Preface
This I & C Maintenance Manual is based on I & C equipment instruction and related drawings. It is only for the maintenance of I & C equipment in Pacitan 2×315MW coal-fired power plant, Indonesia.
Content
1.1 MAINTENANCE OF I/A SERIES CONTROL SYSTEM...5
1.1.1 SYSTEM HARDWARE INSTALLATIONAND ENERGIZATION...5
1.1.2 SYSTEM MONITOR SOFTWARE...7
1.1.3 DAILY MAINTENANCE...11
1.1.4 OPERATIONAND MAINTENANCEOF I/A’S SYSTEM...14
1.1.5 COMMON FAULTSAND SOLUTIONSFOR I/A SYSTEM...19
1.1.6 THE MAINTENANCE MANAGEMENTOFTHE I/A SYSTEM EQUIPMENT...21
1.2 DIGITAL ELECTRO-HYDRAULIC SYSTEM (DEH)...44
1.2.1 DEH SYSTEM GENERAL DESCRIPTION...44
1.2.2 COMPOSITIONOF DEH CONTROL SYSTEM HARDWARE...44
1.2.3 MAIN FUNCTIONSOF DEH CONTROL SYSTEM...61
1.2.4 BASIC MAINTENANCE ITEMSAND TECHNICAL REQUIREMENTS...62
1.2.5 DEH SYSTEM FUNCTION TEST...66
1.2.6 FAULT DIAGNOSESAND COMMON TROUBLE SHOOTING...70
1.3 TSI SYSTEM MAINTENANCE...72
1.3.1 TSI SYSTEM OVERVIEW...72
1.3.2 TSI SYSTEM FUNCTIONSAND COMPONENTS...72
1.3.3 TSI SYSTEM OPERATION MONITORING...79
1.3.4 TSI SYSTEM STARTUP...79
1.3.5 TSI TEST...81
1.3.6 LOCAL MAINTENANCEAND TECHNICAL REQUIREMENTS...81
1.3.7 TYPICAL FAULT ANALYSIS & TROUBLE-SHOOTINGOF TSI SYSTEM...82
1.3.8 CAUSESOF AXIAL DISPLACEMENTAND PROTECTIVE METHODS...83
1.3.9 CAUSESOF EXCESSIVE EXPANSION DIFFERENCEAND MONITORING MEASURES...84
1.3.10 CAUSESOF TURBINE OVER-SPEEDAND PROTECTIVE MEASURES...85
1.4 ETS SYSTEM MAINTENANCE...86
1.4.1 SYSTEM DESCRIPTION...86
1.4.2 WORKING PRINCIPLE...86
1.4.3 MAINTENANCE ITEMSAND TECHNICAL REQUIREMENTSOF ETS...87
1.4.4 TEST PRIORTO UNIT STARTUP...89
1.4.5 OPERATIONAND MAINTENANCEOF ETS...89
1.4.6 COMMON FAULTSAND TROUBLE-SHOOTINGOF ETS...90
1.5 ELEMENT AND INSTRUMENT FOR I&C MEASUREMENT...91
1.5.1 INSTRUMENTFOR TEMPERATURE MEASUREMENT...91
1.5.2 PRESSURE MEASURING ELEMENTAND INSTRUMENT...96
1.5.3 ELECTRIC CONTACT WATER LEVEL GAUGE...100
1.5.4 ROTATION SPEED MEASURING EQUIPMENT...101
1.5.5 ZIRCONIA ANALYZER...102
1.5.7 DRUM WATER LEVEL TV MONITORING SYSTEM...105
1.5.8 BOILER SOOT BLOWING PROGRAM CONTROL SYSTEM...107
1.5.9 MAINTENANCEOF UNIVERSAL SMALL SIZE RELAY...109
1.5.10 MAINTENANCEOF TRAVEL SWITCH...109
1.5.11 ELECTRIC ACTUATOR...109
1.5.12 AI-MI SERIES ELECTRIC ACTUATOR...110
1.1
Maintenance of I/A Series Control System
1.1.1 System Hardware Installation and Energization
Before installation, power supply, grounding, etc. should be checked firstly. Install equipment if everything is right. Usually, the control room should lay static electricity-proof floor; I/A equipment cabinet and operation room should be isolated by transparent glass, therefore, operator could inspect the front parts of cabinets to know operation conditions of I/A modules; cabinet and operation console should be installed on the base plate tightly; when installing cables, cable troughs should be used to keep strong power apart from weak power.
1.1.1.1 Before installation, check whether following tools are well prepared:
(Hex Driver) (Letterbug Tool)
System Installation Drawing System Installation Manual
These goods will be delivered as accessories in I/A system. The Hex driver and the Letterbug Tool are special tools for installing I/A equipment. Besides, the customers should prepare one set of straight screwdrivers or cross screwdrivers. The system installation drawing explains location, inter-connection, power distribution and grounding of I/A system equipment. Equipment showed in installation drawing has the Part Number which consists of numbers and letters. Equipment has attached labels for checking.
Push module into slot. Fasten fix screws with the Hex Driver.
Press terminal cable socket of external equipment with one hand slightly. On the top of module, there is an external equipment loading/unloading screw. Use the Hex Driver to drive this screw for 1/2 circle till contact pin contacting with socket.
1.1.1.2 Installation of AW390
Host computer for 390 is Pentium PC, No special installation and wire connections. Installation of FBM
Before installation, please read System Installation Drawing to check FBM positions in cabinets. Generally, slots for FBM is called FBM slot. Push FBM into slots. Fasten fix screws at upper and lower corners with the Hex Driver. Fit FBM terminal cable connection joints with opposite FBM. Fasten central screw with the Hex Driver.
Notice:
1. Please install I/A series modules according to System Installation Drawing carefully.
2. Connect wires carefully. Arrange wires in order.
3. During installation, please do not hurt equipment contacts pins.
1.1.1.3 Power on procedures
After installation, it can be energized. Before Energization, please check and make sure urban power and UPS are normal. Each power wire is connected correctly. After check, offer power to CRT, printer, etc. for self-inspection, and then, energize equipment with modules. Activate AW work station. Check the green and red lamps of DNBI or DNBX module of AW. At the beginning, red lamp is on, green lamp blinks regularly. After module self-inspection, work station will load work software. At this moment, only green lamp is on. Next, activate other work stations and FBM cabinets. After self-inspections and startup, all the green lamps of module are on while all the CRT displays. That is to say, system starts to work normally. Please set clock after system startup. Detailed information about clock set please refers to Notice: when energizing cabinet, turn on main power source firstly and then secondary power source
1.1.1.4 Shutdown procedures
Operation system for I/A is a multi-customer multi-task system. Therefore, do not cut off power randomly even there is nobody using computer. Shut down it according to following procedures. Otherwise, file system or hardware may be damaged.
AW/WP shutdown: enter into process control engineer station, select [SftMnt], and Shutdown_AW. Wait and then cut off power if handing it.
Click Start button at left corner of Windows XP display and get a menu. Do not use its last item Shut Down to turn off computer. Since that menu only closes XP in C: but not close I/A in D and it may cause computer crash.
