Regarding the offline installation of DCS and SIS systems, as well as the hot-swapping of system cards, how do people prevent the devices from coming to a stop?
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As the title suggests: 1. During the installation of SIS, we experienced interlock actions that caused the plant to stop operating; the reason was an incorrect address for the instruments involved in those interlocks. How can we prevent fluctuations in the plant’s operation when installing DCS and SIS? What situations have you encountered before, and how did you avoid them? 2. The system cards are all designed to be hot-swappable and redundant. Do you replace the cards online while the device is running? How can we prevent the device from stopping operation during plugging and unplugging? 3. What needs to be confirmed before carrying out the work above? ?
Last time we installed it offline, it caused the furnace to enter interlock mode; it was such a hassle~~~~
To prevent problems, conduct more inspections, prepare in advance, and take risk factors into account. It seems that replacing parts is also something that needs attention within SIS, as this can help reduce the likelihood of issues (it’s necessary to check this in detail); there should also be relevant contingency plans
What needs to be prepared in advance? How to prepare it?
If the card slots are also redundant, you can first switch to the normal one, and then hot-swap in the faulty one. The issue with the lower-level components depends on the situation; many hardware configurations can cause the CPU to stop working
If it were me, I would first analyze the potential safety hazards and identify possible problems, then consider appropriate countermeasures based on those findings. The control components have preset parameters, so those need to be checked carefully; if there are interlocks in the input or output sections, they should be bypassed in advance. Additionally, it’s important to communicate with the workshop staff, as they can also provide some suggestions
Modifying the lower components online or replacing hardware inevitably poses a risk of vehicle shutdown.
When installing DCS and SIS offline, as well as performing hot plugging of system cards online, it is necessary to clarify the details with the process engineers and operators and shut down the equipment; the process engineers and operators must be careful during operation...