CN111061235A - DCS equipment diagnosis method with fault early warning function - Google Patents
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/41845—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by system universality, reconfigurability, modularity
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/33—Director till display
- G05B2219/33273—DCS distributed, decentralised controlsystem, multiprocessor
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Abstract
The invention belongs to the technical field of industrial control, and particularly relates to a nuclear power DCS equipment diagnosis method with a fault early warning function. The method comprises the following steps: (1) defining the faults in a grading and layering manner; (2) when the diagnostic software is started, the system is imported; (3) after the system architecture diagram is successfully imported, the main interface of the equipment diagnosis software displays all control station information in the system; (4) after all control stations of the system and all equipment information under the control stations are imported, the software selects different communication modes according to the current operation module of the control stations. The equipment diagnosis system provided by the invention not only provides a fault alarm function, but also facilitates engineering personnel to quickly and accurately position fault information in a system debugging stage. The invention solves the defects of the traditional DCS control system in the aspect of equipment fault diagnosis, and can accurately and timely transmit fault diagnosis information to operators and maintenance personnel through an alarm indication mechanism after a fault occurs.
Description
Technical Field
The invention belongs to the technical field of industrial control, and particularly relates to a nuclear power DCS equipment diagnosis method with a fault early warning function.
Background
The industrial DCS control system is applied to various industries such as chemical industry, electric power, nuclear power and the like, and at present, the DCS control system mainly comprises the following components: the integrated automation system composed of the engineer station, the operator station, the field control station, the communication control station and the data server completes the functions of the large and medium distributed control system.
At present, fault diagnosis for a DCS (distributed control system) is mainly displayed on an operator station and an engineer station, and once a certain device breaks down, alarm information is generated on the operator station and the engineer station to prompt a user that the device breaks down. The display form at the operator station and the engineer station is that the alarm color is displayed at the position of the equipment, and the user can only acquire the fault of the equipment, but cannot check the specific content of the fault.
The early warning function of trouble has important meaning in nuclear power instrument control system, and its operating mechanism is: when the system normally runs, the diagnosis system monitors all the devices in the system; after the fault occurs, the diagnosis system triggers an alarm mechanism, reports the fault information to a user, and files the fault information, so that the user can conveniently inquire and generate equipment fault early warning information; and after the fault information disappears, reporting the fault recovery information to the user in time.
The equipment fault diagnosis function in the traditional DCS control system can not meet the requirement of a nuclear power instrument control system on a fault diagnosis system, so that the invention provides the nuclear power DCS equipment diagnosis system with the fault early warning function, and the equipment diagnosis system provided by the invention diagnoses fault information of different equipment in a layered manner; grading to display the severity of the fault; all fault information is filed; obtaining the probability of equipment failure according to the archived failure information so as to provide data support for the instrument control system to test regularly; and giving a reason analysis chart of fault information.
In the conventional technical scheme, due to the defects, a nuclear power DCS equipment diagnosis method with a fault early warning function needs to be developed urgently, so that the problems are solved.
Disclosure of Invention
The invention aims to solve the technical problem of providing a nuclear power DCS equipment diagnosis method with a fault early warning function, thereby solving the defects of the traditional DCS control system in the aspect of equipment fault diagnosis.
In order to realize the purpose, the invention adopts the technical scheme that:
a nuclear power DCS equipment diagnosis method with a fault early warning function comprises the following steps:
(1) defining hierarchical levels of faults
(2) When the diagnostic software is started, the system is imported;
(3) after the system architecture diagram is successfully imported, the main interface of the equipment diagnosis software displays all control station information in the system;
(4) after all control stations of the system and all equipment information under the control stations are imported, software selects different communication modes according to the current operation module of the control stations;
① if the control station is in running state, the diagnostic software directly receives the data packet sent by the control station for analysis, acquires the fault information of all the devices in the control station, obtains the fault information of the control station through the fault information of the devices, and gives an alarm to the fault information to prompt the user;
① if the control station is in running state, the diagnostic software directly receives the data packet sent by the control station for analysis, acquires the fault information of all the devices in the control station, obtains the fault information of the control station through the fault information of the devices, and gives an alarm to the fault information to prompt the user;
② if the control station is in maintenance mode, representing that the control station is currently in engineering debugging stage, software polls the fault information of all modules in sequence in a question-and-answer mode, analyzes and acquires the fault information of the modules according to the answer of the control station, summarizes and acquires the fault information of the control station where the modules are located according to the analysis of the fault information of all modules, and alarms the fault information to users.