1.1.2 System Monitor Software
I/A system provide one set of software package to monitor working condition of the system. We call it System Monitor. After activation of I/A, the software will put into service automatically. By using the software and its MMI, we can know and respond system equipment operation and system communication conditions.
1.1.2.1 Start MMI
Move the cursor to the SYS on menu, and click mouse left key. The pull-down menu will appear.
This is MMI, which connects operator and system monitor software.
图 1-3 Fig. 1-3
Click CLOSE key on menu for quitting MMI.
Note:Sys_Mgmt location may change since the environment setting is changed for the customer’s requirement. Please ask the designer for exact location.
CLR MSG –Clear testing information on the top of screen ACK CBL - Acknowledge cable alarm
ACK ALL - Acknowledge all alarms
SAL- System Alarm List, displaying alarm equipment name list NETWORK - Display I/A network structure
TIME - Set the clock
PERF - Communication Performance display, display communication conditions CONFIG - Display selected working station
OFFLINE- Offline diagnosis
INH DISP – Equipment name list (its alarm is inhibited)
ACK ALL above is used for acknowledging all alarm. If need to confirm alarming equipment, operate according to following steps:
Select station → Config → select module. At this time, the bottom will appear EQUIP INFO button; press it and then ACK button to confirm module alarm.
1.1.2.2 Time setting
Choose TIME key which is at the bottom of human-computer display. The display, showing in 8-6, will display. Click the big or small arrows to adjust time.
Choose RETURN-SET, confirm time you set and get back to previous display. Choose RETURN-CANCEL; get back to previous display without changing system original time.
图 1－4 Fig 1-4
Notice: Use time setting function to confirm time after I/A system startup to keep time of entire stations are the same. Otherwise, even if the times are correct, some software still can not be activated, like CIO configuration device etc
1.1.2.3 Fault response
Any equipment in system fails to work, like printer cable comes free, the intelligent transmitter can not communicate with I/A system, may activate system monitor software alarm. SYS key zone on the I/A menu will turn to red and flash. At the
same time, the preset printer will send out alarm signal. SYS zone exists in any cases. It has four kinds of color to indicate present condition of different system hardware.
Stable green Normal
Blinking green System had fault but get back to normal now (without acknowledgement)
Blinking red System had fault (without acknowledgement)
Stable red Existing fault have not been solve yet (already acknowledged)
1.1.2.4 Fault location
The system monitor software indicates equipment present condition and system communication condition according to Letterbug color changing and frame color changing situations in each monitor display.
White frame Normal condition; system communication is normal Red frame System has communication fault
Grey Letterbug this module should not be in the system
White Letterbug Module works normally
Yellow Letterbug Sub-equipment of the modules or one part of redundant
modules may work abnormally
Red Letterbug The module has fault.
The shining letters and asterisk(＊) means that there is un-acknowledged faults in system. If “<” appears at the back of equipment name, it means the alarm for equipment is forbidden artificially. This Alarm can be restored in EQUIP CHG. After system alarming, enter MMI of the equipment monitor software. Use the NEXT LEVEL and double-direction arrow interchangeably, find out failed equipment according to the above color definition. Diagnose the problem and find out fault causes. As for the possible causes and solutions, see B0193AD, System Maintenance
1.1.2.5 Fault acknowledgement
After finding out faulty equipment, we can use following methods to inform system that we have already known system alarming reason. As for system communication alarm, use the ACK CBL on the menu to confirm.
There are two methods for confirming equipment alarming:
Acknowledge all: in original display, choose the ACK ALL and acknowledge all the equipment alarming.
Acknowledge individual equipment alarm: in every equipment EQUIP INFO display, choose the ACK to confirm the alarming. After that, the alarming color will not blink.
1.1.3 Daily Maintenance
1.1.3.1 I/A Series system working environment requirements
I/A system working environment must meet some requirements that related to power supply, temperature, humidity, grounding and the air particle.
1.1.3.1.1 Power supply
I/A system requires that the power supply should be continuous and stable and have ability to supply power with battery to deal with the accident happens to the municipal electricity line. It is suggested that the UPS which is constant power supply with isolation should be used. UPS capacity should be decided by I/A system size. Usually, 1.5KVA is enough for one cabinet plus one operating plat. The battery is required to supply the power for 15-30 min.
1.1.3.1.2 Grounding
I/A system must be supplied with one isolated grounding stake. The grounding resistance is smaller than 5Ω (in power plant it is 1Ω). I/A system safety protection area, AC power supply area and the inner signal logic area should be connected with stake. Any equipment belongs to I/A can not be connected with the stake during the grounding.
1.1.3.1.3 Temperature
The temperature in control room should be controlled in the range of 15～30℃. In order to calculate the ability of air conditioner, the radiating amount of the equipment in I/A system has the detailed number in manual. Please refer to the Site Planning in BO193AA manual.
1.1.3.1.4 Humidity
The humidity of control room should be controlled within 20-28%.
1.1.3.1.5 Air particle
The fine dust in air should be controlled in the controlling room to prevent the entering of the dust. Please create the daily rules of controlling room and make sure the normal operation of I/A system.
Besides, the regulations should be created in the computer room, which clearly defines the equipment in the computer room should be maintained by special personnel.
1.1.3.2 Maintenance of hardware
build up a I/A spare parts store. The customer will prepare some spare parts for some components according to the system condition and some spare part for the components that are easily broken (like mouse, ribbon), and purchase some tapes and disks. All these are necessary. And the customers should store the FOXBORO company material, drawing and disk which are attached with the computer. They will play important roles in future.
If the fault equipment is found, and there is spare part, change it soon. During the installation of spare part, please use Letterbug Tool change the Letterbug. Till the new component green light shines, the component name can be seen in the system managing software in white that means the spare part has already worked normally. When the component is disassembled, release the “external equipment assembling screw” first (see 7-3), and then screw off the assembling bolt. The installation step is just opposite.
1.1.3.3 Maintenance of software
As for the maintenance of software, the main work is to make the backup of the software and resume the damage/lost software and to monitor the condition of system hard disk. If possible, it is better to make a tape backup of hard disk. When the system is in normal operation, please do not change, delete or add the system content. Please keep the secret of the code and memorize the code. If the system is change for necessity, the changing part must have the backup. Please give clear indication on the disk with the date and method and keep it well.
1.1.3.3.1 Software backup
Backup work has two types: make the backup to small amount of files and make backup to the entire hard disk.
1.1.3.3.1.1 Files backup
The save path of this system backup file is D:\opt\nw\tools. Ciosave command can be used to save backup file (ciosave command only can be used in commissioning period. It should be deleted when unit is normal).
d:\opt\nw\tools cd/opt/nw/tools ls
ciosave
1.1.3.3.1.2 Hardware backup
70 system operation system uses XP system and its backup method is the same with Windows. Only using COPY and STICK is ok.
