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1、DCS控制系统安全验收评价引言（1） 近年来，自动化控制系统，特别是集散控制系统（DCS控制系统）在石油、化工、电力、冶金、轻纺行业中得到广泛的应用。在降低能源和原材料消耗、提高产品质量、确保安全生产、改善和加强企业管理等方面已取得了明显的经济效益和和社会效益。同时，这种生产过程的大型化、连续化、自动化发展趋势和在集控室内的 集中控制，也增加了安全生产的复杂性。本文针对DCS控制系统的特点，就安全验收评价中涉及的有关技术问题进行阐述。安全评价的总体要求（2）总体要求是：DCS控制系统应能在异常情况下控制设备和装置不发生危险，必要时控制装置要能自动切换到备用电源和备用设备或装置中去；调节装置要有
2、连锁，以防止误操作和自动调节装置的误通、误断；要评价紧急事故开关的设置情况。下列情况须设置紧急事故开关：（1） 发生事故时，不能通过停车开关来终止危险的运行；（2） 不能通过总开关来迅速中断若干个造成危险的运行单元；（3） 由于中断某个单元能出现其它危险；（4） 控制台不能看到所控制的全部装置和设备，无法分析判断和实施有效控制。紧急事故控制要有防止灾害的措施，如防窜压、防逆转等措施。紧急事故开关应该用红色，并能明显区别其它开关。主要危险因素的识别（3）2.1主要危险因素及相关作业场所 DCS控制系统的主要危险因素有：控制系统断电；控制站失灵；仪表损坏和电气联锁失效等。 主要危险因素的相关作业场
3、所是集中控制室和在现场的检测仪表、执行机构。2.2 DCS控制系统所涉及的危险因素及存在的部位 DCS控制系统断电、控制站失灵和电气联锁失效将导致系统的非正常停机。对于有毒和高温、高压设备而言可能导致有毒物质的泄漏、引发火灾或高压设备的爆炸。危险因素存在的部位是UPS电源、DCS控制器和可编程控制器（PLC控制器）。仪表损坏将导致系统的非正常运行。特别是执行机构损环将导致控制失灵，对于有毒和高温、高压设备而言可能导致有毒物质的泄漏、引发火灾或高压设备的爆炸。危险因素存在的部位是现场的检测仪表、执行机构。危险因素安全控制措施（4）首先，要制定DCS控制系统的安全应急救援预案，并组织员工按照安全应
4、急救援预案进行演练。其次，必须针对主要危险因素制定相应的安全控制措施，具体是：3.1DCS控制系统断电的安全控制措施 DCS控制系统通常采用UPS电源，以保证在供电电源断电后，仍能在规定时间内将系统关闭在安全状态，这就要定期检查UPS电源的工作状态和容量，对于冗余电源，应分别切换，确认系统运行正常。3.2控制站失灵的安全控制措施进行控制站冗余安全试验3.2.1在操作站上调出系统状态显示画面，确认控制站OK，在另一操作台上调入该控制站内的某一位号，送420mA信号于该位号，记录测量值（PV）、给定值（SP）和输出值（OP）；3.2.2控制站电源开关置于“OFF”状态，确认冗余的控制站自动投入控制
5、运行，PV、SP和OP值保持不变；3.2.3主控制站电源开关恢复“ON”状态，再确认PV、SP和OP值不变；3.2.4重复以上步骤检测冗余控制站。3.3仪表损坏的安全控制措施3.3.1把好仪表入口关,三证齐全方可使用.三证包括生产许可证、出厂的合格证及化验单、试验报告等。3.3.2定期检查、校验强制性检测的仪表运行情况，以避免仪表失灵。3.3.3对于重要联锁保护系统开关量仪表的整定，及重要调节回路的仪表单体调试，其整定调试完毕到仪表投用之间的存放时间不宜不超过2个月。3.3.4仪表应备有足够的备品、备件。3.3.5仪表应具备如下技术资料：仪表卡片、仪表说明书，检修校验记录、流量计算数据、仪表控
6、制流程图和重要的接线图，以及仪表的设计（包括孔板和调节阀的计算）安装和检修资料。3.3.6当在线仪表发生损坏时，DCS控制系统应能及时的显示、报警，必要时，可启动联锁保护系统按规定要求动作，以确保工艺装置的安全生产或停机。3.3.7电气联锁失效的安全控制措施进行联锁保护系统安全试验 联锁保护系统逻辑设计原则必须满足工艺装置的安全运行，在发生异常情况时发挥作用，使联锁保护系统按规定要求动作，以确保工艺装置的生产安全，避免重大人身伤害及重大设备损坏事故。按照用途，电气安全联锁装置可分为防止触电事故的联锁装置、排除电路故障的联锁装置、执行安全程序的联锁装置和防止非事故的联锁装置。按照试验顺序，电气安
7、全联锁装置可按手动联锁试验、自动联锁试验、机组联锁试验来进行。3.4.1手动联锁试验 对整个逻辑回路所包含的现场输入点，采用模拟现场条件的办法，每次只选择一个能直接影响控制输出接点状态的输入点进行测试，而短接或断开回路中其他相关现 场输入接点。分别使测试点短接或断开，来检验输出接点的动作是否满足设计的联锁功能，然后对能影响这一输出接点状态的所有输入点逐一进行检查，以检验整个 逻辑回路要求的机械设备和阀门开停（启闭）动作信号、声光信号、动作时间等是否符合设计要求，试验完毕恢复接线。3.4.2自动联锁试验 由工艺操作人员现场配合，制造模拟生产现场，待仪表各回路投入正常运行后，按照逻辑图在现场逐项进
8、行故障模拟，检查现场机械设备和阀门开停（启闭）动作、动作时间、控制室内显示的状态和声光信号等联锁系统均应在手动试验合格后进行自动联锁试验。3.4.3机组联锁试验 机组联锁保护系统应在润滑油、密封油系统正常运行的情况下进行试验。机组启动、停车试验时，应切断电动机的供电线路，采用接触器的吸合与释放模拟机组的启动、运行、停车并应满足以下要求：所有启动条件均满足时，机器方可启动；任一条件不满足时，机器均不启动；在运行中，某一条件超越停车设定值，应立即停车；启动、运行、停车时的音响、灯光应符合设计要求；综合上述，DCS控制系统的主要危险因素是控制系统本身产生的不安全因素，只有通过对DCS控制系统全面的安
9、全检查、安全试验来解决。安全评价工作也必须从这二个方面人手。安全检查（5）（5）DCS安全检查 4.1系统送电的安全检查4.1.1送电前系统安全检查 接地系统安全检查 AC安全接地和DCS系统接地是否符合制造厂和设计要求；检查盘内接地、盘间连接是否正确；检查盘设备接地是否合格；检查系统内接地正确与否。电源系统安全检查： 检查电源柜开关容量是否符合设计要求； 检查电源柜到各设备的电源线正确与否；火线、零线的对地电阻，以及线间绝缘电阻是否符合要求。4.1.2系统送电安全检查 电源系统、接地系统检查一切正常后，在UPS正常运行后，在DCS专家、厂家，监理部门和施工单位共同参加的情况下，可以送电。送电
