101 lines
3.9 KiB
Markdown
101 lines
3.9 KiB
Markdown
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# Phase 2: Safety Framework Implementation - COMPLETED
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## Overview
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Phase 2 of the Calejo Control Adapter has been successfully completed. The safety framework is now fully implemented with comprehensive multi-layer protection for municipal wastewater pump stations.
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## Components Implemented
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### 1. DatabaseWatchdog
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- **Purpose**: Monitors database updates and triggers failsafe mode when optimization plans become stale
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- **Features**:
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- 20-minute timeout detection (configurable)
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- Real-time monitoring of optimization plan updates
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- Automatic failsafe activation when updates stop
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- Failsafe recovery when updates resume
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- Comprehensive status reporting
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### 2. EmergencyStopManager
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- **Purpose**: Provides system-wide and targeted emergency stop functionality
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- **Features**:
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- Single pump emergency stop
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- Station-wide emergency stop
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- System-wide emergency stop
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- Manual clearance with audit trail
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- Integration with all protocol interfaces
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- Priority-based stop hierarchy (system > station > pump)
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### 3. AlertManager
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- **Purpose**: Manages multi-channel alert delivery for safety events
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- **Features**:
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- Email alerts with configurable recipients
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- SMS alerts for critical events only
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- Webhook integration for external systems
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- SCADA HMI alarm integration via OPC UA
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- Alert history management with size limits
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- Comprehensive alert statistics
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### 4. Enhanced SafetyLimitEnforcer
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- **Purpose**: Extended to integrate with emergency stop system
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- **Features**:
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- Emergency stop checking as highest priority
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- Multi-layer safety architecture (physical, station, optimization)
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- Speed limits enforcement (hard min/max, rate of change)
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- Level and power limits support
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- Safety limit violation logging and audit trail
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## Safety Architecture
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### Three-Layer Protection
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1. **Layer 1**: Physical Hard Limits (PLC/VFD) - 15-55 Hz
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2. **Layer 2**: Station Safety Limits (Database) - 20-50 Hz (enforced by SafetyLimitEnforcer)
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3. **Layer 3**: Optimization Constraints (Calejo Optimize) - 25-45 Hz
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### Emergency Stop Hierarchy
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- **Highest Priority**: Emergency stop (overrides all other controls)
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- **Medium Priority**: Failsafe mode (stale optimization plans)
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- **Standard Priority**: Safety limit enforcement
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## Testing Status
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- **Total Unit Tests**: 95
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- **Passing Tests**: 95 (100% success rate)
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- **Safety Framework Tests**: 29 comprehensive tests
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- **Test Coverage**: All safety components thoroughly tested
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## Key Safety Features
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### Failsafe Mode
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- Automatically activated when optimization system stops updating plans
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- Reverts to default safe setpoints to prevent pumps from running on stale plans
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- Monitors database updates every minute
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- 20-minute timeout threshold (configurable)
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### Emergency Stop System
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- Manual emergency stop activation via all protocol interfaces
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- Three levels of stop: pump, station, system
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- Audit trail for all stop and clearance events
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- Manual clearance required after emergency stop
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### Multi-Channel Alerting
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- Email alerts for all safety events
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- SMS alerts for critical events only
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- Webhook integration for external monitoring systems
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- SCADA alarm integration for HMI display
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- Comprehensive alert history and statistics
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## Integration Points
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- **SafetyLimitEnforcer**: Now checks emergency stop status before enforcing limits
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- **Main Application**: All safety components integrated and initialized
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- **Protocol Servers**: Emergency stop functionality available via all interfaces
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- **Database**: Safety events and audit trails recorded
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## Configuration
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All safety components are fully configurable via the settings system:
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- Timeout thresholds
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- Alert recipients and channels
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- Safety limit values
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- Emergency stop behavior
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## Next Steps
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Phase 2 is complete and ready for production deployment. The safety framework provides comprehensive protection for pump station operations with multiple layers of redundancy and failsafe mechanisms.
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**Status**: ✅ **COMPLETED AND READY FOR PRODUCTION**
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