access:經(jīng)上述對 DCS組態(tài)及功能測試后，進(jìn)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(yīng)符合精度要求（ 0.2 級）。After testingfunction,enecuting access-testingcompletely. Inputing signal from I/O end, observing indication value on operating station CRT, and outputtingsigna

38、l from measuring value. Output deviation 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。Testingmethod: According to loop drawing,testinginputandoutput signal on the base of classification such as sinullation signal, digital signal, therm

39、ocaple and RTD.調(diào)試過程中，注意回路的分支、 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(biāo)記，并及時填寫調(diào)試記錄。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(yīng)符合設(shè)計要求。若不符，檢查順序表組態(tài)。Sequence an

40、d interlock loop testing: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

41、系統(tǒng)調(diào)試方案另行編制。The scheme has mainly introduced the testing for DCS. The testingwork processin the pane chart(chart3) is generaltestingso brief學(xué)習(xí)參考.introduce inhere. relevant testing for PLC has other scheme.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)場

42、電纜連接后作探頭特性曲線測試后進(jìn)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?xì)怏w檢測系統(tǒng)，在不連接現(xiàn)場電纜的情況下，通過接模擬負(fù)載進(jìn)行聲光報警試驗。For fire alarm and gas detecto

43、r system, under the condition of non connection local cable, executing sound and light alarm test by pulsing simulation loading.控制室內(nèi)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。Checkingallseriessimulationsignalandinterlockalarmingsignalbetween DCSand auxiliary inst

44、rument panel.Itand firstlevel test is the heart of plant testing.確認(rèn)接口組態(tài)正確，檢查串行信號符合設(shè)計要求。keepingconnectorfunctioncorrectandseries linesignalcompliant 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(shè)計要求。All simulation and digital signal conveying between machine and cabinet is right reliable, and complianc

45、e with design.二次聯(lián)校Secondary intertesting:二次聯(lián)校是裝置開車前，設(shè)計、施工、建設(shè)單位對儀表調(diào)試工作的全面檢查與確認(rèn)，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(rèn)。It is entire inspection and affirmation of instrument學(xué)習(xí)參考.testing before starting up with shared participation of client, designer and contractor. For interlock system. It shall be approved by elec

46、trican and process technican.1）首先要對回路電纜進(jìn)行絕緣和導(dǎo)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 transmitterand output switch.2） 在二次聯(lián)校過程中，對檢測系統(tǒng)要進(jìn)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(shè)定置、比例、積分、微分時間預(yù)設(shè)定、輸出正反作用及調(diào)節(jié)閥氣開氣閉是否正

47、確，Duringthe courseofinter testing,checkingsignalrange,unitupper and lowerlimitofalarmingconcerninginspecting ortesting system time, portion, differential, Checking settingvalue, portion, timepresettingof integral anddifferential;positive and back action of output and air opening and closingof control valve concerning to regulation system.對聯(lián)鎖所警系統(tǒng)應(yīng)擬聯(lián)鎖的工藝條件， 檢查動作的正確與可靠性。Forinterlockalarmingsystem, checking correctionandrelianiltyofactioncooperatingwithinterlockprocessterms.6. 質(zhì)量標(biāo)準(zhǔn)6.1 施工圖及組態(tài)工作單。6.2 廠商說明書。6