昌暉儀表編制的DCS調試方案主要為本公司在施工過程中調試DCS系統(tǒng)使用，也可作為自控行業(yè)從業(yè)者在DCS系統(tǒng)調試中借鑒和參考。

1、編制說明
為高效優(yōu)質完成調校工作，確保工藝試車進度，并實現(xiàn)長期、安全穩(wěn)定生產的目標，昌暉儀表特編制本DCS系統(tǒng)調試方案。

2、編制依據(jù)
①工程合同
②施工圖及產品說明書
③《自動化儀表工程施工及驗收規(guī)范》GB50093-2013

3、DCS系統(tǒng)結構
DCS集散控制系統(tǒng)結構包括：
①操作站、操作臺
②工程師站(液晶顯示器和鍵盤)
③激光打印機或彩色打印機
④掃描儀(或帶掃描、復印和打印功能的一體機)
⑤大容量存儲單元
⑥無紙記錄儀
⑦控制站及I/O單元
⑧雙冗余通訊系統(tǒng)(包括通訊總線及接口模件)
⑨聯(lián)鎖停車操作臺
⑩超級用戶(帶打印機)
?PLC(帶編程單元及打印機)

4、儀表系統(tǒng)調試程序
圖1為儀表系統(tǒng)調試程序方框圖。本著分層隔離、平行作業(yè)的方法，昌暉儀表將DCS系統(tǒng)調試分劃為經(jīng)下四個層次：

①層次：DCS及輔助儀表盤儀表調試
在這一層次中，通過設置斷點，使DCS調試與輔助儀表盤儀表調試相對獨立、互不干擾，從而便于實現(xiàn)對這兩個工序的平行作業(yè)，并可避免因設備狀態(tài)不正常或接線錯誤等原因造成設備的損壞。
②第二層次：控制室內部系統(tǒng)調試
此層次在不連接控制至現(xiàn)場電纜情況下，對DCS機柜、PLC柜、火警盤等的系統(tǒng)調試。對于其中的聯(lián)鎖系統(tǒng)調試能否做早、做好、做扎實，對“消除隱患、掌握主動、贏得時間”意義重大。
③第三層次：全裝置儀表二次聯(lián)校
根據(jù)現(xiàn)場施工及工藝試車進度要求，逐點連接控制室至現(xiàn)場電纜，通過在現(xiàn)場加信號進行回路試驗，并陸續(xù)投用。
④第四層次：應用軟件參數(shù)的進一步調整
此為在單體試車、聯(lián)動試車之前、之中、之后，對某些儀表參數(shù)如復雜調節(jié)系統(tǒng)的計算系數(shù)、偏置值、延遲時間、設定值及比例、積分、微分時間等的試驗調整，以獲得運行工況。