Save-all command can be used to save the data of control processor FCP to disk. start run cmd d： sh cd opt/fox/ciocfg/api save-all cp2001 /opt
1.1.3.3.3 Use backup to download the data of control processor FCP.
Load_all command can be used to download the backup file in disk to control processor FCP. start run cmd d： sh cd opt/fox/ciocfg/api lood-all cp2001 /opt
1.1.3.3.4 System software reloading (DAYO reloading)
To ensure the completeness of these teaching materials, the installation of bare computer [computer without software] should be introduced. But if it is not necessary, DAY installation should not be used. We suggest that backup tape is used to restore the hard disk.
AW390 series software installation can be invided into two parts: Windows XP installation 和 I/A's software installation. AW390 series software installation is divided into two parts: Windows XP installation and I/A's software installation.
1.1.3.3.4.1 Windows XP installation
Firstly install the Airows NT 4.0 Workstation correctly. During installation, divide the hard disk into C and D two partition. C disk size should be bigger than 600M and the rest belongs to D disk. Name the computer in the Letterbug name that is needed. During the installation, a password is required to be set, set it as
PASSWORD. Based on your XP edition, it may need to be upgrade.
but if it is not, please install the show-card drive software; otherwise, the I/A can not be installed. The display resolution is required as 1024×768.
Check to make sure the network card is installed well.
1.1.3.3.4.2 I/A's software installation
Put I/A's software CD into CD-ROM, and enter into the CD through Airows Explore and then execute the Setup file in CD.
Then the installation display and the corresponding dialog box appear. When the first Question dialog box appears, choose Yes to build the Fox customer. Then the next dialog box Restart Now appears and choose Yes, I want..., press OK button. After the computer restart, repeat the operation of a).
When the dialog box Committed Install Files Disk ID # 101 appears, put the prepared Commit disk into FD and press Load button and then the installation will continue.
And then the dialog box on the main network card selection will appear, AW70 should choose network card of PCI bus wire; WP70 should choose network card of ISA bus wire. When the network card is selected, press Next button to continue the installation.
When the dialog box Release Level Diskette Disk ID # 11001 appears, put the matched disk into FD and press Load button and then the installation will continue. Repeat the process till the #11005 disk finishes the installation.
If it is not PC-FB, there is no this step. The dialog box PCFB Card Settings appears, set the IRQ as 11, Port as 340 and Shared Memory as D8000, and then press OK button.
At this time the dialog box Setup Complete appears and press View Logs button; the details of the software installation will appear and check whether there is warning (yellow text) or fault (red text) appears during the installation. Press the X button on the right corner of screen to close the box.
Take all of the magnetic disk and the CD out of the drive and choose OK. I want to restart my computer now appears and then press Finish button.
Now the I/A’s software installation finishes.
Notice: do not close eXceed, FoxPanels, RSLinx or any other I/A’s icons.
1.1.4 Operation and Maintenance of I/A’s System
1.1.4.1 Check before activation
1.1.4.1.1 The environment temperature, humidity and cleanness of computer equipment
1.1.4.1.2 The air condition ventilation hole above the electrical equipment cabinet should take measurements to prevent the water leaking.
1.1.4.1.3 The power supply fuse should meet the regulations.
1.1.4.1.4 The controlling cabinet and the intermediate terminal number and name should
strike the eye; terminal block wiring diagram should be put into the cabinet and lightening is good; the wiring of common power supply wiring, earthing wire, light wire and measurement loop wire should be correct and fastened.
1.1.4.1.5 The signal wiring and signal shielding grounding wire which get into the
intermediate terminal cabinet and the controlling station cabinet from the site should be connected correctly, stably and good-looking. The cable number and the wiring number should be complete and clear.
1.1.4.1.6 Check the following items one by one which should meet the requirements:
：
Control station:
1. The power supply module, main controller and the functional module and other equipment in cabinet should be reset and installed correctly and stably. 2. The signal wiring, power supply wiring, grounding wire and the connecting
cable in cabinet should be connected correctly, stably and perfectly.
3. The redundancy communication cable connect with several stations should be connected correctly, stably and perfectly.
4. The data communication wiring in the controlling station and the communication wiring between several controlling stations should be connected correctly, stably and perfectly.
5. Connecting cable between functional module and the corresponding terminal plate in intermediate terminal cabinet should be connected correctly, stably and perfectly.
Operator station, engineer station and service station
1. The power supply of the computer, display and printer of every station should be connected well.
2. The connection between keyboard, mouse, display signal wiring and the printer wiring and the computer should be correct and perfect.
3. The data communication wiring between stations should be connected correctly, stably and perfectly.
1.1.4.2 DCS system operation patrol
controlling system.
1.1.4.2.2 The equipment on site which has the interference should be checked to make sure
the circuit wiring is complete and also it should be equipped with shielding cover.
1.1.4.2.3 There should be the record on the hardware and software faults and the software
modifying to record the details of the faults of system (includes fault information and words), processing process and the modifying record of software each time.
1.1.4.2.4 It is forbidden to take the computer virus into computer. There should be no third
party software on the engineer station. The floppy should be specially used.
1.1.4.2.5 Make record on the defects during daily patrol check; arrange the defects
elimination according to the related regulations; the engineer on I&C should check the patrol checking record periodically and examine the treatment. The content and requirement of patrol checking includes:
1. Check the operation log and extract the problems of the controlling system. 2. Check SOE and the real time printer condition; input Ep content and time f.q
should be same with the reality; check the backup amount of the printing paper, and if there is paper block or lacking, treat the problem as soon as possible.
3. The clocks of the computer controlling system and other system should have the same time with the main clock.
4. Check the display alarm, alarm printing record, sound-light alarming device and the sequence order record (SOE). During normal operation, there should be no alarm displaying.
5. Check the indicating lights of the power supply system and every module which should be in normal operation. If there is any problem, treat it in time. 6. Check the environment temperature and humidity of the computer controlling
system, which should meet the requirements of manufacturer.
7. As for the controlling cabinet with heat dispersion air fan, the air fan should work normally. The failed air fan should be changed or take some necessary measurements.
8. Check the network fault record and make sure the network working condition is normal and has no frequent shift.
9. Check the system blank diagnose function display, it should have no abnormal alarm. The redundant equipment should be in the hot standby state.
10. 操作员站、工程师站、服务站和各控制站的运行状态应无异常。
10. The operator station, engineer station, service station and each controlling stations should work normally.
1.1.4.2.6 The environment index of equipment room, engineer station room and control station room should meet the requirements of the manufacturer.
1.1.4.3 Periodic maintenance during operation of DCS
Periodically check and test the following items during the operation:
1. The operating condition of operator station, communication interfaces, main controller, communication network, system switchover, and main backup power supply;
2. Historical data storage devices should be active or in default status. CD, hard disk and cassette tapes should be replaced if it has insufficient spare space. A cleaning tape should be frequently used to clean the magnetic heads during the using of cassette player;
3. Use a special cleaning disk to clean the CD driver about once a month;
4. Check whether the cooling fans works properly i.e., rotates normally, no abnormal sounds, etc. If it does not work properly, find out the reasons and handle the faults immediately.
