旁路控制系统(BPS)调试方案.
BALCO EXPANSION PROJECT 4×300 MW THERMAL
POWER PLANT
BYPASS CONTROL SYSTEM
印度BALCO扩建 4×300 MW
燃煤电站工程
旁路控制系统（BPS）调试方案
Spe. 2009
2009年9月
Complied by:
编写：
Checked by: 初审：
Revised by: 审核：
Approved by:
批准：
目录
Contents
1. 编制目的 Compile Purpose
2. 调试范围 Scope of commissioning
3. 调试前必须具备的条件 Conditions before commissioning
4. 调试步骤 Process of commissioning
5. 使用工具 Tools used for test
6. 注意事项 Precautions
1.编制目的Compile Purpose
为了指导及规范系统及设备的调试工作，检验系统的性能，发现并消除可能存在的缺陷，保证系统及设备能够安全可靠投入运行，制定本方案。
This commissioning procedure is compiled to guide and standardize the practice of testing and adjusting to facilitate proofing of system performance, finding and repairing of possible defects, thus ensuring that the equipment and system can be brought into operation safely and reliably.
2.调试范围Scope of commissioning
2.1高压旁路系统阀门、测点的传动试验，联锁、保护试验。
Valves and measuring points transmission test and interlock, protection test for high pressure bypass system.
2.2低压旁路系统阀门、测点的传动试验，联锁、保护试验。
Valves and measuring points transmission test and interlock, protection test for low pressure bypass system.
2.3高压旁路压力、温度控制。
Pressure and temperature control of high pressure bypass.
2.4低压旁路压力、温度控制。
Pressure and temperature control of low pressure bypass.
3.调试前必须具备的条件Conditions before commissioning
3.1旁路正式系统恢复完成，正式门芯安装完成。
The formal system of BPC has been restored, with the formal valve plugs fitted.
3.2执行机构安装完毕，并合格。
Actuators have been installed up to standard.
3.3控制柜工作正常。
Control cabinets are operating normally.
3.4测量元件安装、接线情况检查完毕。
The installation and wiring of measuring elements have been checked up to standard.
4.调试步骤Process of commissioning
4.1单体联动试验
Individual equipments linkage test
4.1.1检查控制系统与现场控制设备的接线是否完整、正确。
Check the connections between the control system and the local control equipment are complete and correct.
4.1.2检查I/O端子板供电是否正常，相应的I/O卡件是否推入槽内，卡件状态指示是否正常。
Check that the power supply for I/O terminal boards is normal, relevant I/O modules inserted in place firmly, and the indicators of module condition are normal.
4.1.3受控设备的就地调试工作应已经结束并检验合格。
The local test of the controlled equipments shall be finished up to standard.
4.1.4检查系统控制命令与现场设备所要求的是否匹配，检查反馈状态信号与系统内软件组态是否一致。
Check that the system control orders match the requirements of the local control equipments. Check the feedback signals match the software configuration.
4.1.5在操作站上调出相应的显示画面，选择所需的设备标签窗口，操作启动/停止按键（或开启/关闭按键），观察就地设备是否按照控制命令的要求动作，检查设备的反馈状态是否正确，记录设备的行程时间。
Call the relevant display page on the operator’s station and select the icon of the equipment to be operated. Click the Start/Stop (Open/Shut) buttons, and confirm the local equipment acts exactly as the control order requires. Check the equipment feedback is correct, and note down the travel time.
4.2系统试验前的检查
Inspection before system test
4.2.1检查旁路系统的软件组态是否与设计要求一致，检查软件组态是否有危及系统安全的错误，检查系统的控制顺序是否正确完善。如有重大错误或缺陷应通过正常渠道进行修改。
Check that the software configuration is in conformity with the design requirements. Check for any mistakes or bugs that might imperil the system. Check that the control sequence of the system is correct and complete. Modifications shall be made by appropriate parties if there is any major mistake or defects.
4.2.2被试验的系统所包含的控制设备的单体联动试验应进行完毕且验收合格，参与系统顺序控制的所有测点及联锁保护的所有测点都应经过检验合格。
The individual linkage test for all control devices in the system put to test shall be finished and the devices are accepted. All measuring points for system sequence control, interlocks, and protections have been tested up to standard.
