Talk about what kinds of failures have occurred in the DCS system used in your workplace How to handle it?

This post was last edited by LZ Gas Station on 2009-6-12 at 16:54. The most common issues are blocked channels and reduced accuracy. Others include: communication failures, system instability caused by fluctuations in the external power grid, faults in the system’s DC power supply, as well as errors or omissions in the configuration connection addresses.

Our company’s Yokogawa DCS system, CENTEM CS, has been in operation since 1999. Since it was purchased from France, the project construction took several years longer; as a result, in 2000 the FCS field control station came to a stop due to a total power failure of the system. Upon powering it on again, the system will not work, and a communication error message is displayed. Reason: The program on the FCS field control station is missing, preventing it from starting properly. The battery that prevents program loss has failed; replace it with a new one and install all programs offline. Result: success

The system does not display anything, and there is no activity when it is turned on. The chassis was removed, and a dust blower was used to clear the dust inside; yet the system still wouldn’t display anything. The memory gold contacts and slots were cleaned again. The system is working properly. Microcomputer failure.

VIA system: The microcomputer data line suddenly showed a value of zero; upon inspection, it was found that the 24VDC power supply supplying power to the system was damaged. After replacing the 24V power supply, the data returned to normal. Central control system: The data within the same analog card affect each other, resulting in large fluctuations. Even after ruling out grounding issues, the fault persisted; ultimately, replacing the card resolved the problem and the data returned to normal

The Yokogawa CS 3000 displayed a communication fault; upon inspection, it was found that the network cable was loose at the interface with the switch. After reseating it properly, normal operation was restored. The redundant I/O card suddenly switched to the redundant one; checks revealed that the issue was caused by a loose card, and normal operation was restored after tightening it.

I’ll start by explaining*; I use Zhejiang University’s DCS system. The most common issues I encounter are: 1. The mouse doesn’t appear on the screen – unplugging it and replugging it solves the problem. 2. The computer won’t start, with an error message displayed; removing and reinserting the memory stick resolves this issue. 3. The cards lose their stored data, so it’s necessary to remove and reinsert them. 4. The daily operation list on the operator station does not display real-time operation records; re-transmitting the configuration will resolve this issue.

Our company uses Honeywell’s systems. A problem that occurs frequently these days is that the I/O cards fail to respond (NR); the issue is resolved by unplugging and replugging them. Another common problem is software faults (SF), which are also usually fixed by unplugging and replugging the cards. We consulted Honeywell’s project engineers, who recommended the same solution. I wonder if anyone else has encountered such problems

Let’s continue the discussion: In 2006, I was working on instrument calibration at Weifang Haineng Thermal Power Plant (i.e., starting up individual units, subsystems, and the entire plant). The DCS system used for controlling the turbines and boilers was the EDPF-NT distributed control system developed by Beijing Guodian Zhishen. During debugging, safety measures have been taken to prevent accidental activation of control outputs, which could lead to improper operation of electrical equipment. Therefore, the installation and debugging of the cards are carried out step by step, section by section, and system by system, in strict accordance with the debugging schedule. Fault phenomenon: Even with such diligent efforts, problems still arose inevitably. At the beginning of the startup process for the entire system, it was found that the network communication between the turbine FCS and HIS (i.e., the control station and operator station) had been interrupted. Under normal conditions, two green communication links should be displayed on the system maintenance interface; in the event of a fault, one link will be green while the other is yellow. As the fault progresses, both of the redundant communication networks will turn yellow. Inspection: It was checked whether the network cables and RJ45 connectors on network servers, switches, etc. were firmly connected and undamaged; a thorough inspection of the cabinets in the electronics room was carried out. It was found that the Ethernet communication cards in the cabinet of the on-site control station for the steam turbine system indicated faults, and the CPU module of the control station also showed errors. Solution: 1. Hot-plug the corresponding module, but the issue remains unresolved. 2. Fully opened the CPU module to check its internal condition, and the sight that greeted me was shocking: dust had completely covered the electronic components, rendering the cooling system completely ineffective. The compressed air was used for cleaning, it was installed back in place, and all faults were resolved. Post-analysis: There was inadequate management of the control room and electronic equipment rooms; more critically, the civil construction work in the electronic equipment room had not been completed yet when the owner demanded an accelerated completion schedule. Installation of the DCS system and performance testing were carried out in conditions that did not meet the required environmental standards, resulting in severe interference from concurrent civil engineering work and damage to the system’s hardware equipment. It should serve as a warning! ! !

Our factory also uses HONEYWELL products. We encounter the problems mentioned above frequently, so during shutdowns for maintenance, we cleaned all of our servers and control stations. As for the grounding issue, we conducted thorough inspections and made necessary replacements.

I’ve learned about it. We use the Japanese Yamawa DCS system, and the trends that are generated often stop appearing; restarting it resolves the issue. Additionally, the DCS system displays data very slowly, with no response to operations