1.1.4.4 Maintenance during normal shutdown and long term shutdown of DCS system
1.1.4.4.1 Shutdown computer control system
1.1.4.4.1.1 Normal shutdown of the computer control system:
1. The computer control system should be continuously powered. The power supply to equipment being repaired should be cut off;
2. Before the computer control system is shut down, confirm the relevant production processes have been taken out of service or relevant isolation measures have been conducted. If not, do not shut down the computer control system;
3. All of the required checks, processing and information storage have been finished;
4. All of the subsystems related to the equipment to be power off should be confirmed to be out of service and that power to this system is allowed to be turned off;
5. Confirm no personnel are working within the system and all power off procedures are complete.
1.1.4.4.1.2 Long term shutdown of computer control system:
1. Thorough backup of all software and data should be conducted before long term shutdown;
requirements during long term shutdown;
3. Regularly turn the system on and conduct relevant checks and tests to make sure that the computer control system is in good condition.
1.1.4.4.1.3 Maintenance and testing cycle of the computer control system:
1.1.4.4.1.3.1 The maintenance and testing of the computer control system should be conducted in conjunction with the unit major overhaul. The relevant maintenance should be conducted on the basis of system status when the unit is undergoing minor overhaul.
1.1.4.4.1.3.2 In the following situations, basic performance and functions of the computer control system should be tested.
1. New computer control system is being put into operation;
2. The computer control system has updated hardware and software;
3. The computer control system has important modified hardware and software.
1.1.4.4.1.4 Power off sequence
Power must not be randomly switched off. It must follow the following procedures: 1. Turn off the main power supply of every operator station;
2. Turn off the power supply of peripheral equipment, such as display monitor and printer;
3. Turn off the local power supply of control station; 4. Turn off the system power supply of control station; 5. Turn off the power switch of control station.
1.1.4.4.1.5 Checks and quality requirements relating to system energization
1.1.4.4.1.5.1 Directly energizing the computer control system after it has been repaired or shutdown is not allowed. The following procedures should be obeyed:
1.1.4.4.1.5.1.1 Preparation:
1. Confirm there are no personnel working within the power circuits of the subsystems related to the computer control system;
2. Conform all the subsystems related to the computer control system are allowed to be turned on;
3. The procedures for the operation of the system are complete. 1.1.4.4.1.5.1.2 Requirements of Power－on Process
1 During the Power-on process, every circuit output voltage of power module and power equipment or system power voltage should be inspected one by
one. When faults are found, it should be eliminated in time within the specialized range.
2 Next stage Power-on operations of equipment and system may undergo after confirming power voltage of Power-on equipment and system whether it is normal or not
3 Power-on of Control Station
1） Close main supply switch of control station.
2 ） Close power supply switch in control station and Close field power supply switch.
3） Start up control station to run automatic operation system. The indicator shows a normal state, then run self- diagnostic program to observe.
4 Power-on of operator station, engineer station and service station
1） Close mian supply, main power of engineer station and all service stations. When there is a display on the screen, entry the operation system and start application program (or system stars automatically).
2) Close all the switches for peripheral equipment, including printer, hardcopy unit and monitor.
3) Close the main power station switch of operator station. Application program automatically starts after startups of all operator stations.
5 Startup all computers one by one following stages above until the whole control system have started.
6 Check the indicators of communication link, display and all running equipment of the whole system. Running should respond to the actual statement. If not, problems need to be eliminated. When needed, dedicated inspect tools and soft wares can be used for a further inspection.
1.1.5 Common Faults and Solutions for I/A system
1.1.5.1 Power System Failure Inspections and Solutions
Indicators of power components should be inspected at required time everyday. When equipment operates abnormally and the light turns red, components should be removed immediately (components use matrix power supply mode, and any functional modules will not be affected). And then a new one should be changed. At the same time, check the normal value of UPS, and confirm power supply within stipulated range.
1.1.5.2 Faults and Solutions in Work station Processor
2. Press CTRL_ALT_F1 at the same time, and restart it.
3. Start it from other stations, and then entry SYS-Mgmt. Select fail WP and choose Reboot Station in Equipment Change display.
4. If all above do not work, turn off main power of WP cabinet.Then power on, and start it.
1.1.5.3 Faults of CP (Control Processor)
1.1.5.3.1 Symptom of failure: When one of the redundant CPs operates in a normal
statement, one’s red and green lights are all on or off（One CP runs normally, so it does not effect normal control. So use the following stage to lock CP）.
Solutions:
Entry SYS-Mgmt, and choose CP with faults. Then entry Equipment Change, and choose Reboot Station to start this CP.
If a does not work, this CP could be inserted and removed, then Power-on starts (the other CP should not be removed). If not, this CP should be replaced.
New version of hardware needs to be considered if a new CP does not work. If version marches, confirm that two redundant CPs are removed synchronously, and inserted again in accordance with production. If two CPs running at the same time is permitted, onsite monitoring should undergo closely with technologist. If not, maintenance personnel should observe closely when a CP is running.
1.1.5.3.2 Faults: red light and green light of two sets of redundancy CP are both on (or red
light is on while green one is off)
Analysis: at this time, the producing device may out of control, so redundancy CP should be started again. At same time, inform technical personnel to monitor field device operation strictly.
Solutions:
In order to restore CP control function as soon as possible, unplug CP with fault immediately, if the CP still cannot work normally, replace these two sets of CP.
1.1.5.3.3 Faults: one module in some loop or one control loop cannot operate normally.
(Especially PID, PIDE) Solutions:
Switch this loop to manual mode immediately, and then withdraw the AOUT module of this loop, which is used for technical personnel to control field operation manually
Enter into CIOS configuration, select module loop and edit all parameters if there are any faults, quit if the parameters are correct.
Choose DELETE in the menu, delete this module, and then choose UNDELETE to restore this module. In this way, module fault can be eliminated.
1.1.5.4 Input/output module, FBM trouble-shooting
There are two state indicating lights on FBM board. Maintenance personnel should pay attention to light state during daily inspection, and take immediate measure if there is fault.
1.1.5.4.1 Faults: one FBM state indicating light is abnormal: red light is on (green light is on
or off). Solutions:
1 Inform technical personnel to monitor the field in FBM area carefully. 2 Replace FBM
1.1.5.4.2 Faults: channel alarm of AIN appears frequently, or the signal which is detected by
technical personnel is not correct. Solutions:
1 Check the meter once, and put it into operation if there is no fault.
2 If the loop is control loop, change to manual operation firstly, and disconnect FBM channel terminal which connects with this detecting signal, use this signal to check FBM channel conversion accuracy. If this channel has fault, connect FBM channel terminal to the reserved channel terminal. At the same time, revise CIO parameters or replace FBM.
1.1.5.4.3 Faults:
Seen from operation interface, the loop can work normally, which means the output parameters are consistent with that of original design. However, the parameter which needs to be adjusted does not change correspondingly. or there is I/O channel alarm on operating interface.