5、DCS系統(tǒng)調試內容及方法
①DCS調試
現(xiàn)場調試工作主要是檢查使用系統(tǒng)軟件，并對應用軟件進行組態(tài)確認和功能測試。
Local testing mainly including: checking and applying system software.
Executing function approval and function test.
A、通電前的檢查
Inspection prior to making contact.
a、電纜絕緣電阻符合要求(大于5MΩ)，查看電纜絕緣電阻測試記錄，必要時抽查實測。
Insulation resistance is more than 5MΩ, checking resistance test record.
If necessary sampling and testing.
b、核對所有電源線、信號線、通訊總線，應連接無誤。
Checking all power supply lines, signal lines, and communication trunk
line right and identical.
c、控制站、操作臺、工程師站等各機框內插卡、適配器及其接口的型號、位置正確無誤。
For control station, operation table, engineer station, specification and site
 of all insert cards, adaptors and nozzle connection shall be correct.
d、各插卡預設定旋鈕位置正確。
Location for presetting button of insert cards is right.
e、供電電源單元及插卡上電源開關均處于“OFF”位置，所有保險完好無損。
Power unit and switch of insert card shall shut off, and fuses are undamaged and fine.
f、機柜內所有連接螺釘均應牢固、無松動。
Tightly fixing connection screw to machine and cabinet.
g、接地系統(tǒng)接地電阻測試
Grounding resistance testing:
◆ 從控制室接地板上拆除“MG”、“CG”接地母線，用接地電阻測試儀分別測量基接地電阻，應符合設計要求(小于10Ω)。
Dismantling MG and CG, from grounding plate of control room. Measuring grounding resistance and compliance with design(less than10Ω)
◆ 用萬用表檢查各機柜接地匯流排是否分別與“MG”、“CG”接地板插通。
Testing using multimeter whether grounding bus-bars of cabinet well connect with MG or Cg grounding plate or not.
◆ 測量“MG”、“CG”間絕緣電阻應符合HG/T20513-2104規(guī)范要求(大于5MΩ)。
Insulation resistance between MG and CG shall be compliance with HG/T20513-2104(more than 5MΩ)
h、UPS電源測試
UPS Testing:
◆ 檢查電源盤內和電源開關均處于“OFF”位置。
Make sure power panel switch and power switch shall shut off.
◆ 由電氣人員將UPS投運，測量送至儀表電源盤主電源開關前電壓應為220VAC±10%，50Hz±2%。
Electrican put UPS into use. Measuring voltage delivering to instrument power panel is 220VAC±10‰, 50HZ±2‰.
◆ 由電氣人員做UPS不間斷試驗。(滿負荷投用后，重復此項試驗，蓄電池供電時間應不小于30分鐘)
Electrican execute UPS testing (After overloading running do it again. Time of battery-supplying is no less than 30 minutes.)

B、DCS系統(tǒng)通電試驗
Testing of making contact.
逐個地將各機柜、操作臺進行以下通電試驗：
Testing every cabinet, operation-table one by one as follow:
a、將電源盤內去機柜電源開關置于“ON”位置用數(shù)字萬用表檢查機柜主電源開關前電壓，應為220±22VAC。
The switch in power supply panel to cabinet shall be on. Measuring voltage of cabinet main power prior to closing by digital universalmeter. The range of result is 220±22VAC.
b、確認機柜內各卡件(除電源卡件外)已拔離卡座，然后依次將機柜主電源開關、電源單元、電源卡件上電源開關置于“ON”，用數(shù)字萬用表測量各直流電壓輸出，應符合廠商說明書要求(5.1±0.02V、-12±0.3V、12±0.3V、24 VDC)。若超過允許偏差范圍，則進行調整。
Make sure all card components shall be pulled from plug. And then switch on main power switch of cabinet, power unit, power components. Applying voltage meter to measure direct output voltage, the measuring results shall be compliance with manufacture instruction. (5.1±0.02V,-12±0.3V, 12±0.3V,24+3.5VDC). Adjusting if out of deviation allowance.
c、進行雙電源手動切換試驗
Executing manual switch test with double power supply.
d、將各嵌套扇、信號變換器風扇、硬盤驅動器風扇、柜頂、門風扇等電源接通，檢查各風扇，應運行正常。
Running all ferrule fans, signal conrertor fans , hardpand-driving fans,top cabinet, door-fans, and checking whether they are normal or not.
e、檢查電源報警電路是否起作用。
Checking the reaction of power alarm circuit.

C、DCS系統(tǒng)啟動、裝載
System starting up and loading.
a、工程師站驅動程序
Starting procedure of engineer station
b、操作站驅動程序
Starting procedure of engineer station
c、控制站驅動：通電后，調出系統(tǒng)狀態(tài)畫面，確診狀態(tài)正常。
Control station starting: After making contact, selecting system status screen ans making sure it normal.
d、裝載操作
Loading operation.。
各站裝載程序詳見說明書。
All loading procedures refer to manufacture instruction.