10、前，须检查所有开关必 须是OFF状态，在DCS专家指导下按顺序送电，同时观察每一个节点受电后的节点状态及地址、指示灯闪烁方式、CRT画面和所有卡件显示是否正常。4.2现场仪表的安全检查 现场仪表必须“测量灵敏，控制可靠”，其基本标准如下：4.2.1全套仪表（包括测量元件、引线、调节阀附件等）安装正确，管线横平、竖直、无惨漏，导线排列整齐，信号线无干扰，符合相应要求。4.2.2全套仪表整体整洁，零部件完整无缺，无严重损锈蚀。4.2.3仪表刻度清晰、鲜明，记录打印清晰。4.2.4仪表的测量系统必须灵敏，灵敏度不得低于允许值。4.2.5指示误差符合相应仪表的技术要求.4.2.6仪表应具备如下技术资料
11、：仪表卡片、仪表说明书、检修校验记录、流量计算数据、仪表控制流程图和重要的接线图，以及仪表的设计（包括孔板和调节阀的计算）安装和检修资料。有关生产许可证、出厂合格证及化验单、试验报告等。4.3报表的检查 报表的检查应包括事故报警的检查及年报、月报、日报的检查，检查项目包括报表题头、报表格式、打印数据、被报告的设备、计划打印的顺序、打印的要求内容等。安全试验（6） DCS控制系统的安全试验是指对整个装置控制方案的检测，应按照检测系统、调节系统、报警系统、联锁保护系统、冗余系统、输入/输出（I/O）系统分别进 行安全调试，达到具备试车的条件。试验合格填写系统试验记录，由甲方有关人员现场共同确认，并
12、在确认单上签字；对于重要联锁保护系统开关量仪表的整定，及 重要调节回路的仪表单体调试，其整定调试完毕到仪表投用之间的存放时间不宜超过2个月。5.1检测系统安全试验 结合仪表单校时的方法，在检测系统的信号发生端输入模拟信号（比如，热电偶温度计从现场加mV信号；压力、差压变送器可用于压钳和FLUKE741及其配 套模块从变送器输入端加压力或差压信号），在操作站的CRT显示屏上检查PV值，计算系统误差，其误差值不应超过系统内各单元仪表允许基本误差平方和平方 根值。系统校检点不得少于3点，分别为设汁量程的0、25%、100%。带报警点的检测系统同时应在操作站CRT显示屏上对报警功能进行检查，增大或减小
13、输入信号，确认报警值与设计值是否相符，报警动作是否正常报警，以及画面上是否有报警信息显示。5.2调节系统安全试验 在操作站CRT显示屏上把调节器输出设定到手动状态，用手动方式输出420mADC信号，检查现场执行器从始点到终点的全行程动作及回迅器动作应良好，精度合格；同时确认流程图画面上相应阀的颜色发生变化。基地盘控制系统则用手动操作系统的输出信号进行上述检查。5.3报警系统安全试验 系统中的信号输入元件，如压力开关、温度开关、液位开关及各种仪表的附加报警机构应根据设计提供的设定值进行参数整定，没有设计认可，设定值不得随意改 变：根据线路原理图，提供系统的动作状态表，在全部线路接通的情况下，逐点
14、输入测量信号，在操作站的CRT显示屏上相应符号的PV状态应与输入的信号相 符，同时确认报警笛响及画面上的报警信息。5.4系统的冗余安全试验5.4.1网络通讯电缆冗余安全试验 在系统状态显示画面上，确认网络通道的A与B电缆状态显示为绿色； 除去电缆A或接线端子，检查电缆B可否切换，电缆A颜色同时变成黄色，且不影响网络通道正常运行； 恢复网络通道的A 的电缆，待A电缆颜色变绿时，再用同样的方法检查B缆。5.4.2I/O卡件冗余安全试验 在操作站上调出控制站细目显示画面，确认全部I/O卡件状态“OK”。在另一个操作站上调出该卡件含有某一位号，输入420mA信号给该位号，记录PV、SP和OP值；关闭主
15、I/O卡件的电源开关，确认冗余的I/O卡件自动投入控制运行，控制站细目显示画面状态正确，确认其PV、SP和OP值保持不变；主I/O卡件电源重新置于“ON”状态，再确认PV、SP和OP值保持不变；重复以上步骤检测冗余的I/O卡件。5.5DCS的I/O安全试验 对于模拟I/O信号，应从现场加实际的0、50%、100%、模拟信号，观察监视器上是否有对应的0、50%、100%量程变化，或者在操作站上强制输出0、50%、100%，观察现场是否有对应的4mA、12mA、20mA变化。对于数字I/O信号，应从现场加实际的闭合、断开信号，观察监视器上是否有对应的状态改变，或者在操作站上强制输出“ON”、“OF
16、F”信号，观察现场是否有对应的闭合、断开变化。结束语（7） 在DCS控制系统安全验收评价中，总体要求是系统应能在异常情况下控制设备和装置不发生危险，必要时控制装置要能自动切换到备用电源和备用设备或装置中 去，调节装置要有连锁，以防止误操作和自动调节装置的误通，误断；系统必须进行全面的安全检查和安全试验；按照“评价、分析、评估、整改”的方法，通过自 评价和专家评价法，完成对DCS控制系统的安全验收评价。（英文版 ） Two regulations promulgated for implementation is in the party in power for a long time and
17、 the rule of law conditions, the implementation of comprehensive strictly strategic plan, implementation in accordance with the rules and discipline to manage the party, strengthen inner-party supervision of major initiatives. The two regulations supporting each other, the adhere to a positive advoc
18、ate, focusing on morality is of Party members and Party leading cadres can see, enough to get a high standard; around the party discipline, disciplinary ruler requirements, listed as negative list, focusing on vertical gauge, draw the party organizations and Party members do not touch the bottom lin
19、e . Here, the main from four square face two party rules of interpretation: the first part introduces two party Revised regulations the necessity and the revision process; the second part is the interpretation of the two fundamental principles of the revision of laws and regulations in the party; th