Solutions:
Firstly check whether adjusting valve is blocked, at the same time, check accuracy of positioner. If there is no fault, use MA ammeter to check whether the corresponding FBM output channel can complete D/A signal conversion correctly. In this way, we can judge whether the output channel has fault or not. If there is fault, ask technical personnel to operate at local immediately, and exchange with reserved FBM channel, meanwhile revise CIO or replace the FBM.
1.1.5.5 System crash
Phenomenon: DCS display cannot be refreshed; the panel cannot be operated and data indication shows no changing.
Solutions: close the host computer power of crashed system, after waiting for three minutes, supply host computer power; after PASSWORD interface shows, input gnomes to restore the system.
1.1.6 The Maintenance Management of the I/A System Equipment
1.1.6.1 Basic maintenance items and quality requirements
1.1.6.1.1 Check up before shutdown
1 Check the condition of the computer control system, take a record of the abnormal conditions for further maintenance.
2 Check the operating condition of the hot air fans
3) Check the power supply voltage of the uninterrupted power supply (UPS) and the power supply voltage of each cabinet, check the voltage of DC power supply and the operating condition of each power module.
4) Check the working condition of each module in the cabinets, check the conditions of each channel and the operating condition of each operator station, control station, service station and the communication network, etc. 5) Check alarm system, take a detailed record of the crucial abnormal
information (such as redundance loss, abnormal switch, loss of important signal, data spill, frequent bus switch, etc.).
6) Check varied printing records and hard copy records.
7) Measure the temperature and humidity of control room, engineer station and electronic equipment room.
8) Check the operation log and the data base alarming log of the computer control system.
9) Check the computer self-diagnosis system and collect the abnormal records of self-diagnosis.
10) Check the equipment and daily maintenance record of computer system, collect the items which need to be solved after shutdown.
11) Check and record the surrounding conditions, such as temperature, of the field bus and the long-distance input/output local cabinets.
12) Make backup computer control system software and data, for the data and documents which stored in the memorizer (RAM, for example) should be uploaded and backed up in time.
1.1.6.1.2 Maintenance after shutdown
1.1.6.1.2.1 General regulation
computer control system. Cut off the power supply ， pull out the plug of the equipment which needs to be repaired.
2. The air conditioner system inside electronic room, engineer room and control room should have enough capacity. adjusting performance of temperature and humidity are good. the ambient temperature， humidity and cleanness should comply with GB2887 or the regulation of the manufactory.
3. The fuse of all the power circuit and channel fuse of module should comply with the requirements of equipment operation. If any damage is found, take a record of it, and after verifying the causes of the damage，make replacement with the same capacity and mode of the fuse.
4. The computer equipment should be complete, without rust corrosion, deformation or distinct damage.
5 Confirm the computer equipment are in order and the marks are complete and
clear.
6 Clean the equipment after electricity of system or equipment is cut off.
7 For the equipment with antistatic requirements, anti-static measures must be made before maintenance. Maintenance personnel must wear antistatic grounding bracelet and keep away from circuit. The disassembled equipment should be laid on anti-static plate, and the compressed air gun used for purge should be grounded.
8 The compressed air for purge should be dry and without oil dirt, and the pressure should be controlled around 0.05Mpa. the power of cleaner should be big enough to absorb the dust, and special detergent must be used for cleaning equipment.
9 The parts inside and outside cabinet should be installed firmly, all screws are
in place. The bolts of connection terminal board and grounding bus are tight. 10 The connection cable and lead in the computer equipment room should be
complete and and in good order, and the marks should be complete and clear.
1.1.6.1.2.2 The hardware maintenance of operator station, engineer station and service
station.
1. Confirm the power of the equipment which needs to be repaired has been cut off, and then open the cover of the cabinet.
2 There is no clear mark of damage or burning in circuit board, the elements of
circuitry plate has no weld loose. There is no line break of the connections or connection cable, and the fixing of the inner equipment, cards and the connection parts are tight, the fixing bolts are complete.
clearing, the radiator fan should run flexibly
4. Install the cover of the cabinet, and confirm that the power supply voltage grade is set correctly.
5 After the power is supplied, equipment can be started normally and enter the
operation system, the equipment has no abnormal sound or smell. There is no incorrect information in the process and the status indicator lights and interface displays of the are normal. Check the radiator fan runs normally and the rotate direction is correct. For the service station that has no display or operating equipment (such as keyboard or mouse) in normal working condition, display and operation equipment can be connected for inspection.
1.1.6.1.2.3 The maintenance of the control station:
1 Corresponding equipment of unit and computer control system are stopped,
the control system is stopped as well. Stop the sub-system and power supply of the equipment that is to be repaired.
2 Take an detailed record of the module cabinet , slot number and the jumper
wire setting that need cleaning.
3 Clean the module and heat radiator fan, and confirm ther are no dust, dirt,
damage and burn. The module has no corrosion and contact pin or the finger has no bend and crack. the assemblies in the module are firmly fixed, the setting of jumper wire and the pin are correct, the connection is reliable. The type and capacity of module are correct. all the marks of the module are clear.
4 Check the power-fail protection switch of the module of control station and the
jumping wire setting are correct. For the module with standby batteries, the batteries should be examined and replaced in accordance with the relevant regulation and requirements of the manufactory. When replacing the batteries, make sure that the electricity loss time is within the permitted range.
5 After clean and inspection, restore cabinet, frame and slot of module
accroding to the number, and the position should be correct.
6 When the module is in place, check and make sure that the connection cable
of the module (such as the flat connection cable) are inserted at the proper position and the installation is firm, and tighten the fix screw and bolts if necessary.
7 Before energization of the module, check the fuse and capacity of module.
after energization, the indication of indicator light should be correct and the heat radiator fan runs normally.
8 For the control station with display or keyboard or mouse interface, connect
display and operation equipment (keyboard, mouse) for checkup if necessary.
1.1.6.1.2.4.1 The maintenance items of indicator:
1 Cut off the power supply of indicator.
2 Clean the inside and outside of the display, and clean the display screen with
specialized lotion. After maintenance, the appearance should be clean. Check the elements inside circuit plate to make sure that the connection lines and plugs are correct and without breake and loose, tighten the elements if necessary. Check the signal cable inside indicator to confirm there is no short circuit, breake or crack. The insulation of equipment should be measured qualified.
3 Energize the display for checkup after the maintenance, the display menu
should be clear, without twinkle, twitter and abnormal color. The button function of brightness, contrast, color temperature, focus and positioning are normal. Adjust big screen display carefully to make sure the brightness and color are even.
4 The running of heat radiator fan of the big screen display should be normal.
1.1.6.1.2.4.2 The maintenance items for printer:
1 Turn off the power of printer, and disconnect the power plug.
2 Clear out the wastepaper inside the printer, and clean the paper conveyer and
paper conveying channel. Confirm the printer has no dust and dirt, and the elements of inner inner circuit plate has nothing abnormal. the connection parts or connection wires are correct and without loose and breaks, tighten the elements if necessary. The insulation should be measured qualified. add oil to the mechanical rotating part of the printer accordingly.
