With the advancement of automation technology, DCS (Distributed Control System) has gradually replaced traditional instruments. Its advantages are widely accepted by operators. However, when a fault occurs, it can lead to system shutdown or even accidents. Therefore, it's crucial to identify and resolve faults early to minimize their impact on production. Our company uses multiple sets of Zhejiang University Central Control JX-300X DCS systems in the ammonia synthesis process. These systems are stable and reliable. Based on years of maintenance experience, we have developed effective methods for identifying and handling DCS-related issues. 1. **Monitor Screen Data Check** When certain conditions arise, such as data remaining unchanged for long periods, inability to switch between manual and automatic modes, constant trend lines, or simultaneous fluctuations across multiple screens, it may indicate a problem with the control system. In such cases, maintenance personnel should be notified immediately, and on-site checks should be carried out. If the fluctuating data is related to the process, it could be due to an adjustment system issue. The affected system should be switched to manual mode, and if necessary, adjustments should be made on-site. 2. **Check Operation Station Functionality** If an operation station becomes unresponsive, with no screen updates or failed adjustments, check the system alarm indicators and ensure other stations are functioning. If only one station is affected, notify IT staff. If all stations are impacted, there may be a communication network failure, requiring immediate attention from maintenance teams. 3. **Observe Power Outage at Operation Stations** If some stations lose display, it may indicate a power failure. Notify IT personnel for repairs. If the station has power but displays normally, it won’t affect control operations. 4. **All Control Stations Power Failure** Although rare, if all control stations lose power, the system alarms will turn red, communication will stop, and all control valves will return to their default positions. At this point, emergency measures must be taken to prevent further damage. 5. **All Operation Stations Power Failure** If all operation stations go offline, check the control station’s power and card diagnostics. If everything appears normal, the issue is likely with the monitoring interface, not the system itself. Notify IT and proceed with on-site monitoring. 6. **Low Instrument Air Pressure or Complete Loss** If multiple control loops fail and valves appear fully open or closed, check the instrument air pressure. If it drops below 0.4 MPa, inspect the pipeline for blockages or leaks. Below 0.2 MPa, an emergency shutdown is required. Switch to manual mode, adjust valve positions to safe settings, and close the shut-off valves while using bypass valves. In conclusion, when DCS failures occur, operators should be trained to detect issues early and respond appropriately to prevent disruptions and maintain safe operations.
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