Practical application and work experience of DCS system - Database & Sql Blog Articles

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Before selecting a DCS system, it's crucial to clearly define the application goals and functional requirements. This process involves collaboration between instrument automation experts, process engineers, computer specialists, and design institutes to ensure the system meets all operational needs effectively.

1. Application Objectives of DCS

(1) Enhance production and management levels: Improve efficiency, reduce costs, save energy, enhance product quality, increase flexibility in production changes, and improve equipment management. This supports better labor competition and helps uncover hidden production potential.

(2) Upgrade device control levels: Achieve stable operation, advanced control, sequence logic control, fault diagnosis, and interlock protection. Optimize local or full equipment control, ensuring safe, stable, long-lasting, efficient, and high-quality production with significant economic and social benefits.

2. System Function Requirements

(1) Data acquisition and storage: Define scan times for analog and digital signals, historical data types, number of points, and signal processing capabilities.

(2) Control functions: Include monitoring, adjustment, sequence control, and interlock protection. Ensure feedback control, process control languages (like ST, FORTRAN, BASIC), and advanced control software are available.

(3) Display functions: Support CRT size, color, refresh rate, multiple screens, Chinese character support, and touch screen functionality.

(4) Alarm functions: Monitor analog/digital signals, instrument deactivation, system component faults, and manage alarm resolution, grouping, and suppression.

(5) Report and screen copy: Enable real-time and scheduled reports, alarm summaries, operation logs, and screen printing.

(6) Operation safety: Implement password-based access, engineer/operator key functions, and redundancy measures.

(7) System flexibility: Ensure reliability, scalability, compatibility, and openness for future expansion.

These requirements should be tailored to specific project characteristics. For instance, fast scan speeds and sequence control execution must align with process needs. In one case, a DCS model was found inadequate for a patent vendor’s sequential control, leading to additional PLC investment.

3. DCS Selection

Choosing the right DCS model is critical. With rapid technological advancements, it's important to evaluate not just initial costs but also long-term performance, reliability, and support. Consider well-known manufacturers, industry examples, and after-sales service. A balanced approach ensures the selected DCS meets both current and future needs.

4. System Configuration

System configuration involves determining I/O points, control stations, monitoring stations, operation stations, communication systems, power supply, and spare parts. It's essential to balance hardware requirements with cost-effectiveness while leaving room for future expansion. Redundancy, especially in critical areas, is vital to prevent downtime.

5. Establishing the System Environment

A suitable environment is essential for DCS performance. Factors like temperature, humidity, dust, and grounding must be carefully controlled. Proper air conditioning, lighting, and anti-interference measures are necessary to ensure reliable operation over time.

6. Staff Training

Training is a key step in DCS implementation. Engineers, operators, and maintenance personnel should receive comprehensive training on system operation, configuration, and troubleshooting. Effective training ensures smooth operation and long-term system success.

7. System Configuration and Generation

Configuration involves both hardware setup and application software development. It requires careful planning, understanding of system functions, and collaboration with process engineers. Successful configuration depends on integrating practical experience and user needs into the design.

8. Installation and Commissioning

Installation must follow strict guidelines to ensure proper setup. Commissioning includes testing individual components, verifying system functionality, and ensuring seamless integration with field devices. Thorough debugging is essential to identify and resolve any issues before full operation.

9. Commissioning and Evaluation

Once installed, the DCS must be tested under normal operating conditions. Key metrics include system uptime, reliability, and performance. Evaluation after 72 hours of continuous operation ensures the system meets all technical and operational standards.

10. Ongoing Maintenance and Development

Maintaining a DCS involves regular checks, updates, and repairs. As the system evolves, continued software development enhances its capabilities. Localizing spare parts and investing in research can significantly reduce dependency on foreign suppliers and improve long-term sustainability.

In summary, a successful DCS implementation requires meticulous planning, skilled execution, and ongoing maintenance. When done correctly, it becomes a cornerstone of efficient and sustainable production, driving both economic and operational success for enterprises.