3 Recover the printer, and check the switches, jumper wire and the setting of relevant parameters are correct.
4 For the stylus printer, the paper thickness adjusting bar should be readjusted according to the thickness of the printing papers. after energization of printer, the automatic test program will be carried out to ensure that the characters are correct and clear. If there is break, replace typing head or ribbon.
5 For the ink-jet printer, after energization, the self-test program will be carried
out to ensure that the characters are correct and clear, and there are no deformed character, line loss or ink drop. when replacing the ink box, its type must match the printer.
6 For the laser printer, after energization, the automatic test program will be
carried out to ensure that the characters are correct and clear, and there is no character deformation, black lines or loose ink powder.
1 After deenergization, pull out the connection between the track ball and the computer or between mouse and the computer.
2 Clean the track ball and mouse carefully, including the ball, the pulley and the
light mouse glistening board.
3 Confirm the elements of the circuit plate are normal, the connnection wire is
correct and there is no wire break and wire loose. fasten the fixing screws if necessary.
4 Resume the connection with system, after energization, the operation for the
track ball and mouse should be flexible.
1.1.6.1.2.4.4 Maintenance items for the keyboard:
1 Operate each key under safety condition, if there is any key that moves not
flexibly or has no respond or wrong input, record its position.
2 Turn off the computer, pull out the connection between the keyboard and the
computer to clean the keyboard and shoot the trouble of keyboard, especially the keyboard which record with defects previously. The elements of circuit plate should be under good condition after maintenance, and there is no connection loose or cable break.The contact point of keyboard and the connection of the computer should be good and without dust or dirt.
3 Resume the connection with the system, and test each of the keys again after
energization to confirm that responses of the keys are quick and correct.
1.1.6.1.2.5 Maintenance of the network and interface:
1.1.6.1.2.5.1 The maintenance items for communication network:
1 Withdraw system
2 Replace the cable and fiber optic cable with fault, the communication cable has no damage and break after the maintenance, and the cable or fiber optic cable are well fixed and without bend.
3 Check the grounding condition of metal protective bushing of communication
cable (the metal protective bushing applied for local installation)
4 Measure the insulation resistance, and the impedance of the terminal matcher
to make sure they can meet the requirement.
5 Tighten all the connectors (or connector firm screws), all the insert connectors
(such as RJ45, AUI, BNC, etc.) and the terminal connection. After maintenance, test each of the connector, plug-in connector and terminal connection by pulling slightly to confirm there is no loose.
6 After energization, check the module indication lamps or via system diagnosis
system can work normally. The redundant bus should be at working condition, and the indication of the indicator lamp of the exchanger, the collecting tray, the coupling, the transponder and the bus module are normal after energization .
7 Check the control subsystem, I/O channels and the communication indications
via the system diagnosis or other methods provided by manufactory.
1.1.6.1.2.5.2 The checkup items of network interface equipment:
1 Before inspection, cut off the power supply of all equipment and mark the
connection cable and fiber optic cable, then disconnect the connection cable and fiber optic cable, and wrap the connector of the fiber optic cable which has been disconnected to prevent it from contamination.
2 Clean and repair the inside and outside of the network equipment, such as the
exchanger, the collecting tray, the coupler, transmitter and the fiber optic converter. tighten wire connection if necessary. The equipment should be clean and without dust or dirt after maintenance. the elements inside circuit plate has no abnormal condition, and the wire connection or the cable connection should be correct and without loose or break. all plugs should be under working condition, and the insulaton test for fans and other equipment should be qualified.
3 Carefully check the optical cable connection, Rj 45 interface or BNC interface
to confirm that there is no break, crack or deformation.
4 Restore the cover and supply power to confirm that the rotating direction of the
fan is correct, and there is no abnormal sound and smell. The automatic test has no fault, and the indication of the light is normal.
1.1.6.1.2.6 Maintenance of power supply equipment:
1.1.6.1.2.6.1 Maintenance items of module power, system power and cabinet power supply
1.1.6.1.2.6.1.1 Cleaning and common test
1) Stop relevant system, mark the power plugs or wire connection before pulling out.
2 Clean power supply equipment and fans, pull out the inner pieces of the power
supply carefully, confirm that there is no burning mark in inner printed circuit plate. The elements are normal, the connection wire, connection cable, signal cable, power line and grouding cable have no break or loose, tighten again if necessary. The big capacitance inside the power supply should have no expansion, deformation or leakage, otherwise, replace the capacitance with a new one with the same type and mode. Check the fuse, if there is any damage, replace with the same type and mode.
side of the transformer, and between the terminal in primary side and the ground, make sure that the insulation resistance can meet the requirement.
4 Resume the elements of power supply, the equipment should be clean and
without dust or dirt after maintenance. Insert the plugs according to the marks that have been made, and supply power after confirmation.
1.1.6.1.2.6.1.2 The energization test:
1) Before the energization , confirm that the voltage stage set of the power supply is correct. After energization , there is no abnormal sound or smell from the power device, and the temperature rising is normal. the fans rotate normally, and the rotating direction is correct.
2) Measure the output voltage according to the regulation to confirm the voltage meets the requirement.
3) Start the sub-system and make sure it works normally and without any alarm fault, the indicating lights of the power supply indicate correctly.
4） For the redundant power supply, cut off any circuit of it to check whether the relevant controller of it can work normally, or replace it.
1.1.6.1.2.7 The master clock and the GPS standard clock:
1.1.6.1.2.7.1 Cut off the power supply of the master clock system, clean the master clock or the
GPS standard clock.
1.1.6.1.2.7.2 The connection of the communication interface of the master clock should be right,
the communication cable has no damage. Startup the master clock, conduct synchronized calibration for the master clock and the standard clock.
1.1.6.1.2.7.3 The GPS antenna should be installed upright, there is no surrounding building or
sundries. The antenna plugs should be inserted firmly, and there is no damage or break in the feeder line.
1.1.6.1.2.7.4 The connection of the communication interface of the GPS standard clock should
be right, and the communication cable has no damage . Switch on the power to do the initialization test and self-test to make sure there is no fault; after the initialization test and the self-test, the indication of the GPS clock synchronization system is normal. If the GPS is out-of-step, the punctual clock inside the device should work normally.
1.1.6.1.2.7.5 Start the clock calibration function of each station, and calibrate the time indication
in each station to fulfill the synchronization of its master clock and the GPS standard clock.
1.1.6.1.2.8 Software check
1. Energize each computer, start the display menu and the self-test, if there is wrong information hint, take corresponding measure.
2. Generally, there is no wrong information hint during energization and self-start process of the operation system, and if there is erro, the error will be repaired automatically. Restart operation system to check there is no error indication, otherwise, consider back up resume or reinstallation.
3. After startup of the operation system, the entire application document should be closed. Start the disk testing and repairing program to test and repair the disk error.
4. Check and calibrate the system date and time.
5. Search and delete the temporary document in the system, clear up the recycle bin; for the computer station without the function of the automatic deleting of the data document, clear up the useless data document manually.