4.2.3根据设计资料、设备说明、运行规程等资料将有关参数定值输入到计算机中去。根据单体试验测取的有关参数应输入到相应的功能块中去。
Input the parameters and set-values to the computers based on the relevant documents such as design documents, equipment manuals, operation regulations. Input the parameters obtained from individual tests to the corresponding functional blocks.
4.3系统试验
System test
4.3.1系统试验时，应由调试单位人员、安装单位人员、运行人员共同参加完成。由于系统试验是计算机真实的控制现场设备的过程，所以在本试验进行以前，计算机调试人员应务必对系统的软件组态参数，计算机系统与现场的I/O接口进行仔细检查，待确认各项准备工作就绪后方能进入旁路控制试验。
The system test of BPC shall be carried out jointly by the commissioning, erection, and operation engineers. Because the system test is an actual computer-based control process of local equipment, the commissioning engineers must make a thorough inspection of the system software configuration parameters and I/O interfaces between the control system and the local equipments. The system test shall not be started before ensuring all the preparations are completed.
4.3.2在进行试验期间，调试人员应对试验过程进行详细的观察记录，并根据记录情况对系统的有关功能块参数进行必要的修改或调整。
During test, commissioning engineers should take full record and make necessary adjustments or modifications to the relevant functional block parameters.
4.3.3系统试验完成并合格后，应做好试验记录备查。
On completion of the system test, complete the test record for future reference.
4.3.4系统整套投运期间，如出现新的问题，计算机调试人员还应根据实际情况对系统进行调整修改以使系统更趋完善。
During the system integral trial operation, in case any bug appears, the commissioning engineers shall make adjustments and modifications on the situation to improve system reliability
5.使用工具Tools used for test
万用表: FLUKE 17B
Multimeter: FLUKE 17B
信号发生器：: FLUKE 744
Signal Source: FLUKE 744
6.注意事项Precautions
6.1参加调试的所有工作人员应严格遵守现场有关安全规定，确保调试工作安全可靠地进行。
All personnel participating in commissioning should strictly execute relevant site-safety-rules to ensure the work can be done safely and reliably.
6.2如在调试过程中可能或已经发生设备损坏、人身伤亡等情况，应立即停止调试工作，并分析原因，提出解决措施。
In case of any misfortune already or possible happened, such as equipment-damage or
health-hazard, the commissioning work should be suspended. The solution must be issued after analysis.
6.3如在调试过程中发现异常情况，应及时调整，并立即汇报指挥人员。
If any abnormality is discovered during commissioning, adjustment must be executed in time and report the instructor as soon as possible.
6.4调试全过程均应有各相关专业人员在岗，以确保设备运行的安全。Throughout commissioning, technical personnel of the relevant specialties shall be on duty in order to ensure safety of equipment operation.
6.5参加BPC系统投入的人员包括热控调试人员、热控设备厂家服务人员、机炉调试人员以及机炉运行人员，参加人员须密切配合，明确自己的职责。
BPC system commissioning is performed jointly by I&C commissioning engineers, manufacturer representatives, boiler/turbine commissioning engineers and operators. They should closely cooperate and have their duty nailed down.
6.6机炉调试、运行人员应熟悉热控设备的操作以及系统投入的方法、步骤。保证机组处于稳定运行工况，使机炉主设备、系统工作正常，并具备BPC系统投入的条件，BPC系统投入后，密切注意机组运行情况以及系统各部分的运行情况，如有异常应立即切除控制采用手动控制，按运行规程操作，使机组继续运行，并通知热控调试人员BPC已切除。
Boiler/turbine commissioning engineers and operators must fully understand I&C methods and procedures and be skillful at operating I&C devices to ensure that the boiler/turbine is operating under normal condition and satisfies the condition of BPC operation. After the BPC is put into operation, observe closely the behavior of the unit and the components of the system. In case that something abnormal occurs, change over to “Manual”mode immediately, and keep the unit running according to the operation regulations. Then inform the I&C commissioning engineers that the BPC has been taken offline.