20、e third part introduces two party regulations modified the main changes and needs to grasp several key problems; the fourth part on how to grasp the implementation of the two regulations of the party. and revised the necessity and revised history of the CPC Central Committee the amendment to the Chi
21、nese Communist Party members and leading cadres honest politics several guidelines and column 1 by 2015 to strengthen party laws and regulations focus. Two party regulations revision work lasted a Years, pooling the wisdom of the whole party, ideological consensus, draw historical experience, respec
22、t for the wisdom of our predecessors, which reflects the unity of inheritance and innovation; follow the correct direction, grasp the limited goals, adhere to the partys leadership, to solve the masses of the people reflect a focus on the problem. The new revision of the and , reflects the partys 18
23、 and the eighth session of the third, the spirit of the fourth plenary session, reflecting the experience of studying and implementing the General Secretary Xi Jinping series of important speech, reflects the partys eighteen years comprehensive strictly practice. (a) revised two regulations of the p
24、arty need of in based on revised, the promulgation and implementation of January 2010, to strengthen the construction of the contingent of leading cadres play an important role. But with the party to manage the party strictly administering the deepening, has not been able to fully meet the actual ne
25、eds. Content is too complicated, eight prohibition, 52 are not allowed to hard to remember, and also difficult to put into practice; the second is concisely positive advocated by the lack of prohibited provisions excessive, no autonomy requirements; the third is banned terms and discipline law, both
26、 with the party discipline, disciplinary regulations repeat and Criminal law and other laws and regulations repeat; the fourth is to clean the theme is not prominent, not for the existing problems, and is narrow, only needle of county-level leading cadres above. is in 1997 based on revision, in Dece
27、mber 2003 the promulgation and implementation, to strengthen the construction of the party play very important role. Along with the development of the situation, which many provisions have been unable to fully meet the comprehensive strictly administering the practice needs. One is Ji law, more than
28、 half of the provisions and criminal law and other countries laws and regulations Repetition; two is the political discipline regulations is not prominent, not specific, for violation of the party constitution, damage the authority of Party Constitution of misconduct lack necessary and serious respo
