This project developed and implemented safety control systems for a laboratory station used for advanced energy storage research. The objectives were to analyze safety incident causes, design and install new safety controls, and develop documentation and user training. The work resulted in improved safety protections, remote monitoring capabilities, a graphical user interface, and user guides. Documentation of the new system design and implementation was also created.

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Implementation of safety control systems in laboratory
station for advanced research in energy storage
Introduction
Automated systems have proven to improve safety
and increase productivity. In compliance with Oregon
Tech’s Safety Policy, this project will outline safe and
reliable equipment to further the research in energy
storage on campus.
Objectives
Method Results
Renewable Energy Engineering
Paulo Vasconcelos, Frank Rytkonen, PE, Dr. Claudia Torres Garibay, Dr. Lawrence J Wolf, PE
The main objectives of this project are:
1. To develop a Safety Study Analysis of incident
causes
2. To design and implement safety control systems
3. To develop engineering documentation and
training
Motivation:
• Safety is a priority for Oregon Tech.
• Help fellow students to focus on their research
not on monitoring the system.
Fig. 2. Damage inside
glovebox after incident.
Fig. 6. Protection Layers. Old system had only the
first layer of protection.
Fig. 7. Remote monitoring system schematic.
Acknowledgements
I would like to thank the following people:
• Frank Rytkonen, PE, Dr. Claudia Torres Garibay and Dr.
Lawrence J Wolf and John Beaudry from Jacobs.
• Jeremiah Deboever, Michelle Kantor and Jon Waldrip that
provided me the inspiration to take-on this project.
• All Oregon Tech classmates, staff and faculty who were
involved in the process.
Conclusions
Paulo.SantosVasconcelos@oit.edu
503.781.8577
Fig. 3. Major damage.
Reconstruction to determine
cause of implosion.
Preliminary Hazard Analysis Examples
Fig. 1. Glove box in operation
Documentation & Training - Phase 3:
• System documentation (i.e. PFD, P&IDs, Loop
diagrams, mechanical installation details, spec
sheets)
• Operation Manual
• Maintenance Manuals
• User’s training.
Process
Function
Potential Failure Potential Effect RPN
Normal
Operation
Low pressure inside
work chamber Gloves implosion,
equipment/materials
damage
and human injury
1000
Gas supply depleted 800
Boundaries leak
outwards work chamber
Oxygen levels inside
work chamber
increase damaging
chemicals, solutions,
cathodes and
anodes
720
Oxygen levels inside
work chamber high
Start-up after
emergency
shut down
Oxygen levels inside
work chamber high
Chemicals, solution,
cathodes and
anodes damage
800
Table I – Highest Risk Priority Numbers (FMEA)
Monitoring System
This work developed safety control systems that were
installed on the glove box in the REE Laboratory. The final
goal ensured that the laboratory station is safer for student
researchers develop projects without the need to constantly
monitor the glove box variables.
Multiple new features:
(1)improved safety
(2)remote monitoring capabilities
(3)graphic user interface (GUI)
(4)user's guide and maintenance manuals
(5)design and implementation documentation
(6)connection to an external Potentiostat.
Contact Information
Fig. 9. Personal devices GUI
Fig. 4. Incident about
to happen.
Fig. 5. Engineering Design Process (Hynes, 2010)
Fig. 11. PLC and Vacuum Pump control panels.
Fig. 8. DL06-AR PLC and DIN-AP3 home automation unit
Fig. 12. System setup.
Student Project
Symposium
June 2016
Fig. 10. HMI Screens and Alarms