D、DCS系統(tǒng)診斷及冗余試驗
System diagnosis and redundancy testing.
a、調出DCS系統(tǒng)診斷畫面，對各站、臺等進行診斷檢查。
Selecting system diagnosis screen,  and checking.
b、對DCS系統(tǒng)的各種冗余模件，人為地模擬故障(通過切斷電源；拔掉電源插頭、插卡等方法)，觀察備用模件能否在規(guī)定的時間內運行，并在操作臺上觀察切換過程，觀察自動切換過程是否正常。
Under the term of man simulation default, observing the running of spare module within specified time and converting. Inspecting automatic converting is normal or not.
◆ 電源冗余試驗
Power supply spare testing.
◆ 通訊冗余試驗
Communication  spare testing.
◆ 雙重化控制器冗余試驗
Spare testing of double-control controller.
◆ 操作站冗余試驗
Operating station spare testing.
◆ 打印機熱備用試驗
Heatintg spare testing of printer

E、DCS系統(tǒng)畫面測試
Screen Testing:
a、流程圖畫面測試
Screen testing of flow-process.
◆ 流程畫面以PID圖形式顯示，頁數(shù)及畫面內容應符合組態(tài)要求。
Showing flow, in from of PI.Page and content shall be compliance with function requirement.
◆ 畫面靜態(tài)顯示檢查。
Static display of screen testing:
● 檢查標題的位置、顏色、文字說明。
Checking title including site, color and word description.
● 圖形的形狀、大小、位置、顏色。
Shape, size, site and color of picture.
● 工藝管線的寬度、位置、顏色及進出接頭。
Width, site, color and inlet or outlet connector of process pipeline.
● 測量變量的符號、文字、大小、位置、顏色。
Symbol, word, size, site, color of measured variables.
● 儀表信號的箭頭、寬度、位置、內容。
Slope, width, site and content of instrument signal.
● 頁連接符號的形狀、大小、位置、顏色、進出箭頭。
Shape, size, site, color, and inlet and outlet slope of page nexto page.
● 工程測量單位符合設計要求。
Engineering measurement unit shall comply with design.
◆ 畫面動態(tài)顯示檢查：
Active display of screen testing.
● 測量變量的變化值應在系統(tǒng)可識別的精度范圍內。
Variable range shall be within the pricision recognized by system.
● 閥、電機運行狀態(tài)的顏色變化。
Color change of running status of pump or valve.
● 報警狀態(tài)變化，且應是正確的優(yōu)先級別。
Change of alarm status, which are right priority level.
● 從流程畫面選擇回路，進行調整設定值、控制模式(自動/手動)和手動輸出的試驗。
Selecting loop from flow screen and regulating set data, control model (Auto/ manual ) and manual output.
b、總貌畫面測試
Genera appearance screen testing:
◆ 確認總貌畫面已按組態(tài)數(shù)據(jù)表組態(tài)。
Making sure general appearance functioned according to function data.
◆ 檢查總貌畫面每個區(qū)內組和單元的正確組態(tài)。
Examining correct function of each unit and group of general appearance.
c、組畫面調試
Group-screen Testing:
◆ 確認組畫面中回路，與總貌畫面中描述的組一致。
Affirming loops of group-screen corresponding with those of general appearance screen.
◆ 各測量值、設定值、模擬和數(shù)字形式的輸出均正確組態(tài)。
Measuring data, specified data, simulation and digital output are identical.
◆ 進行改變設定值、控制模式和輸出試驗。
Testing of changing set data, control module and output.
◆ 對數(shù)字或程序回路的組畫面，通過改變其狀態(tài)，觀察塊的顏色或狀態(tài)顯示信息的變化應符合組態(tài)要求。
For group-screen of digital or procedure loop, color of observation block or change of indication result shall meet function requirement by changing its status.
◆ 確認對可選擇功能
Selection function:
高低限報警、偏差報警、輸出限制、調整參數(shù)、電源故障重新啟動模式、串級或前饋回路信息、濾波器參數(shù)以及其它與回路或數(shù)字程序有關的信息的組態(tài)。
Functioning of high or low limit alarm, deviation alarm, output restict, modulating parameter, restarting pattern of power default, loop of series or pre—feedback, filter para. And other messages related to loop or number procedure.
d、回路畫面測試
Loop screen testing:
◆ 鍵入位號，調出回路畫面，確認回路類型組態(tài)正確。
In putting tag No. and finding loop screen.
Making sure function of loop type is right.
◆ 確認測量值、設定值、輸出等正確組態(tài)。
Making sure correct functions such as measured data, set date , and output.
◆ 進行改變設定值、控制模式和輸出的試驗。
Testing of changing specified data, control moclule and output.
◆ 確認可選擇的功能已按設計正確組態(tài)。
Ensure Selection function:
◆ 用工程師鍵盤在此畫面上進行修改組態(tài)參數(shù)，如在線改變調整參數(shù)、組態(tài)信息的定義、算法選擇等試驗。
Modifying function parameter using engineer keyboard on the screen. Such as, changing regulation para, on line, concept of function, selection of caculation method.
e、歷史趨勢畫面測試
Testing of history trend screen:
◆ 確認該畫面已按組態(tài)數(shù)據(jù)表組態(tài)。
Afirming screen functioned on basis of function data.
◆ 時間基準變更試驗(從30分鐘到12小時變更)
Altering test of time basis (from 30 minutes to 12 hours)
◆ 通過輸入信號，觀察畫面能按實時信息自動更新，對設計的變量進行歷史趨勢系統(tǒng)儲存時間檢查，應能保存20-30天。
Observe screen can renew automaticly according to actual information through inputting signal. Storage time of specified variability history trend shall be checked and preserved 20-30days.

