Detailed Description of DCS System Operation and Maintenance Management
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The operation and maintenance of thermal control equipment involves managing system inspections, the operation and shutdown of thermal control devices, equipment integrity, and the analysis and handling of abnormalities. DCS operation management should follow standard thermal control practices and include spare parts management. A specific operation and maintenance plan should be developed based on the unique features of the DCS system.
For historical data stations, it is essential to maintain and improve the database to support accident analysis. Regular checks of the hard disk are necessary to prevent full storage and ensure new data can be saved. When shutting down a workstation, always execute the proper shutdown procedure; never cut power directly. Data communication lines must be protected from physical damage, and their connections should not be tampered with to avoid disconnection. When wiring these lines, keep them separate from high-voltage cables and use protective conduits to reduce interference. DCS spare parts should be stored according to manufacturer guidelines and inspected regularly. Before using any spare part for replacement, it must be functionally tested to avoid potential issues.
Strengthen Software Management
Many power plants focus heavily on hardware maintenance but often neglect software management. If on-site personnel can modify configurations, it is crucial to back up and manage software properly, as uncontrolled changes can pose serious risks. Both hardware and software should be managed equally, with standardized procedures for DCS system and application software. Any modifications, updates, or upgrades must go through an approval process and be assigned to responsible individuals. Before making any changes, a backup should be created, and the DPU program should be backed up after logic changes. Operator station keyboards should have defined access rights to prevent misuse. Each workstation's software version must be consistent, and untested software must not be installed in the running DCS system. Anti-virus measures should also be implemented to protect the system.
(1) Software Backup and Management
DCS system software includes both the system configuration and the application database. The system software is used for reinstallation, while the database supports plant process monitoring. All software changes must be documented and backed up to allow quick recovery if needed. For systems connected to MIS or other networks, communication software plays a critical role in security. Faults from external systems can affect the DCS, so bidirectional data flow should be restricted. Backups should be stored in multiple formats, such as CDs or floppy disks, and old backups should not be used beyond their lifespan. To enhance reliability, backups should be stored in different locations and checked periodically.
(2) Software Inspection and Functional Testing
Check the operating system startup process to ensure no errors occur. If there are errors, restart the system and perform a disk check. Ensure sufficient free space on each hard drive by cleaning temporary files and optimizing disk performance. Verify that the system date, time, user permissions, and file access settings are correct. Check that all network ports and services are configured securely and unnecessary services are disabled. Confirm that the database has enough free space, and clean logs when necessary. Test application software functions such as data processing, system configuration, and report generation to ensure they meet industry standards like DL/T659-1998.
(3) Software Copying, Checking, Upgrading, and Protection
Regularly back up system and configuration software, keeping at least two copies stored in CD-ROMs for a minimum of five years. Before upgrading the DCS operating system, prepare a detailed report and obtain manufacturer support. Unauthorized software or changes should be strictly prohibited. Only authorized personnel should have access to engineer workstations and configuration tools. This ensures system stability and prevents accidental or malicious modifications.
Two. DCS Operation and Maintenance Content
(1) Daily and Regular Maintenance Measures
Avoid using devices that generate electromagnetic interference (e.g., mobile phones, walkie-talkies) in electronic rooms during normal operations. If necessary, follow manufacturer guidelines, such as closing cabinet doors and maintaining a safe distance. Shield field devices that may introduce interference. Conduct regular inspections of the DCS system to detect and address issues promptly. Maintain daily logs to track system status and identify problems early. Monitor environmental conditions, including temperature and humidity, to ensure optimal performance of electronic components. Check the health of redundant systems, alarms, and communication networks. Ensure that print paper is sufficient and clocks are synchronized across systems. Update passwords periodically to enhance security.
(2) Spare Parts Management
According to DL/T774-2001, DCS spare parts must be stored in anti-static bags under controlled temperature and humidity. Regular inspections should be conducted every six months to test functionality, communication ports, and redundancy. Before using any spare part, verify its compatibility and configuration. Proper documentation and verification are required before installation to ensure reliability and minimize downtime.
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