【Daily Question 20090331】What types of DCS system crashes have you encountered at work?
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Please share your experiences: what kinds of DCS system crashes have you encountered at work, what were the consequences of those crashes, what were the underlying causes, and how were they resolved? We hope everyone will organize their thoughts and speak freely, participating actively; valuable insights from those who take part in the discussion will be highly rewarded. Original work is encouraged. In the future, we will discuss such practical situations based on on-site work to provide references for everyone. Thank you for your participation. This post was last edited by wopale3 on 2009-4-1 10:05.]
Frequently, the image doesn’t move and the mouse doesn’t work either; there’s no other option but to restart and log back into the system. It was fortunate that this didn’t have any impact on production, but I’m worried that it might go unnoticed during night shifts and cause problems. The reason, according to the instrument maintenance team, is a system issue
The download process of Huawen HPCS-3000 freezes; Huawen DPU performs the download in 2 steps: first downloading it to the backup controller, then switching the system to that backup controller, and finally downloading it to the main controller. It didn’t cause any damage; later, when it was taken back to the factory for testing, it was found that the DPU was broken. To this day, I still don’t know how it got damaged. If the I/O module is damaged, it has to be replaced; and if there are interlocked points that cause the machine to stop abnormally due to this module, the consequences are obvious. It seems to have been acquired by Far East Instruments now. Last edited by faner on 2009-3-31 12:31.]
HollySys~MACSV: Pulling the network cable from the server causes the server to freeze; or all data on the operator station becomes 0. The power supply of the problematic server is simply turned off, the network cable is reconnected, and then the server starts up normally. It is believed that there is a dual-server diagnosis process during startup, and pulling the network cable leads to an incorrect switch over by the server. Sometimes, pop-up windows related to motors and valves fail to appear, while the historical data remains unchanged (the curves appear as straight lines). Everything works normally after switching to another server. This post was last edited by afei6896 on 2009-3-31 at 12:31
In the systems I have worked with, the control stations from Yokogawa, Honeywell, and ABB have shown excellent stability, with no instances of crashes occurring. The DCS system used in our company’s gas tanks, which is equipped with a Siemens S7400 as its controller, has experienced shutdown failures; however, since it was primarily used for monitoring, no serious consequences resulted. Later, the cause of the accident was analyzed as being due to multiple damages to the IO cards.
The DCS system of Zhejiang University Zhongkong crashed due to a faulty hard drive, primarily caused by excessive environmental vibration. Later, vibration-damping measures were taken for the device’s environment, with good results.