6. Check each user authority, the account command, the auditing and clientage relation and the setting of the area and group are correct, and meet the requirement of system. Check the authority set for the equipment or the document, the document share and the access of document should be right and meet the requirement.
7. Check the residual space of the disks and make sure there is some spare space. The disk chip tidying program should be started to optimize the disk.
1.1.6.1.2.8.2 The application software and the integrality test:
1. After modifying of the computer control system logical configuration, back up the software again.
2. Check the integrality of application software according to software list supplied by manufacturer.
3 Check and confirm system integrality according to system startup conditions 4. There are no abnormal and error indicates during startup of application system
software (as for energization auto start system, it will start after startup of operation system
5. Start other software of operation station, engineer station and service station separately, and there are no faults.
6. Scan and check the integrality of the software system by employing the utility program device that is provided,
7. Start the self-monitor, fault searching, and self-diagnosis software of computer control system to check whether the function can meet the regulation of the manufactory,
1.1.6.1.2.8.3 Check the authority setting:
1. Check the setting of user’s authority in each operator station, engineer station and service station to make sure the settingcan meet the requirement of management and safety regulation.
2. Check the user’s authority setting of the interface station network or the gateway to make sure they can meet the requirement of management and safety regulation.
3 Check the net work interface station or end VI service setting of gateway, and
stop the end VI service that is not used.
1.1.6.1.2.8.4 Data base checkup
1. The setting of data base visitation authority should be correct and meet the requirement of management and safety regulation.
2. Explore the data base, and the relevant information of data base and sheets should be correct.
3. If the record of the data base diary is full, back up immediately and then delete it.
1.1.6.2 The test after small repair and overhaul of DCS
1.1.6.2.1 For the computer control system after maintainance or upgrad, the performance
and functions of its system should be tested according to relevant requirements.
1.1.6.2.2 For the computer control system after maintainance or upgrad, if the test of the
performance and function of the equipment is normal, do the off-line operation for 72 hours to test the stability of the system, only when the stability of the system meet the requirements can the system be put into on-line operation.
1.1.6.2.3 The DCS system redundant switch test
1.1.6.2.3.1 The redundant switch test of the module, system and cabinet power supply
1.1.6.2.3.1.1 For the self power supply or redundant power supply system of the module, control
system and computer cabinet, do the following redundant switch test：
1） Disconnect the working power circuit to check that the stand-by power supply is automatically put into service;
2) For redundant power supply, cut off any circuit of the power supply. 3) Do the reverse switch test for the above 1) and 2) in the same way.
1.1.6.2.3.1.2 Recover the system into normal status.
1.1.6.2.3.1.3 During the above test, the control system should work normally, no loss of the
middle data and the accumulated data, and the fault diagnosis indication should be correct. There should be no fault, or other abnormal condition except I&C
equipment fault alarms.
1.1.6.2.3.2 The redundant switch test of the operator station and the service station:
1.1.6.2.3.2.1 For the equipments that are in parallel operation, the operator station, for example,
shut down one of the equipment or one part of the equipment, and this should not influence the normal operation of the whole computer control system.
1.1.6.2.3.2.2 For the equipment with redundant switch, when the main operation equipment is
shut down by cutting off the electricity or by shutting down the application software, the subordinate operation equipment should be automatically started or switched into main operation status.
1.1.6.2.3.2.3 Do the reverse switch test in the same way.
1.1.6.2.3.2.4 Recover the system into normal state.
1.1.6.2.3.2.5 During the above test, the fault diagnosis indication should be correct, there should
be no fault, or other abnormal condition except there is fault alarms from the I&C equipment relevant to this test.
1.1.6.2.3.3 The main controller and module redundant switch test in the control station:
1.1.6.2.3.3.1 Before energization of the main controller and the module, check the fuse to ensure that it is fine and complete, and the capacity is correct.
1.1.6.2.3.3.2 After energization of the main controller and the module, make sure that the indication of the indicating light matches the normal practical condition.
1.1.6.2.3.3.3 Select the following methods to do the redundant switch test of the main controller
and the module.
1. Take out the fuse of module and main controller under operation 2. Reset the main controller and the module in main operation.
3. Pull out the main controller and the module in main operation (the module can be pulled out or inserted when it is live)
1.1.6.2.3.3.4 Do the reverse switch test in the same way.
1.1.6.2.3.3.5 Recover the system into normal state.
1.1.6.2.3.3.6 During the above test, the system should be able to be switched into the operation
of the main controller and module in the subordinate operation, or is able to change the main controller and module from the subordinate operation into the state of main operation. the fault diagnosing indication should be correct. There is nothing abnormal in the system except the alarm for module fault and the redundant loss occurs.
1.1.6.2.3.4 The redundant switch test of the communication bus
1. There is no damage or break in the bus cable;
2. The connect and insert devices should be firm, the contact should be good, and the end connection should be correct and firm.
3. Check the resistance value in the bus terminal is normal, the connection is firm and the indication of the exchanger, the collecting tray and the bus module indicating lampare correct.
4. Check that system works normally through system diagnosis and bus module work indication. Redundant bus should be in redundant work condition.
1.1.6.2.3.4.2 Activate or deactivate the equipment on any node of the communication network,
the communication of the bus should be normal.
1.1.6.2.3.4.3 Cut off the communication connection between the node equipment and the bus
communication network in turn, there should be no fault, crash or other abnormal condition in the system.
1.1.6.2.3.4.4 Take the following methods to do the redundant switch test of the communication
bus:
1 Cut off the power supply for the main operating bus module;
2 Pull out the plugs of the main operating bus;
3 Disconnect the main operating bus cable or the terminal matcher;
4 Simulate other conditions.
1.1.6.2.3.4.5 Do the reverse switch test of c) and d) in the same way.
1.1.6.2.3.4.6 Recover the system into normal condition.
1.1.6.2.3.4.7 During the test, the communication bus should be switched into redundant bus
operation automatically.The indication of the indicating light and the system should be normal, and there is no system data loss, at the same time, confirm the communication is not interrupted, the fault alarm of I&C instrument is correct and the diagnosis menu display matches the practical condition.
1.1.6.2.3.5 Control loop redundancy switch test:
1.1.6.2.3.5.1 Put the computer control system as well as the main controller and modules related to the control loop into service normally.
1.1.6.2.3.5.2 Select one of the following methods to conduct the control loop redundancy switch
test:
1) Use a manual operating device or other equipment to manually make the control loop to output a static value or status. Then reset or turn off the corresponding main controller or output module that run in the main operation state;
2） Directly reset or turn off the corresponding main controller or output module that run in the main operating mode.
1.1.6.2.3.5.3 The same method is used to conduct control loop reverse redundancy selecting
test.
1.1.6.2.3.5.4 Restore the system.
1.1.6.2.3.5.5 Observe the control loop output during the test. There should be no changes or
disturbances. Check whether the operating mode of standby main controller or output module is right.
1.1.6.2.3.6 Fault tolerance performance test of the system:
1.1.6.2.3.6.1 When any undefined keys are operated on the keyboard of the operator station or
a series of illegal orders are inputted on the operator station, faults, crashes or other abnormal situations of the operator station and control system should not be occurred.