f、報警匯總畫面測試
Testing of alarm collective screen:
◆ 檢查報警畫面應按各報警發(fā)生時間先后順序排列，且報警畫面一旦被調用，即在畫面頂部顯示的報警。
Inspecting alarm screen according to alarming time sequence. If selected and used, latest alarm shall be showed at the top of screen.
◆ 確認每個報警的操作組號、說明文字、優(yōu)先級別等正確，且不同優(yōu)先級別的報警的聲光區(qū)分正確。
Making sure operation No, instruction words, priority level is correct. Sound and light classification of different priority level alarm is true.
◆ 確認任一操作臺上消聲操作均能關閉所有的蜂鳴器。
Affirming sound—absorption plant of every operation table can close all sounders.
g、系統(tǒng)狀態(tài)畫面測試
Testing of system status screen:
◆ 調出系統(tǒng)狀態(tài)畫面，檢查連接在通訊系統(tǒng)上的各節(jié)點已正確組態(tài)。
Finding system status screen. Checking all joints connecting with communication system have been correctly functioned.
◆ 當其中任一節(jié)點發(fā)生故障時，應能發(fā)出報警信號。
Alarming if each joint is wrong.

F、DCS系統(tǒng)操作鍵盤功能試驗
Keyboard Function testing:
a、確認由操作員直接操作的功能鍵操作正常，能調出各種顯示，操作每個回路(包括控制模式、設定值、設定串級、輸出信號調整等)，報警確認，執(zhí)行打印機的各種功能。
Operating keyboard directty operated by operator is normal. Finding all indications  and operating every loop (including control module, set data, setting series-level, output signal ). Alarming and Executing all functions.
b、確認由鍵鎖或口令啟動的操作員鍵盤功能操作正常，能改變測量范圍，報警值及輸出信號限制等。
Making sure keyboard function locked by key or password is normal. It can change measuring range, alarming data, and output signal restrict.

G、打印機、拷貝機用報表測試
Testing chart for printer and copier.
a、檢查打印機能將操作站規(guī)定的信息進行打印。
Checking printer can print information specified by operation station.
b、確認報警打印自動發(fā)生，排列順序與報警匯總畫面一致。
Affirming alarm-printing automatically. Sequence keep compliance with alarm collection screen.
c、檢查“確認”或“恢復”時間的打印與實際發(fā)生時間相同。
Keep printing time of verifying and resuming identical with actual time.
d、檢查如報警發(fā)生數(shù)量比打印速度快，報警打印不會丟失
Checking alarm-printing can not lose if alarming speed is faster than printing speed.
e、檢查如打印機發(fā)生故障，修復后仍能將這段時間內的報警點正確打印。
If printer is wrong, alarming spot can be correctly printed during default time after repairation.
f、確認由PLC來的聯(lián)鎖報警在規(guī)定的組(整個聯(lián)鎖被劃分為組)中具有信號顯示，并具有300ms的分辨率。
Verify interlock alarm signal PLC. In specified group has prior indication, and precision of 300ms.
g、確認拷貝機能對各臺CRT屏幕顯示的任何畫面進行硬拷貝，測試時每臺CRT至少各拷貝一個畫面。
Affirm all screens from every CRT indicating screen shall be hard-copied by copier. At least copying a picture to each CRT.
h、確認報表能按組態(tài)的格式打印。
Affiring chart can print according to function format.
i、檢查小時報表、班報表、日報表、月報表的自動打印功能。
Checking automatic printing function of hour chart, daychart , monthly month.
j、檢查報表數(shù)據(jù)可是瞬時值、平均值、前30小時累計值(且含有小時平均值)
Checking chart data such as movent value, average value, and 30 hours acculation value (including hour coverage value