29、nsibility to pursue; third is the main discipline for the leading cadres, does not cover all Party members. Based on the above situation, need to and the two is likely to be more relevant regulations first amendment. By revising, really put the authority of Party discipline, the seriousness in the p
30、arty tree and call up the majority of Party members and cadres of the party constitution of party compasses party consciousness. (II) two party regulations revision process the Central Committee of the Communist Party of China attaches great importance to two regulations revision . Xi Jinping, gener
31、al books recorded in the Fifth Plenary Session of the eighth session of the Central Commission for Discipline Inspection, on the revised regulations made clear instructions. According to the central deployment, the Central Commission for Discipline Inspection from 2014 under six months begin study t
32、wo regulations revision. The Standing Committee of the Central Commission for Discipline Inspection 4 review revised. Comrade Wang Qishan 14 times held a special meeting to study two regulations revision, amendment clarifies the direction, major issues of principle, path and target, respectively hel
33、d a forum will listen to part of the province (area) secretary of the Party committee, Secretary of the Discipline Inspection Commission, part of the central ministries and state organs Department The first party committee is mainly responsible for people, views of experts and scholars and grassroot
34、s party organizations and Party members. Approved by the Central Committee of the Communist Party of China, on 7 September 2015, the general office of the Central Committee of the Party issued a notice to solicit the provinces (autonomous regions, municipalities) Party, the central ministries and co
35、mmissions, state ministries and commissions of the Party (party), the General Political Department of the military, every 3 people organization of Party of two regulations revision opinion. Central Commission for Discipline Inspection of extensive solicitation of opinions, careful study, attracting,
36、 formed a revised sent reviewers. In October 8 and October 12, Central Committee Political Bureau Standing Committee and the Political Bureau of the Central Committee After consideration of the two regulations revised draft. On October 18, the Central Committee of the Communist Party of China formal
37、ly issued two regulations. Can say, two laws amendment concentrated the wisdom of the whole party, embodies the party. Second, and revision of the basic principles of two party regulations revision work and implement the partys eighteen, ten eight plenary, the spirit of the Fourth Plenary Session of
