Most industries from corporate, commercial, industrial and utility to military are rapidly moving towards Ethernet (Network) or more commonly known as “IP” solutions due to the large amount of benefits Ethernet has to offer.
The introduction of IV&C into the Industrial Industries has immediate benefits such as safety with integration into existing Scada/HMI systems.
The keys to a successful implementation are extensive LAN and WAN bandwidth Control of the camera feeds and viewing feeds, an integration mechanism for use within existing systems as to ensure no interruption of any critical processes.
Safety in the mines and any of the above mentioned industries is critical for countless reasons. With the integration of a Smart Camera Management System such as Industrial Video and Control, one can now make use of the benefits and add to the safety of the processes at hand.
A sensitive Gold Mine Client was able to see the need for such a system and has now integrated this into their existing underground network and with their Scada Systems.
One of the many pro’s to an IP Camera Management System is the amount of flexibility that is offered. The Gold mine is currently making use of old and new Analog Camera’s underground as this was the most viable option for them since it was not financially feasible to replace there existing analog camera’s.
With the use a device that is able to convert this Analog feed into an IP network feed, such a device is referred to as an IP to Analog Encoder, one can have a hybrid system consisting of Analog and IP Cameras in one flexible system that offers integration in Scada/HMI and remote monitoring! Encoders are typically in a build up of 1 or 4 Analog Port Options, or a Rack Solution which caters for expansion using hot swappable blades and caters for up to 48 Analog Camera Inputs. Each blade has Digit Inputs and Digital Outputs, the same as the 1 or 4 port Encoders.
One of the requirement was to monitor and integrate camera’s from each of the different levels running underground. This was achieved by placing certain port encoders on relevant levels to convert their existing Analog Camera’s to IP. Once encoded they were plugged into the backbone of the network in their own VLAN (Virtual Local Area Network) to gain communication to the control room on the surface.
Once the system was configured with bandwidth control activated in order to not use to much available traffic on the network, over 64 Camera’s were able to be viewed from the control room without effecting Automation traffic and with catering for plenty growth on the IP Camera and Automation logical networks.
The next task was to integrate the Camera Solution with the Automation in place. A PLC (Programmable Logic Controller) is typically used now days for Automation Systems. The engineers on the mine configure and wired the PLC to the Digital Input of the camera Encoder.
Now when the PLC starts a process or task such as starting a conveyer belt, the camera system automatically activates the relevant camera’s with live alerts on the monitoring screen to ensure the environment is safe for the process to begin.
The Relay Server is the heart of the IV&C System and has the following set of tasks in the solution such as :
- Control the bandwidth consumption from the camera to the NVR (Network Video Recorder)
- Record to the NVR
- Playback feature through Internet Explorer or compatible browser from any accessible PC of hand held device on the network
- Security Restriction based on Security Access via configurable username and passwords
- High Security with Integration into Active Directory Environments
- Enable Live View of up to 4 simultaneous views from any accessible PC or hand held device on the network
The View Station offers the following functionality
- Monitor up to 99 IP Camera feed simultaneously on multiple Screens
- Have Multiple Screens for different purposes with automated change over to other live feeds
- Integration with Digital Input and Digital Output operations directly to the IP Camera or IP Encoder
- Enable Alarm Log with Alarm features based on configurable options
The client now has a scenario where the IP Camera’s or Analog converted to IP Camera’s are running on his existing automation network running underground with a negligible bandwith utilitisation increase still allowing for growth in other VLAN’s on their system.
The mine is now able to enjoy the benefits of safety! That now when a process is started such as a conveyer belt or pressure pump, a live feed of the area and any concerning factors are displayed remotely to the Control Room for visual confirmation of happenings in the field.
The project started with converting only 16 camera’s to IP and integrating them into their process. As their budgets allowed and catered so the system has grown up to over 96 Camera Feeds. With the design and scope of the system, the client is able to still grow and expand the system as he requires when he requires due to the extensive bandwidth management of IV&C.