1.1.6.2.3.6.2 Conduct the reset test on the part of system and peripheral equipment:
1) Shut off the system power supply of control station, and shut off all of the power supply when the configuration is redundant. Turn it on after 30 seconds; 2) Shut off the running display monitor, and then turn it on again;
3) Shut off the running main computer of the operator station, and then turn it back on;
4) Shut off the running main computer of the communication station, and then turn it on;
5) Shut off the printers respectively then turn them on. This operation should be conducted both when the printer is working and when it is not working;
6) The control system should work normally and there not produce abnormal situations during the test. The displaying of fault diagnosis should conform to the actual situations.
1.1.6.2.4 UPS power auto activation and switch test
1.1.6.2.4.1 UPS test
1.1.6.2.4.1.1 UPS performance test:
1.1.6.2.4.1.2 Connect the UPS current input terminal to the output terminal of 0-250W AC regulator. Connect the regulator input terminal to the 220V AC power supply, then turn it on. According to the UPS manual, the current of voltage regulator should be adjusted to AC 190V, AC 220V and AC250V. Then respectively measure the output voltage of UPS power supply, which should be kept in the AC range of (1±5 ％ ) ×220V；
1.1.6.2.4.1.3 Connect the UPS power supply to AC 220V. Start the computer system powered by UPS power supply. Conduct the power switchover test and standby time test: 1) Connect the testing circuit to oscilloscope.
2) Confirm the charging indicator of UPS power supply is off. When the switched voltage is equivalent with the output voltage adjusted by the voltage regulator, UPS power supply should be switched to battery supply. Measure the output voltage of UPS. It should in the AC range of (1±5％)×220V.
3) Shut off the external power supply of the UPS and switch the UPS to battery power until the computer system is automatically shut down, then correctly shut down the computer.
4) Check the standby time of the UPS. It should not be less than the required time stated in the manufacturer’s manual. Generally, 30 minutes of continuous supply should be guaranteed;
5) Restore the UPS external power supply. Switch the power supply from battery power to external power supply;
6) Record the switchover time of the UPS power supply. It should be less than 5 mins;
7) Observe the switchover process to check the corresponding sound and light alarms, fault diagnosis displays and printing information. There should be no abnormal situations occuring in the operation of computer control system and other equipment. If there is, the UPS power supply should be repaired or replaced.
1.1.6.2.4.1.4 Inspection of communication between UPS and computer
1.1.6.2.4.1.4.1 Check the communication between UPS and computer is in a normal state. Start self-check of the UPS, and inspect the self-check report. It should be normal and with no fail information.
1.1.6.2.4.1.4.2 Start up UPS power test program from the computer, and check the communication with UPS is normal.
1.1.6.2.4.1.4.3 Cut off the UPS external power supply and transfer to battery supply, or cut off the power before the computer shutdown and there should be relevant alarm information.
1.1.6.2.5 Inspection and test of I/O module
1.1.6.2.5.1 Hot insertion and removal test of modules
1) Confirm the modules which will be tested have hot insertion and removal functions.
control system or equipment should automatically carry out relevant handling (such as transferring to manual operation, actuator holding its position, etc). During insertion and removal, other functions of the control system should not be affected.
3) When current signal is inputted into one I/O module channel and remains constant, insert and remove this electrified I/O module twice. It should not affect the system operation, process control and other inputs. Then the display should show corresponding state when the module is inserted and removed. The display’s corresponding physical quantity value should remain constant both before and after the test.
1.1.6.2.5.2 Real-time Test of System
1.1.6.2.5.2.1 Display response time: continuously switch display of the operator station 10 times, and test the time from the last operation to all contents of every display through program or stop watch. Then calculate and the average response time should be less than 1.5s. For normal displays, the time should be less than 1 second, 2 seconds for complex displays. The time should also not be lower than the manufacturer’s standards.
1.1.6.2.5.2.2 Date refresh time in the display: observe process variable real-time data and operation state change in the display. Then test 20 times via program or stop watch. Display real-time date and operation state refresh period should be 1s. Titles and display colors should change as the process changes.
1.1.6.2.5.2.3 Real–time function of on-off variables acquisition: select several on-off variables channels, connect several test signals and alternately change state in accordance with design on-off variables acquisition cycle. Check the real-time function of on-off variables acquisition via on-off variables print function. The printing should be in accordance with design acquisition cycle.
1.1.6.2.5.2.4 Processing cycle of controller module: test analog quantity and on-off variables processing cycle via program to confirm analog quantity control system is no more than 250ms and on-off variables control system no more than 100ms. In rapid process loop, analog quantity control system should be no more than 125ms and on-off variables control system no more than 50ms.
1.1.6.2.5.3 Test of System Response Time
1.1.6.2.5.3.1 Direct the switch value operation output signal to feedback signal input of operation object. Then record the response signal time which the operation station panel gives the command to display. Do it 10 times and take an average. The average response time should be not more than 2.0s.
1.1.6.2.5.3.2 Put analog quantity value operation output signal to response signal input of operation object directly. Then record the response signal time which the operation station board gives the commander to display (or select one analog quantity value
of engineer station as the detection point. Observe and record date change time of the signal which is inputted through the keyboard is sent to another display). And it should be done 10 times and take an average value of the time. The average response time should be not more than 2.5s.
1.1.6.2.5.4 Test of system memory space and loading rate:
1.1.6.2.5.4.1 Use the system tool or the method provided by manufacturer. Check the memory and external memory capacity and usage of historical data station or the station with function of historical data storage of every control station. It should meet the following requirements:
1) The memory space should not less than 40%.
2) The external memory space should not less than 40%.
1.1.6.2.5.4.2 Use the system tool or the method provided by manufacturer. Test the loading rate of computer control system and data commnication bus. The loading rate should be tested 5 times under the different working conditions and each test time is 10 seconds. The average value should meet the following requirements:
1) The loading rate for all the CPU of control stations should not more than 60% under the severe working conditions.
2) The loading rate for the CPU of operator station and service station should not more than 40% under the severe working conditions.
3) In the loading rate of data communication bus, ethernet should not more than 20% and other networks should not more than 40%.
1.1.6.2.5.5 Test of anti-jamming capacity:
1.1.6.2.5.5.1 The test of anti-jamming capacity should be conducted when the operating environment of the computer control system has been changed.
1.1.6.2.5.5.2 Test that bring interference voltage into onsite:
1) Use the transformer as interference source. Bring the common-mode disturbance voltage and differential-mode disturbance voltage from the singal loop of onsite current, thermocouple and thermal resistance. Measure the actual common-mode disturbance voltage and differential-mode disturbance voltage on the input terminal of I/O of control station (see the method in Appendix C).
2) If the test condition that bring the interference voltage from the onsite is not meet the requirement, Measure the actual common-mode disturbance voltage and differential-mode disturbance voltage brought from the onsite on the input terminal of I/O of control station when the accuracy of analog signals being tested.