Further, according to the nuclear power DCS equipment diagnosis method with the fault early warning function, in the step (1), the classification of the fault is different according to the hierarchy to which the fault belongs, and the classification is different, and the specific method is as follows:
fault classification is done from two levels: one is to grade the faults from the module layer, and grade the influence degree of the faults on the functions of the modules by analyzing the faults; the other is that the control station level grades the faults, and grades the control station by analyzing the influence degree of the faults on the control station;
(1.1) module level fault classification: according to the severity of the influence on the functions of the module after the fault occurs, grading the fault in the module into a serious fault and a common fault;
(a) serious failure: a catastrophic failure can result in a loss of module functionality and require human intervention to clear the failure;
(b) general failure: a general failure refers to an error that does not affect the functional integrity of the module;
(1.2) controlling station level fault classification: according to the severity of the influence on the control station after the fault occurs, the fault is classified into a serious fault, a communication alarm fault, an input/output alarm fault and a prompt alarm fault;
(a) serious failure: after such a failure, the control station cannot continue to perform its functional fatal abnormality;
(b) communication class alarm failure: after the fault occurs, the data communication function of the control station part fails, and the data processing function normally operates;
(c) input output class alarm fault: after the fault occurs, the acquisition and output functions of the control station part are invalid, and the data communication and data processing functions are normally operated;
(d) prompting a class alarm fault: after the fault occurs, the whole safety function of the control station is not influenced, and only a prompt alarm is output.
Further, according to the nuclear power DCS device diagnosis method with the fault early warning function, in the step (2), when the diagnosis software is started, the source of the data is a data packet sent by a system in which the engineer station configuration software is successfully compiled.
Further, according to the nuclear power DCS device diagnosis method with the fault early warning function, in the step (2), in order to ensure the correctness of the data source, validity check and verification are performed in the importing process.
Further, in the nuclear power DCS device diagnosis method with the fault early warning function, in step (3), the device diagnosis software main interface visually displays the control station information in the form of a relational graph, where the displayed control station information includes: the ring of the control station, the information of all the control stations in the ring and the position of the control station in the ring network.
Further, according to the nuclear power DCS equipment diagnosis method with the fault early warning function, in the step (3), the current different grades of control station level faults are displayed in the control station through different fault colors.
Further, in the nuclear power DCS device diagnosis method with the fault early warning function, in step (4), while the diagnosis software reads the fault information of the device to alarm, the diagnosis software archives the fault information of all the devices, and the user performs log management according to the data in the archives, and performs the following operations on the fault information: and (6) checking and screening.
Further, according to the nuclear power DCS equipment diagnosis method with the fault early warning function, in the step (4), the diagnosis software stores data for the early warning function of the generation equipment, after the fault information is filed, a user selectively checks the fault probability map of specific equipment under a specific control station according to the filed fault information, and performs equipment maintenance and periodic tests specifically according to the fault probability map, so as to realize the early warning function of the equipment fault.
Further, according to the nuclear power DCS equipment diagnosis method with the fault early warning function, in the step (4), when the fault information of the module is analyzed, the fault information of the module channel is obtained together, and the fault information of the module channel only analyzes the quality level; in the system operation stage, the control station actively uploads the fault information of all modules to a diagnosis tool system, the diagnosis tool system analyzes and obtains the fault information of the modules and the quality bit information of module channels according to the received data, and the fault information of the control station where the modules are located is obtained through summarizing according to the analyzed module fault information; the diagnostic tool does not send any data packet to the control station in the system operation stage, does not interfere with the normal logic processing of the control station, and shields the influence of the diagnostic tool on the operation data in the controller.
