Lab Pressure Monitoring and Integrated Gas Detection with Shutdown Control

At Vanco Electrical Solutions, we take pride in highlighting innovative projects that push the boundaries of safety and efficiency. We’re excited to feature the outstanding work of Aman Marchildon, who designed and implemented a cutting-edge system for lab pressure monitoring and integrated gas detection with automatic shutdown control. Combining reliable hardware with custom programming, Aman’s solution delivers unparalleled safety and flexibility in critical environments.

Comprehensive Gas Pressure Monitoring

Aman’s system keeps a close eye on around 120 pressure transducers using the x600 controller and x22s modules. The x22s modules allow for direct 4-20mA input, making integration with the pressure sensors seamless. Each gas bottle is equipped with low-power solenoids that can automatically shut off and vent the gas lines if a leak is detected by the lab’s gas monitors, ensuring a quick and effective response to potential hazards.

Redundant Emergency Shutdown System

Safety redundancy is at the heart of this control system. Aman’s design uses relay cards to:

• Manage solenoids and power supply systems.

• Cut off power to the lab in the event of a gas leak, preventing ignition risks in potentially explosive situations.

To ensure uninterrupted operation, the relay outputs are wired with redundancy. Even if a module or relay fails, the emergency shutdown system remains operational. Additionally, secondary relay cards feature power injection, ensuring the relays maintain power and prevent unintended shutdowns, even if the x600 controller encounters a failure.

Versatile Custom Programming

The x600 scripts are the backbone of this system’s functionality. Aman utilized these scripts to:

• Simplify Calibration: Streamlining the calibration and replacement of 4-20mA transducers.

• Forecast Consumption: Using SQLite databases to track daily pressure losses and predict monthly and annual gas supply needs.

• Enable Advanced Monitoring: Managing shutdown control, translating gas detection error codes, and facilitating XML data transfer for synchronization.

By relying heavily on scripting, Aman separated the hardware from the software. This approach not only simplifies troubleshooting but also ensures the system can adapt to future requirements with ease.

Integrated Gas Detection and Oxygen Monitoring

For enhanced safety, the x404 controller polls RS485 MODBUS sensors to:

• Monitor gas and oxygen levels.

• Display sensor status, lifespan, and error codes in plain text.

• Provide this data to HMIs for real-time monitoring.

This functionality allows for comprehensive oversight of lab conditions, ensuring a safer working environment.

Remote System Synchronization

Aman miniaturized and replicated this system at a remote shed housing additional gas supplies and independent gas detection systems. The lab and shed systems are fully self-standing but synchronize via XML data transfer. This setup ensures:

• Mutual shutdowns between the lab and shed during emergencies.

• Independent operation if communication is lost.

• Automatic resynchronization upon reconnection.

Using XML transfer simplifies SCADA integration, presenting the two systems as a unified unit without sacrificing individual functionality.

Reliable Power Supply

Both the lab and shed systems include redundant power supplies with battery backups, providing over 24 hours of operational power during outages. This ensures continuous monitoring and control, even in prolonged power failures.

Efficient HMI Integration

Aman’s system features 10 HMIs across the lab, providing real-time data from the x600 and x404 controllers in both the lab and shed. To optimize the limited number of TCP MODBUS sockets (five per controller), Aman used two master HMIs, leaving one socket free for SCADA integration. This approach ensures seamless performance and scalability.

Proven Performance

Having worked with ControlByWeb products in smaller-scale applications for years, Aman trusted their reliability for this ambitious project. After eight months in operation, the system has proven to be rock solid, meeting all expectations in this safety-critical environment.

Conclusion

Vanco Electrical Solutions is proud to showcase Aman Marchildon’s innovative work. By prioritizing safety, redundancy, and adaptability, Aman created a solution that not only meets but exceeds the demanding requirements of modern laboratory environments. His project is a shining example of how expertise and thoughtful design can drive advancements in safety-critical systems. Thank you for your submission Aman!