The on-site debugging work mainly involves checking and using the system software, and conducting configuration confirmation and functional testing on the application software.
1. Inspection before power on
The cable insulation resistance meets the requirements (greater than 5M ohms). Check the cable insulation resistance test records and conduct spot checks and measurements if necessary.
Verify that all power lines, signal lines, and communication buses are connected correctly.
The models and positions of the cards, adapters, and their interfaces in the control station, operation console, engineer station, and other frames are correct and correct.
The preset knob positions for each card are correct.
The power switch on the power unit and card is in the “OFF” position, and all fuses are intact.
All connecting screws inside the cabinet should be firm and not loose.
Grounding system grounding resistance test:
Remove the “MG” and “CG” grounding busbars from the control room grounding plate, and use a grounding resistance tester to measure the basic grounding resistance separately, which should meet the design requirements (less than 10 ohms).
Use a multimeter to check if the grounding busbar of each cabinet is connected to the “MG” and “CG” grounding plates.
The insulation resistance between “MG” and “CG” measured should meet the requirements of GBJ93-86 specification (greater than 5M ohms).
UPS power supply test:
Check that both the power panel and the power switch are in the “OFF” position.
The UPS will be put into operation by electrical personnel, and the voltage measured before being sent to the main power switch of the instrument power panel should be 220VAC ± 10% and 50Hz ± 2%.
UPS uninterrupted test shall be conducted by electrical personnel. (After full load operation, repeat this test, and the battery power supply time should not be less than 30 minutes)
2. Power on test
Perform the following power-on tests on each cabinet and operating console one by one:
Place the cabinet power switch inside the power panel in the “ON” position and use a digital multimeter to check the voltage before the main power switch of the cabinet, which should be 220 ± 22VAC.
Confirm that all cards in the cabinet (excluding power cards) have been unplugged from the card holder, and then place the main power switch, power unit, and power switch on the power card in the cabinet in sequence to “ON”. Use a digital voltmeter to measure the DC voltage output, which should meet the manufacturer’s instructions (5.1 ± 0.02V, -12 ± 0.3V, 12 ± 0.3V, 24 VDC). If it exceeds the allowable deviation range, make adjustments.
Perform a manual switching test with dual power sources.
Connect the power to each nested fan, signal converter fan, hard drive fan, cabinet top, door fan, etc., and check that each fan is operating normally.
Check if the power alarm circuit is working.
3. System startup and loading
L Engineer station startup program.
L Operation station startup program.
L Control station startup: after power on, call out the system status screen, and confirm that the status is normal.
Load operation.
The loading procedures for each station are detailed in the manual.
4. System diagnosis and redundancy testing
① Call up the system diagnostic screen and perform diagnostic checks on each station, station, etc.
② Simulate faults artificially for various redundant modules in the system (by cutting off the power supply, unplugging the power plug, inserting cards, etc.), observe whether the backup modules can operate within the specified time, and observe the switching process on the operating console to see if the automatic switching process is normal.
Communication redundancy test
Redundancy test of dual controller
L Operation station redundancy test
L Printer hot standby test
5. Screen testing
1) Flowchart screen test:
a) The process screen is displayed in the form of a P&I diagram, and the number of pages and screen content should meet the configuration requirements.
b) Screen static display inspection:
*Check the position, color, and text description of the title.
*The shape, size, position, and color of a graphic.
*The width, position, color, and inlet and outlet joints of the process pipeline.
*Measure the symbol, text, size, position, and color of variables.
*Arrows, width, position, and content of instrument signals.
*The shape, size, position, color, and entry and exit arrows of page connection symbols.
*The engineering measurement unit meets the design requirements.
c) Screen dynamic display inspection:
*The variation value of the measured variable should be within the identifiable accuracy range of the system.
*Color changes in the operating status of valves and pumps.
*The alarm status changes and should be the correct priority level.
d) Select the circuit from the process screen and conduct experiments on adjusting the set value, control mode (automatic/manual), and manual output.
2) Overall appearance test
a) Confirm that the overall screen has been configured according to the configuration data table.
b) Check the correct configuration of each group and unit in the overall picture.
3) Group screen debugging
a) Confirm that the circuit in the group screen is consistent with the group described in the overall picture.
b) All measured values, set values, analog and digital outputs are correctly configured.
c) Conduct set point change, control mode, and output tests.
d) The color or status display information of the observation block should comply with the configuration requirements by changing the state of the group screen of the digital or program circuit.
e) Confirm the configuration of selectable functions: high and low limit alarm, deviation alarm, output limit, parameter adjustment, power failure restart mode, cascade or feedforward circuit information, filter parameters, and other information related to the circuit or digital program.
6. Operation keyboard function test
1) Confirm that the function keys directly operated by the operator operate normally, can call up various displays, operate each circuit (including control mode, set value, set cascade, output signal adjustment, etc.), alarm confirmation, and execute various functions of the printer.
2) Confirm that the operator keyboard function activated by keylock or password operates normally and can change the measurement range, alarm values, and output signal limits.
7. Report testing for printers and copying machines
1) Check that the printer can print the information specified by the operating station.
2) The confirmation alarm printing automatically occurs, and the order of arrangement is consistent with the alarm summary screen.
3) Check that the printing of the “confirm” or “restore” time is the same as the actual occurrence time.
4) Check that if the number of alarms occurs faster than the printing speed, the alarm printing will not be lost.
5) Check that if the printer malfunctions, the alarm points during this period can still be printed correctly after repair.
6) Confirm that the interlocking alarm from the PLC has the first signal display in the specified group (the entire interlocking is divided into groups) and a resolution of 300ms.
7) Confirm that the copying function can hard copy any screen displayed on each CRT, and during testing, at least one screen should be copied from each CRT.
8) Confirm that the report can be printed in the configured format.
9) Check the automatic printing function of hourly reports, shift reports, daily reports, and monthly reports.
10) Check the report data for instantaneous values, average values, and cumulative values from the first 30 hours (including hourly average values)
8. System recorder testing
Confirm that the recorder has been programmed and its functionality meets the design requirements.
Add at least one input signal to each recorder (3 pens) to check if it can be recorded through the configured channel.
9. DCS channel testing
After the DCS configuration and functional testing mentioned above, a 100% channel test is conducted, which involves adding a signal from the I/O input end, observing the indicated value on the operating station CRT, outputting a signal from the operating station, and measuring the output value at the I/O output end. The deviation should meet the accuracy requirements (level 0.2).
Test method: According to the circuit diagram, group the input and output signals into analog, digital, thermocouple, thermal resistance, and other types for debugging.
During the debugging process, pay attention to the simultaneous testing of circuit branches, indications, records, alarms, etc.
After completing the debugging of each circuit (or part of it), mark the circuit one with a color pen and fill in the debugging record in a timely manner.
Test on sequence and interlocking circuit: Check the sequence and interlocking action according to the logic diagram and input signal to ensure they meet the design requirements. If not, check the sequence table configuration.