The technical scheme of the invention has the beneficial effects that:
the equipment diagnosis system provided by the invention not only provides a fault alarm function, but also facilitates engineering personnel to quickly and accurately position fault information in a system debugging stage. The invention solves the defects of the traditional DCS control system in the aspect of equipment fault diagnosis, and can accurately and timely transmit fault diagnosis information to operators and maintenance personnel through an alarm indication mechanism after a fault occurs.
The diagnostic system of the invention manages fault information in layers from equipment to a control station where the equipment is located by a hierarchical management mode at the beginning of design; and for each kind of fault information, hierarchical management is realized, so once the fault information appears, a user can clearly check the specific content and the fault level of the fault and determine the severity of the fault.
Meanwhile, the software stores all fault information, and the probability of equipment fault occurrence is obtained according to the collected equipment operation data and the fault occurrence condition.
In the system debugging stage, the engineering personnel can quickly position the fault according to the fault information provided by the tool, and conveniently contact related personnel for maintenance; in the system operation stage, the system obtains the rule of the equipment fault according to the equipment fault information collected in the operation stage, and the user can carry out targeted maintenance and periodic test according to the equipment fault rule table generated by the system, thereby realizing the early warning function of the equipment fault in the system, reducing the occurrence probability of the fault and saving the maintenance cost of the system.
Detailed Description
The technical solution of the present invention will be described in detail with reference to the following specific examples.
The invention relates to a nuclear power DCS equipment diagnosis method with a fault early warning function, which comprises the following steps:
(1) defining hierarchical levels of faults
In discussing the failure level, it is important to distinguish the level of impact of the failure, whether it is an impact on a single module or an impact on the entire system, and a catastrophic failure of a single module may not affect the ability of the system to perform functions. The fault grade classification has different grade classifications according to different fault belonged layers, and the specific method is as follows:
fault classification is done from two levels: one is to grade the faults from the module layer, and grade the influence degree of the faults on the functions of the modules by analyzing the faults; the other is that the control station level grades the faults, and grades the control station by analyzing the influence degree of the faults on the control station;
(1.1) module level fault classification: according to the severity of the influence on the functions of the module after the fault occurs, grading the fault in the module into a serious fault and a common fault;
(a) serious failure: a catastrophic failure can result in a loss of module functionality and require human intervention to clear the failure;
(b) general failure: a general failure refers to an error that does not affect the functional integrity of the module;
(1.2) controlling station level fault classification: according to the severity of the influence on the control station after the fault occurs, the fault is classified into a serious fault, a communication alarm fault, an input/output alarm fault and a prompt alarm fault;
(a) serious failure: after such a failure, the control station cannot continue to perform its functional fatal abnormality;
(b) communication class alarm failure: after the fault occurs, the data communication function of the control station part fails, and the data processing function normally operates;
(c) input output class alarm fault: after the fault occurs, the acquisition and output functions of the control station part are invalid, and the data communication and data processing functions are normally operated;
(d) prompting a class alarm fault: after the fault occurs, the whole safety function of the control station is not influenced, and only a prompt alarm is output.
The hierarchical management mode of the fault information can facilitate quick and accurate diagnosis of the fault information by users in the debugging stage and the system operation stage of engineering personnel. The problem that the traditional DCS diagnosis tool only reports faults and does not carry out hierarchical and hierarchical detailed management on the faults is solved.