H、DC系統(tǒng)記錄儀測試
System recorder testing:
a、確認無紙記錄儀已編程，功能符合設計要求。
Making sure recorder has been complied. Function is compliance with design.
b、給每臺無紙記錄儀(4通道)至少加一個輸入信號，檢查能否經(jīng)已組態(tài)的通道記錄。
Adding an input signal at least to every recorder. Checking wherher pass functioned access recorder or not.

I、DCS通道測試
Testing of DCS Access:
經(jīng)上述對DCS組態(tài)及功能測試后，進行99%通道測試，即從I/O輸入端加信號，在操作站CRT上觀察指示值，從操作站輸出信號，在I/O輸出端測量輸出值，其偏差應符合精度要求(0.2級)。
After testing function, enecuting access-testing completely. Inputing signal from I/O end, observing indication value on operating station CRT, and outputting signal from measuring value. Output deviation allowance shall be compliance with accuracy requirement. (0.2 level)
a、測試方法：根據(jù)回路圖，將輸入輸出信號按模擬量、數(shù)字量、熱電偶、熱電阻等類型分組調試。
Testing method: According to loop drawing, testing input and output signal on the base of classification such as sinullation signal, digital signal, thermocaple and RTD.
b、調試過程中，注意回路的分支、指示、記錄、報警等同時試驗。
Testing loop branch, indication, record, alarming simulltanously.
c、每完成一個回路(或其中一部分)調試后，用色筆在回路一作出標記，并及時填寫調試記錄。
Making sign on the loop using color—pen and filling testing record on time after testing.
d、對順序及聯(lián)鎖回路試驗：根據(jù)邏輯圖、輸入信號檢查順序及聯(lián)鎖動作應符合設計要求。若不符，檢查順序表組態(tài)。
Sequence and interlock loop testing:
According to logic drawing and input signal, checking action of sequence and interlock compliant with design. If no , checking function of sequence table/schedule

②DCS系統(tǒng)其它層次調試
Other grade testing.
由于本方案主要述及DCS調試流程和DCS調試內容。儀表系統(tǒng)調試程序方框圖中的層次調試(序2)及第二、三、四層次調試均為常規(guī)調試。故本方案僅作簡要敘述，其中有關PLC聯(lián)鎖系統(tǒng)調試方案另行編制。
The scheme has mainly introduced the testing for DCS. The testing work process in the pane –chart (chart 3) is general testing so brief introduce inhere. relevant testing for PLC has other scheme.

A、輔助儀表盤儀表調試
Testing of auxiliary instrument panel:
以壓縮機盤為例：對其中的壓縮機盤主要是調速器、軸瓦溫度監(jiān)視器、機組PLC調試。至于振動、位移監(jiān)視器調試，需待現(xiàn)場電纜連接后作探頭特性曲線測試后進行。
Compressor panel testing mainly includes acculator axle temperature monitor, PLC group. After connection of local cable and testing of detector charactertistic contour , testing vibration and site-change monitor.
對火警和可燃氣體檢測系統(tǒng)，在不連接現(xiàn)場電纜的情況下，通過接模擬負載進行聲光報警試驗。
For fire alarm and gas detector system, under the condition of non-connection local cable, executing sound and light  alarm test by pulsing simulation loading.

