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Embedded Systems Portfolio: Guarantor of Technogenic Safety
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Embedded Systems Portfolio: Guarantor of Technogenic Safety

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GTS is the hardware-software complex, developed by Edgewood Services engineers for the plant that produces the polyurethane. Fire and gas leaks constitute a potential hazard for the public, therefore ...

GTS is the hardware-software complex, developed by Edgewood Services engineers for the plant that produces the polyurethane. Fire and gas leaks constitute a potential hazard for the public, therefore the plant needed the automated system for proper control, reducing the possibilities of damage and performing actions according to emergency response plan in case of the accident.

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Embedded Systems Portfolio: Guarantor of Technogenic Safety Embedded Systems Portfolio: Guarantor of Technogenic Safety Presentation Transcript

  • GUARANTOR OF TECHNOGENIC SAFETY PROJECT Hardware-Software Complex by Edgewood Services© 2011 Edgewood Services LLCGuarantor of Technogenic Safety Project www.edgewoodservices.com
  • PROJECT OVERVIEW Human impact on the environment is boundless. Although we can’t abandon dangerous industries, we can reduce the risks of man-made accidents to acceptable minimum, and in many cases even prevent them. In accordance with the Law On Environmental Protection in Ukraine, every hazardous plant must have a plan of actions to minimize the threat of industrial emergencies by automating the control of key production parameters and execution emergency response plan in case of an accident. For this purpose the GTS hardware-software complex was developed.© 2011 Edgewood Services LLCGuarantor of Technogenic Safety Project www.edgewoodservices.com
  • REQUIREMENTS Design, develop and implement enterprise class monitoring solution for the plant in Ukraine that produces the polyurethane. Fire and gas leaks constitute a potential hazard for the public, therefore the plant needed the automated system for proper control and reducing the possibilities of damage. • Provide access to monitoring of hazardous enterprise by emergency services • Develop the system that can run without operator supervision in fully automatic mode • Develop Automated Alert System for alerting staff on the plant and Automatic Emergency Call system for auto-dial to Ministry of Emergency Situations, emergency services and nearby buildings located in the affected area. Perform complex actions to prevent accidents. • Management Node works independently without server on the basis of data obtained from the Sensors© 2011 Edgewood Services LLCGuarantor of Technogenic Safety Project www.edgewoodservices.com
  • IMPLEMENTATION Considering customer requirements, our team developed and implemented the GTS hardware-software complex: • Client-server architecture was chosen because of the need in several workplaces and possibility to work remotely • Server side software interacts with Log Server and Weather Server via TCP/IP Protocol, with Management Node via RS-485 protocol. Also, it has expert system for predicting the consequences of an accident, developed according to the Ukrainian standards. • Client side software – rich client model has been selected to give opportunity to work in conditions of non-permanent connection. • Management Node - Hardware: full cycle solution - drawing circuit, fabricating prototype and launching into production - Software: developed firmware for communication with GTS Server and for autonomous execution of emergency response plan in case the connection with GTS Server is broken. • GTS Application Protocol – designed data communication protocol for interaction of GTS server with Management Nodes via RS-485.© 2011 Edgewood Services LLCGuarantor of Technogenic Safety Project www.edgewoodservices.com
  • GTS SYSTEM OVERVIEW GTS hardware-software complex consists of three main components. 1) Servers of GTS complex include: • GTS Server – gathers information about the objects and execute actions to contain the accident • Weather Server – controls external weather station • Log Server – records all operator actions, management nodes and system events for further analysis • Database Server – stores data that come from the server 2) GTS Client is the client interface used for: • Monitoring the situation on the plant – Industrial Zone Workspace • Displaying detailed information about each object beyond the plant – Map Workspace. • Displaying execution and providing users the opportunity to control the process of the emergency response plan in case of an accident – Emergency Response Actions Workspace • Configuration of the GTS System 3) Industrial Zone includes: Management Nodes (MN), Executive Mechanisms (EM) and Hubs (HUB), with attached Sensors (S) and Network.© 2011 Edgewood Services LLCGuarantor of Technogenic Safety Project www.edgewoodservices.com
  • GTS SERVER GTS Server software is implemented with Finite state machine technology. GTS Server functions: • Gathers information about potentially hazardous factors with the help of sensors, connected with Management Node (MN) • Forecast hazards based on data received from Sensors and data stored in Database. • If the accident occurs, it can generate a list of necessary actions using data from the Weather Server. • Performs actions according to emergency response plan with the help of Executive Mechanisms, connected with the Management Node (MN). In an emergency, it alerts the staff of the plant by loudspeaker and calls to emergency services and nearby municipal institutions. • With the help of GTS client, it reports data to the operator, receives commands from the operator, and if there is no response from the operator, independently performs the set of actions.© 2011 Edgewood Services LLCGuarantor of Technogenic Safety Project www.edgewoodservices.com
