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產品詳情資料

分散控制系統(DCS)的主要作用是對生產過程進行控制、監視、管理和決策，因此具有很高的可靠性，才能保證工廠的、經濟運行。隨著大規模計算機系統和計算機通信網絡的不斷發展，可靠性問題己經成為一個十分重要的問題，其理論也在這種形勢下不斷地發展和完善。可靠性技術的研究內容大致分為四個方面：可靠性設計、可靠性分析、可靠性試驗、可靠性管理。

　　一、DCS系統的可靠性措施

　　在DCS系統中，采用了許多提高可靠性的技術措施。這些技術措施是建立在以下四種基本思想上的：

　　①使系統本身不易發生故障，即所謂的故障預防。

　　②在系統發生故障時盡可能減少故障所造成的影響，即所謂的故障保安和故障弱化。

　　③當系統發生故障時，能夠讓系統繼續運行，即所謂的故障容錯。

　　④當系統發生故障時，可以在不停止系統運行的情況下進行維修，即所謂的在線維修。

　　基于這四種基本思想，DCS系統中采用了各種各樣的可靠性措施降低事故的發生及所造成的損失。

　　1、質量管理和提高系統硬件水平

　　為了實現DCS系統的硬件可靠，DCS系統的制造商采取了一系列提高硬件質量的措施，如對元器件進行嚴格的篩選、老化元器件的降額使用、充分考慮到參數變化的影響、采用低功耗元件、采用噪聲抑制技術等。

2、DCS系統現場設計的可靠性措施

　　DCS出現問題后，將會有無法操作、無法監視等造成設備失控的情況出現。輕者出現設備停運影響經濟效益，重者危及人身和設備的。所以在設計中要根據現場的具體情況認真的考慮系統以下幾點可靠性：

　　(1)電源系統

　　DCS系統的供電系統是其運行的基礎，電源負荷不要超過60%，以免電源高負荷運行。同時要考慮用的電源，一般采用UPS電源，采用兩臺UPS互為備用好，一臺出現故障后備用機能夠無擾切換，提高電源的可靠性。UPS輸入電源不要采用電氣的同一母線，要根據電氣廠用接線取可靠性高的不同母線段電源，這樣保證電氣一段母線出現問題后不會影響DCS系統的電源。

　　DCS電源系統(UPS、電源柜等)在現場安裝時要安裝在滿足無塵、無振動、防腐等要求的電子設備間內，同時安裝完畢通電前把電纜孔封堵，以防泄漏蒸汽從電纜孔進入電源系統造成電源短路。在DCS電源上電后，要在UPS、電源柜等設備上掛“設備帶電運行禁止操作"標識牌，更不準可以在DCS電源系統上接入與DCS系統無關的負載，如檢修電源、檢修照明、充電設備、空調等。

　　(2)冗余系統

　　現場考慮人們有必要對重要的I/O模塊進行冗余，同時考慮操作員站的N:1冗余結構，這樣避免由于卡件或操作員站出現硬件故障造成設備停運。

　　(3)采用后備措施

　　①手動后備

　　對于重要的控制回路，可以采用手動后備的方法來提高可靠性。一旦自動控制失靈，用手動操作站直接進行操作，在這種情況下，手動操作站直接輸出4～20mA或1～5V的模擬量信號去控制執行機構或直接接地進行設備的操作，可以手動控制生產過程。

　　②自動后備

　　自動后備是采用冗余的方式設置另外一套或幾套備用控制裝置。當處于運行狀態的自動控制裝置發生故障時，備用控制裝置自動投入，維持系統的自動控制。自動后備是冗余系統的一種形式，冗余有主控單元冗余、電源系統冗余、網絡冗余、I/O模塊冗余、操作員站冗余、服務器冗余等。運行設備出現故障時，熱備設備會自動無擾的運行，同時不影響對故障設備的檢修。

英文產品詳細信息

The main function of a distributed control system (DCS) is to control, monitor, manage, and make decisions during the production process. Therefore, it must have high reliability to ensure the safe and economic operation of the factory. With the continuous development of large-scale computer systems and computer communication networks, reliability has become a very important issue, and its theory has also been continuously developed and improved in this situation. The research content of reliability technology can be roughly divided into four aspects: reliability design, reliability analysis, reliability testing, and reliability management.

1、 Reliability Measures for DCS System

In the DCS system, many technical measures have been adopted to improve reliability. These technical measures are based on the following four basic ideas:

① Making the system itself less prone to malfunctions is known as fault prevention.

② When a system malfunctions, minimize the impact of the malfunction as much as possible, known as fault security and fault weakening.

③ When a system malfunctions, it can continue to operate, known as fault tolerance.

④ When a system malfunctions, maintenance can be carried out without stopping the system operation, known as online maintenance.

Based on these four basic ideas, various reliability measures have been adopted in the DCS system to reduce the occurrence of accidents and the resulting losses.

1. Quality management and improvement of system hardware level

In order to achieve hardware reliability of the DCS system, manufacturers of the DCS system have taken a series of measures to improve hardware quality, such as strict screening of components, derating of aging components, fully considering the impact of parameter changes, using low-power components, and adopting noise suppression technology.

2. Reliability measures for on-site design of DCS system

After DCS issues occur, there will be situations where equipment cannot be operated or monitored, resulting in loss of control. In light cases, equipment shutdown may affect economic benefits, while in severe cases, it may endanger personal and equipment safety. So in the design, the following reliability points of the system must be carefully considered based on the specific situation on site:

(1) Power system

The power supply system of the DCS system is the foundation of its operation, and the power load should not exceed 60% to avoid high load operation of the power supply. At the same time, it is necessary to consider using high-quality power supply, generally using UPS power supply. It is best to use two UPS as backup for each other, and one backup machine can switch without disturbance in case of a fault, improving the reliability of the power supply. The UPS input power supply should not use the same electrical busbar. It is necessary to choose different bus section power supplies with high reliability according to the electrical factory wiring, so as to ensure that the power supply of the DCS system will not be affected if there is a problem with the electrical busbar section.

When installing the DCS power supply system (UPS, power cabinet, etc.) on site, it should be installed in an electronic equipment room that meets the requirements of dust-free, vibration free, and anti-corrosion. At the same time, after installation, the cable holes should be sealed before power on to prevent leakage steam from entering the power supply system through the cable holes and causing power short circuits. After powering on the DCS power supply, a "No operation allowed for live operation of equipment" sign should be hung on equipment such as UPS and power cabinet, and it is not allowed to connect loads unrelated to the DCS system, such as maintenance power supply, lighting, charging equipment, air conditioning, etc., to the DCS power supply system.

(2) Redundant system

On site, it is necessary to consider the redundancy of important I/O modules, while also considering the N: 1 redundancy structure of the operator station, in order to avoid equipment shutdown caused by hardware failures of cards or operator stations.

(3) Adopting backup measures

① Manual backup

For important control circuits, manual backup methods can be used to improve reliability. Once the automatic control fails, the manual operation station can be used for direct operation. In this case, the manual operation station can directly output 4-20mA or 1-5V analog signals to control the actuator or directly ground the equipment for operation, which can manually control the production process.

② Automatic backup

Automatic backup is the use of redundancy to set up another set or several sets of backup control devices. When the automatic control device in operation malfunctions, the backup control device automatically switches on to maintain automatic control of the system. Automatic backup is a form of redundant system, which includes redundancy in the main control unit, power supply system, network, I/O module, operator station, and server. When there is a malfunction in the operating equipment, the hot standby equipment will automatically operate undisturbed without affecting the maintenance of the faulty equipment.

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