B、控制室內部系統(tǒng)調試
CR system testing:
這一層次調試檢查DCS與輔助儀表盤間的所有串行信號模擬及聯(lián)鎖報警信號等，它與層次一起，構成了裝置調試的核心。
Checking all series simulation signal and interlock alarming signal between DCS and auxiliary instrument panel. It and first-level test is the heart of plant testing.
a、確認接口組態(tài)正確，檢查串行信號符合設計要求。
keeping connector function correct and series-line signal compliant with design.
b、各機柜間所有模擬、數(shù)字(報警聯(lián)鎖)信號傳遞正確，動作可靠，符合設計要求。
All simulation and digital signal conveying between machine and cabinet is right reliable, and compliance with design.

C、二次聯(lián)校
Secondary inter-testing:
二次聯(lián)校是裝置開車前，設計、施工、建設單位對儀表調試工作的全面檢查與確認，尤其是對聯(lián)鎖系統(tǒng)要組織電氣及工藝專業(yè)人員共同確認并簽署相關文件。
It is entire inspection and affirmation of instrument testing before starting up with shared participation of client, designer and contractor. For interlock system. It shall be approved by electrican and process technican.
a、首先要對回路電纜進行絕緣和導通試驗，然后在現(xiàn)場變送器、發(fā)訊開關處加模擬工藝信號。
First, executing insulation and conductivity test for loop cable. Then, pulsing simulation signal at place of local transmitter and output switch.
b、在二次聯(lián)校過程中，對檢測系統(tǒng)要進一步核對信號的量程、工程單位、報警上下限等，對調節(jié)系統(tǒng)要檢查設定置、比例、積分、微分時間預設定、輸出正反作用及調節(jié)閥氣開氣閉是否正確，
During the course of inter-testing, checking signal range, unit upper and lower limit of alarming concerning inspecting or testing system time, portion, differential, Checking setting value, portion , time presetting of integral and differential; positive and back action of output and air opening and closing of control valve concerning to regulation system.
對聯(lián)鎖所警系統(tǒng)應擬聯(lián)鎖的工藝條件，檢查動作的正確與可靠性。
For interlock alarming system, checking correction and relianilty of action cooperating with interlock process terms.

6、質量標準
①施工圖及組態(tài)工作單。
②廠商說明書。
③施工圖及組態(tài)工作單。
④《工業(yè)自動化儀表工程施工及驗收規(guī)范》GB50093-2013
⑤《自動化儀表安裝工程質量檢驗評定標準》50131-2007
  
7、施工技術及安全措施
①通過對儀表系統(tǒng)調試程序的劃分，實現(xiàn)層次及工序間的隔離，這樣既能縮短工期，提高工作效率，又能保證人身與設備的安全。
②調試時一次完成每個回路及聯(lián)鎖分支的復蓋，避免遺漏和人力物力的浪費，確保調試進度和質量。
③二次聯(lián)校通過設置斷點，各回路逐點開通，調試合格后現(xiàn)場掛牌，避免造成現(xiàn)場短路而燒毀保險或損壞設備。
④在DCS調試過程中注意：
A、DCS調試及運行時應連續(xù)供電。
B、裝載時不能切斷電源，否則將損壞U盤，也不要觸摸鍵盤上的任何鍵.
C、拔出或插入卡件時，需佩帶防靜電接地帶，卡件檢查也應放在經(jīng)1M歐接地電阻接地的導電板上進行，卡件應裝于防靜電袋中存放。
D、更換組件或卡件時，嚴格按照廠商說明書操作程序進行。
E、組態(tài)的任何增、刪及修改，需辦理操作票，并作詳細記錄。
F、為確保系統(tǒng)正常工作，任何與DCS無關的存儲設備(如u盤等)不能插入控制室控制電腦。
⑤建立門衛(wèi)安全保衛(wèi)制度，專人值班，憑證出入。
⑥控制室內嚴禁吸煙。
⑦配備消防器材，預防火災發(fā)生。

8、施工網(wǎng)絡計劃
根據(jù)具體情況編排。

9、DCS系統(tǒng)調試勞動力安排


10、DCS系統(tǒng)調試用主要標準儀器
①高精度過程校驗儀：昌暉過程校驗儀YR100
②數(shù)字萬用表：FLUKE福祿克F87V/C
③精密電阻箱