1. Check before power-on
If the cable insulation resistance meets the requirements (greater than 5M ohms), check the cable insulation resistance test record, and spot check the actual measurement if necessary.
Check that all power cables, signal cables, and communication buses should be connected.
The model and location of the plug-in card, adapter and its interface in each chassis such as the control station, operator station, and engineer station are correct.
The setting knob of each card is in the correct position.
The power supply unit and the power switch on the plug-in card are in the "OFF" position, and all fuses are intact.
All connecting screws in the cabinet should be firm and not loose.
Grounding System Grounding Resistance Test:
l Remove the "MG" and "CG" grounding buses from the grounding floor of the control room, and measure the base grounding resistance with a grounding resistance tester respectively, which should meet the design requirements (less than 10 ohms).
l Use a multimeter to check whether the grounding busbar of each cabinet is plugged in with the "MG" and "CG" grounding plates respectively.
l The insulation resistance between "MG" and "CG" should meet the requirements of GBJ93-86 specification (greater than 5M ohms).
UPS Power Test:
l Check that the power panel and the power switch are in the "OFF" position.
l The UPS will be put into operation by the electrical personnel, and the voltage before the measurement and transmission to the main power switch of the instrument power panel should be 220VAC±10%, 50Hz±2%.
l UPS uninterrupted test by electrical personnel. (After full load is put into use, repeat this test, and the battery power supply time should not be less than 30 minutes)
2. Power-on test
Carry out the following power-on tests on each cabinet and console one by one:
l Put the power switch in the cabinet in 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.
l Confirm that each card in the cabinet (except the power card) has been unplugged from the card holder, and then put the main power switch of the cabinet, the power supply unit, and the power switch on the power card to "ON" in turn, and measure the DC voltage output with a digital voltmeter, which should meet the requirements of the manufacturer's manual (5.1±0.02V, -12±0.3V, 12±0.3V, 24 VDC). If the allowable deviation range is exceeded, the adjustment is made.
l Carry out the manual switching test of dual power supply.
l Turn on the power supply of each nested fan, signal converter fan, hard disk drive fan, cabinet roof, door fan, etc., and check each fan, which should run normally.
l Check whether the power alarm circuit is working.
3. Start and load the system
l Engineer station start program.
l Operating station starting procedure.
l Control station starts: After the power is turned on, the system status screen is called up, and the confirmed status is normal.
l Loading operation.
The loading procedures of each station are detailed in the manual.
4. System diagnosis and redundancy test
(1) Call up the system diagnosis screen and perform diagnostic inspections on each station and station.
(2) For various redundant modules of the system, artificially simulate faults (by cutting off the power supply; Unplug the power plug, plug-in card, etc.), observe whether the spare module can run within the specified time, and observe the switching process on the operating table to observe whether the automatic switching process is normal.
l Communication redundancy test
l Redundancy test of dual controller
l Operation station redundancy test
l Printer hot standby test
5. Picture test
1) Flowchart screen test:
a) The process screen is displayed in the form of P&I diagram, and the number of pages and the content of the screen should meet the configuration requirements.
b) Static display check:
* Check the position, color, and text description of the title.
* The shape, size, position, and color of the graphic.
*Width, location, color and inlet and outlet joints of the process line.
* Measure the symbol, text, size, position, and color of the variables.
* Arrow, width, position, content of the gauge signal.
* Page connection symbols of shape, size, position, color, in and out arrows.
*The engineering survey unit meets the design requirements.
c) Screen dynamic display check:
*The change value of the measured variable should be within the accuracy range that the system can recognize.
*Color change of valve and pump operating status.
* The alarm status changes and should be the correct priority level.
d) Select a loop from the process screen and perform an experiment to adjust the setpoint, control mode (auto/manual), and manual output.
2) General picture test
a) Confirm that the overview screen has been configured according to the configuration data sheet.
b) Check the correct configuration of the groups and units in each area of the general picture picture.
3) Group screen debugging
a) Confirm that the loops in the group screen are the same as those described in the general view.
b)that the individual measured values, set values, and outputs in analog and digital form are correctly configured.
c) Perform a test to change the setpoint, control mode and output.
d) For the group screen of the digital or program loop, by changing its state, the color of the observation block or the change of the status display information should meet the configuration requirements.
e) Confirm the configuration of the selectable functions: high and low limit alarms, deviation alarms, output limits, adjustment parameters, power failure restart modes, cascade or feedforward loop information, filter parameters, and other information related to the loop or digital program.
6. Function test of operating keyboard
1) Confirm that the function keys directly operated by the operator are operating normally, can call up various displays, operate each loop (including control mode, setting value, setting cascade, output signal adjustment, etc.), alarm confirmation, and execute various functions of the printer.
2) Confirm that the operator's keypad activated by the key lock or password is operating normally, and can change the measurement range, alarm value and output signal limit.
7. Report testing for printers and duplicators
1) Check that the printer can print the information specified by the operating station.
2) Confirm that the alarm printing occurs automatically, and the order is the same as that of the alarm summary screen.
3) Check that the print of the "confirm" or "restore" time is the same as the actual occurrence time.
4) Check that if the number of alarms is faster than the printing speed, the alarm printing will not be lost.
5) Check that if the printer fails, the alarm points during this time can still be printed correctly after repair.
6) Confirm that the interlock alarm coming from the PLC has the first signal display in the specified group (the whole interlock is divided into groups) and has a resolution of 300ms.
7) Confirm that the copy function can make a hard copy of any screen displayed on each CRT screen, and at least one screen per CRT during the test.
8) Confirm that the report can be printed in the configured format.
9) Check the automatic printing function of hourly report, shift report, daily report, and monthly report.
10) Check that the report data can be instantaneous values, average values, and cumulative values for the previous 30 hours (and include hourly averages)
8. System recorder test
Confirm that the logger is programmed and functions as designed.
Add at least one input signal to each recorder (3 strokes) to check whether it can be recorded through the configured channel.
9. DCS channel test
After the above-mentioned DCS configuration and function test, 100% channel test is carried out, that is, the signal is added from the I/O input terminal, the indication value is observed on the CRT of the operation station, the signal is output from the operation station, and the output value is measured at the I/O output terminal, and its deviation should meet the accuracy requirements (0.2 level).
Test method: According to the loop diagram, the input and output signals are grouped and debugged according to analog, digital, thermocouple, thermal resistance and other types.
During the debugging process, pay attention to the branching, indication, recording, alarm and other simultaneous tests of the circuit.
After each circuit (or part of it) is debugged, mark the circuit with a color pen and fill in the debugging record in time.
For sequence and interlocking loop test: according to the logic diagram, input signal check sequence and interlocking action should meet the design requirements. If not, check the sequential table configuration.
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