(2) When the diagnostic software is started, the system is imported;
according to the design idea of hierarchical ranking, the diagnosis system reads the data packet sent by the control station, and analyzes and acquires the fault information of the module. In the system, when the diagnostic software is started, the data source is a data packet sent by the system successfully compiled by the engineer station configuration software; carrying out validity check and verification for ensuring the correctness of the data source in the importing process;
(3) after the system architecture diagram is successfully imported, the main interface of the equipment diagnosis software displays all control station information in the system;
the equipment diagnosis software main interface visually displays the control station information in a relational graph form, and the displayed control station information comprises the following steps: the ring where the control station is located, information of all the control stations in the ring and the positions of the control stations in the ring network; in the control station, displaying the current control station level faults of different grades through different fault colors;
(4) after all control stations of the system and all equipment information under the control stations are imported, software selects different communication modes according to the current operation module of the control stations;
① if the control station is in running state, the diagnostic software directly receives the data packet sent by the control station for analysis, acquires the fault information of all the devices in the control station, obtains the fault information of the control station through the fault information of the devices, and gives an alarm to the fault information to prompt the user;
② if the control station is in maintenance mode, representing that the control station is currently in engineering debugging stage, software polls the fault information of all modules in sequence in a question-and-answer mode, analyzes and acquires the fault information of the modules according to the answer of the control station, summarizes and acquires the fault information of the control station where the modules are located according to the analysis of the fault information of all modules, and alarms the fault information to users.
When the diagnostic software reads the fault information of the equipment to give an alarm, the diagnostic software archives the fault information of all the equipment, a user performs log management according to data in the archives, and the following operations are performed on the fault information: and (6) checking and screening. The storage of the fault information is to realize the function of early warning the equipment fault. The early warning function of the fault is managed by taking the control station and the equipment under the control station as a unit, and meanwhile, classified management is carried out according to the fault grades of the control station and the equipment. Therefore, the system can quickly inquire faults in all control stations and all equipment in the whole system.
The diagnostic software stores data for the early warning function of the generating equipment, after the fault information is filed, a user selectively checks a fault probability chart of specific equipment under a specific control station according to the filed fault information, and performs equipment maintenance and periodic tests in a targeted manner according to the fault probability chart to realize the early warning function of equipment faults;
when analyzing the fault information of the module, the fault information of the module channel is obtained together, and the fault information of the module channel only analyzes the quality of the quality bit; in the system operation stage, the control station actively uploads the fault information of all modules to a diagnosis tool system, the diagnosis tool system analyzes and obtains the fault information of the modules and the quality bit information of module channels according to the received data, and the fault information of the control station where the modules are located is obtained through summarizing according to the analyzed module fault information; the diagnostic tool does not send any data packet to the control station in the system operation stage, does not interfere with the normal logic processing of the control station, shields the influence of the diagnostic tool on the operation data in the controller, and further ensures the safety problem of the system in the operation stage.
In a nuclear power DCS instrument control system, a diagnosis function and a periodic test function are collectively called as a monitoring test function. The monitor test function must be monitored throughout the range from the sensor to the actuator. Therefore, the diagnostic function and the periodic test function are complementary to each other, and have strong correlation. Therefore, the fault early warning function designed in the system is to generate a probability table of faults from equipment to a controller in the nuclear power DCS system, and the fault early warning function is realized. In the system operation stage, according to the equipment operation data collected by the diagnosis system and the related fault occurrence condition, a user can carry out targeted maintenance and periodic test, thereby reducing the fault occurrence probability and saving the maintenance cost of the system.
Claims (10)
1. A nuclear power DCS equipment diagnosis method with a fault early warning function is characterized by comprising the following steps: the method comprises the following steps:
(1) defining hierarchical levels of faults
(2) When the diagnostic software is started, the system is imported;
(3) after the system architecture diagram is successfully imported, the main interface of the equipment diagnosis software displays all control station information in the system;
(4) after all control stations of the system and all equipment information under the control stations are imported, software selects different communication modes according to the current operation module of the control stations;
① if the control station is in running state, the diagnostic software directly receives the data packet sent by the control station for analysis, acquires the fault information of all the devices in the control station, obtains the fault information of the control station through the fault information of the devices, and gives an alarm to the fault information to prompt the user;
② if the control station is in maintenance mode, representing that the control station is currently in engineering debugging stage, software polls the fault information of all modules in sequence in a question-and-answer mode, analyzes and acquires the fault information of the modules according to the answer of the control station, summarizes and acquires the fault information of the control station where the modules are located according to the analysis of the fault information of all modules, and alarms the fault information to users.