  • GTS SERVER The following cards are the components of the computer with GTS Server installed: • RS-485 Card is used for connection to the management nodes (MN) located in the industrial area • Voice Card is used to alert the workers at the plant by loudspeaker (Voice Alarm System) • PSTN Card is used for automatic notification via telephone lines about an emergency situation beyond the enterprise Expert system of GTS Serves assesses the situation at the plant and reveals the threat of man-made disasters. Each time it assigns the current state of safety level: • Normal – all systems are working normally. Operator’s intervention is not required. • Test Alarm – this level of safety is assigned by the operator in manual mode and is designed for a scheduled inspection of the system • Increased Attention – set in case of failure of any node of the system and requires a mandatory intervention. • Accident – set under the threat of an accident or immediately on the occurrence of emergency. Depending on the cause of the "Accident" status, the system can work out a few different scripts.© 2011 Edgewood Services LLCGuarantor of Technogenic Safety Project www.edgewoodservices.com
  • GTS CLIENT Management of the GTS complex is realized from the workplace of the operator. For this purposes special software «GTS client» was developed and implemented. In GTS complex, the role-based access control model is applied. It allows flexible share of the access rights to the nodes of the complex. Currently, the following roles are realized: • Observer • Operator • Administrator of the System Configuration • Administrator of the Security System The system operator can monitor and control all system nodes in a single interface. With the help of software, he can initialize or terminate the work of any script, use additional safety and conduct self-test of the nodes. GTS can be integrated with other safety systems due to the presence of API. It greatly simplifies the implementation of the system. GTS client has three workspaces.© 2011 Edgewood Services LLCGuarantor of Technogenic Safety Project www.edgewoodservices.com
  • GTS CLIENT: Industrial Zone Workspace Interface Displays plant with industrial zone hardware, shows information about all network and state of each device in graphical form. Functions Allows to configure the hardware, view the state of devices in detail and manage these devices© 2011 Edgewood Services LLCGuarantor of Technogenic Safety Project www.edgewoodservices.com
  • GTS CLIENT: Map Workspace Interface The plan area with surrounding objects is displayed in graphical form. In case of an accident, it shows a zone of possible damage, calculated for particular weather conditions and a specific type of an accident. Functions It is possible to see detailed information about each object and edit it.© 2011 Edgewood Services LLCGuarantor of Technogenic Safety Project www.edgewoodservices.com
  • GTS CLIENT: Emergency Response Actions Workspace Interface Shows full list of planned actions for the accident containment. This workspace becomes available only when emergency occurs. Functions Operator can enable/disable any action of the process; interrupt/resume execution of the accident containment.© 2011 Edgewood Services LLCGuarantor of Technogenic Safety Project www.edgewoodservices.com
  • INDUSTRIAL ZONE HARDWARE Management Node is the autonomous system with its own set of plug-executive mechanisms, which can make independent decisions and resolve problems based on the data received from other Sensors and other Management Nodes. It provides high fault tolerance of the system, even in the case of loss of access to the GTS server. Сommunication protocol for data exchange between the GTS server and Management Nodes was designed by our engineers according to the specifications. It is running over the GTS Application Protocol for RS-485. Executive Mechanisms represents any external system that needs to be managed. This may be an emergency removal of gas, electric locks on the doors, alarm systems etc. Sensors are attached to the Hub© 2011 Edgewood Services LLCGuarantor of Technogenic Safety Project www.edgewoodservices.com
  • INDUSTRIAL ZONE NETWORK We have chosen IEA/TIA-485 network for several reasons : • Long range communication distance – 1200 m over the lines • It can contain up to 256 devices • Simple organization of lines, type of network connection is bus • Balanced transmission line GTS Network Layers Standard IEA/TIA-485 has physical and data link layers. Existing data link layer protocols did not suit us, so our team designed own data communication protocol – GTS Application Protocol for RS-485. It was optimized corresponding to the specifications, in order to GTS Application Frame increase the line capacity and reduce the device response time. Error control system was used for maintaining data integrity. Network was implemented utilizing the master-slave arrangement.© 2011 Edgewood Services LLCGuarantor of Technogenic Safety Project www.edgewoodservices.com
  • TOOLS Server side Development platforms OS Windows 2008 server RAD Studio2010 GTS server service Microchip MPLAB IDE Firebird database PSTN device Embedded platform RS-485 card Microchip PIC Microcontrollers Client side Languages OS Windows 7 C/C++ GTS Client software Assembler SQL Network side TCP/IP network Fieldbus network based on RS-485© 2011 Edgewood Services LLCGuarantor of Technogenic Safety Project www.edgewoodservices.com
  • BENEFITS • GTS complex significantly increased the level of safety and environmental considerations • With this decision remote monitoring of situation on the plant became possible that helps to prevent the potential danger • In future, basing on the existing scheme, the engineers can implement the Central System for Monitoring and Management of hazardous industries around the country.© 2011 Edgewood Services LLCGuarantor of Technogenic Safety Project www.edgewoodservices.com
  • CONTACTS Edgewood Services LLC www.edgewoodservices.com sales@edgewoodservices.com Tel: +38 (056) 770 76 11 Cell: +38 (067) 637 12 56 11 Sninnaya St. Dnipropetrovsk 49107 Ukraine© 2011 Edgewood Services LLCGuarantor of Technogenic Safety Project www.edgewoodservices.com