38、 the Eleventh Central Committee and General Secretary Xi Jinping important instructions on the revised and , highlighting the ruling party characteristics, serious discipline, the discipline quite in front of the law, based on the current, a long-term, advance as a whole, with Bu Xiuding independent
39、 and . Main principle is: first, adhere to the party constitution to follow. The constitution about discipline and self-discipline required specific, awaken the party constitution of party compasses party consciousness, maintaining the authority of the constitution. General Secretary Xi Jinping poin
40、ted out that no rules, no side round. Party constitution is the fundamental law, the party must follow the general rules. In early 2015 held the eighth session of the Central Commission for Discipline Inspection Fifth Plenary Session of the 16th Central Committee, Xi Jinping again pointed out that c
41、onstitution is the party must follow the general rules, but also the general rules. the revision of the and is Method in adhere to the regulations established for the purpose of combining rule of virtue is to adhere to the party constitution as a fundamental to follow, the constitution authority set
42、 up, wake up the party constitution and party rules the sense of discipline, the party constitution about discipline and self-discipline specific requirements. 4 second is to adhere to in accordance with the regulations governing the party and the party. The Party of rule of virtue de, mainly refers
43、 to the partys ideals and beliefs, excellent traditional style. The revised the closely linked to the self-discipline, insisting on the positive initiative, for all members, highlight the vital few, emphasized self-discipline, focusing on the morality, and the majority of Party members and the ideol
44、ogical and moral standards. The revised Ji method separately, Ji, Ji Yan to Method, as a negative list, emphasizing the heteronomy, focusing on vertical gauge. Is this one high and one low, a positive reaction, the strict party discipline and practice results transformation for the integration of th
45、e whole party to observe moral and discipline requirements, for the majority of Party members and cadres provides benchmarking and ruler. Third, insist on to. In view of the problems existing in the party at the present stage, the main problems of Party members and cadres in the aspect of self-disci
46、pline and abide by the discipline to make clearly defined, especially the partys eighteen years strict political discipline and political rules, organization and discipline and to implement the central eight provisions of the spirit against the four winds and other requirements into Disciplinary provisions. Not one pace reachs the designated position, focusing on in line with reality, pragmatic and effective. After the revision of major changes, major changes in the and modified and needs to grasp several key problems (a) adhe