2. The nuclear power DCS equipment diagnosis method with the fault early warning function of claim 1, characterized by comprising the following steps: in the step (1), the classification of the fault grades is different according to the belonged hierarchy of the fault, and the classification of the fault grades has different grades, and the specific method is as follows:
fault classification is done from two levels: one is to grade the faults from the module layer, and grade the influence degree of the faults on the functions of the modules by analyzing the faults; the other is that the control station level grades the faults, and grades the control station by analyzing the influence degree of the faults on the control station;
(1.1) module level fault classification: according to the severity of the influence on the functions of the module after the fault occurs, grading the fault in the module into a serious fault and a common fault;
(a) serious failure: a catastrophic failure can result in a loss of module functionality and require human intervention to clear the failure;
(b) general failure: a general failure refers to an error that does not affect the functional integrity of the module;
(1.2) controlling station level fault classification: according to the severity of the influence on the control station after the fault occurs, the fault is classified into a serious fault, a communication alarm fault, an input/output alarm fault and a prompt alarm fault;
(a) serious failure: after such a failure, the control station cannot continue to perform its functional fatal abnormality;
(b) communication class alarm failure: after the fault occurs, the data communication function of the control station part fails, and the data processing function normally operates;
(c) input output class alarm fault: after the fault occurs, the acquisition and output functions of the control station part are invalid, and the data communication and data processing functions are normally operated;
(d) prompting a class alarm fault: after the fault occurs, the whole safety function of the control station is not influenced, and only a prompt alarm is output.
3. The nuclear power DCS equipment diagnosis method with the fault early warning function of claim 1, characterized by comprising the following steps: in the step (2), when the diagnostic software is started, the data source is a data packet sent by a system successfully compiled by the engineer station configuration software.
4. The nuclear power DCS equipment diagnosis method with the fault early warning function of claim 1, characterized by comprising the following steps: in the step (2), in the importing process, validity check and verification are carried out for ensuring the correctness of the data source.
5. The nuclear power DCS equipment diagnosis method with the fault early warning function of claim 1, characterized by comprising the following steps: in the step (3), the equipment diagnosis software main interface visually displays the control station information in a relational graph form, wherein the displayed control station information comprises: the ring of the control station, the information of all the control stations in the ring and the position of the control station in the ring network.
6. The nuclear power DCS equipment diagnosis method with fault early warning function of claim 5, characterized in that: and (3) displaying the current control station level faults of different grades in the control station through different fault colors.
7. The nuclear power DCS equipment diagnosis method with the fault early warning function of claim 1, characterized by comprising the following steps: in the step (4), when the diagnostic software reads the fault information of the equipment to alarm, the diagnostic software archives the fault information of all the equipment, and the user performs log management according to the data in the archives to perform the following operations on the fault information: and (6) checking and screening.
8. The nuclear power DCS equipment diagnosis method with the fault early warning function of claim 1, characterized by comprising the following steps: in the step (4), the diagnostic software stores data for the early warning function of the generating equipment, after the fault information is filed, a user selectively checks a fault probability chart of specific equipment under a specific control station according to the filed fault information, and performs equipment maintenance and periodic tests in a targeted manner according to the fault probability chart, so as to realize the early warning function of equipment faults.
9. The nuclear power DCS equipment diagnosis method with the fault early warning function of claim 1, characterized by comprising the following steps: in the step (4), when analyzing the fault information of the module, the fault information of the module channel is obtained together, and the fault information of the module channel only analyzes the quality level; in the system operation stage, the control station actively uploads the fault information of all modules to a diagnosis tool system, the diagnosis tool system analyzes and obtains the fault information of the modules and the quality bit information of module channels according to the received data, and the fault information of the control station where the modules are located is obtained through summarizing according to the analyzed module fault information; the diagnostic tool does not send any data packet to the control station in the system operation stage, does not interfere with the normal logic processing of the control station, and shields the influence of the diagnostic tool on the operation data in the controller.
10. The nuclear power DCS equipment diagnosis method with the fault early warning function of claim 1, characterized by comprising the following steps: in the step (1), the classification of the fault grades is different according to the belonged hierarchy of the fault, and the classification of the fault grades has different grades, and the specific method is as follows:
fault classification is done from two levels: one is to grade the faults from the module layer, and grade the influence degree of the faults on the functions of the modules by analyzing the faults; the other is that the control station level grades the faults, and grades the control station by analyzing the influence degree of the faults on the control station;
(1.1) module level fault classification: according to the severity of the influence on the functions of the module after the fault occurs, grading the fault in the module into a serious fault and a common fault;
(a) serious failure: a catastrophic failure can result in a loss of module functionality and require human intervention to clear the failure;
(b) general failure: a general failure refers to an error that does not affect the functional integrity of the module;
(1.2) controlling station level fault classification: according to the severity of the influence on the control station after the fault occurs, the fault is classified into a serious fault, a communication alarm fault, an input/output alarm fault and a prompt alarm fault;
(a) serious failure: after such a failure, the control station cannot continue to perform its functional fatal abnormality;
(b) communication class alarm failure: after the fault occurs, the data communication function of the control station part fails, and the data processing function normally operates;
(c) input output class alarm fault: after the fault occurs, the acquisition and output functions of the control station part are invalid, and the data communication and data processing functions are normally operated;
(d) prompting a class alarm fault: after the fault occurs, the whole safety function of the control station is not influenced, and only a prompt alarm is output;
in the step (2), when the diagnostic software is started, the data source is a data packet sent by a system successfully compiled by the engineer station configuration software; carrying out validity check and verification for ensuring the correctness of the data source in the importing process;
in the step (3), the equipment diagnosis software main interface visually displays the control station information in a relational graph form, wherein the displayed control station information comprises: the ring where the control station is located, information of all the control stations in the ring and the positions of the control stations in the ring network; in the control station, displaying the current control station level faults of different grades through different fault colors;
in the step (4), when the diagnostic software reads the fault information of the equipment to alarm, the diagnostic software archives the fault information of all the equipment, and the user performs log management according to the data in the archives to perform the following operations on the fault information: checking and screening;
the diagnostic software stores data for the early warning function of the generating equipment, after the fault information is filed, a user selectively checks a fault probability chart of specific equipment under a specific control station according to the filed fault information, and performs equipment maintenance and periodic tests in a targeted manner according to the fault probability chart to realize the early warning function of equipment faults;
when analyzing the fault information of the module, the fault information of the module channel is obtained together, and the fault information of the module channel only analyzes the quality of the quality bit; in the system operation stage, the control station actively uploads the fault information of all modules to a diagnosis tool system, the diagnosis tool system analyzes and obtains the fault information of the modules and the quality bit information of module channels according to the received data, and the fault information of the control station where the modules are located is obtained through summarizing according to the analyzed module fault information; the diagnostic tool does not send any data packet to the control station in the system operation stage, does not interfere with the normal logic processing of the control station, and shields the influence of the diagnostic tool on the operation data in the controller.
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Cited By (2)
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| CN111830931A (en) * | 2020-07-15 | 2020-10-27 | 中国科学院微电子研究所 | Fault diagnosis method of DCS (distributed control system) |
| CN113238535A (en) * | 2021-06-03 | 2021-08-10 | 中国核动力研究设计院 | Fault diagnosis method and system for nuclear safety level DCS analog input module |
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| CN113238535A (en) * | 2021-06-03 | 2021-08-10 | 中国核动力研究设计院 | Fault diagnosis method and system for nuclear safety level DCS analog input module |
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