Video surveillance system of the Orekhovo-Zuevsky Glass Factory.
A unique project in terms of the complexity of the implementation conditions for the implementation of a video surveillance system at the Orekhovo-Zuevsky Glass Factory was successfully completed by the company «Fort-Security Engineering» (Moscow).
The company's specialists created a system designed, at the request of the Customer, to control the technological processes of container glass production.
Control points with installed video cameras are distributed across three workshops along the conveyors, where the full production cycle of finished product manufacturing takes place. The length of the conveyor line is more than 2 km.
Video control points are equipped:
Glass batch preparation workshop, where it is necessary to carry out constant monitoring of the conveyor, on which various components are injected into the glass mixture (glass batch) in precise proportions from more than 10 tanks automatically with an accuracy of up to a milligram.
Machine shop: hot production.
This section has video surveillance of four glass-forming machines, where, according to programs, a certain type of finished product is formed from molten glass.
Machine shop: cold production.
The areas of assembly of finished products into flights, packaging and shipment of goods are under video control, video recording of the process of operation of automatic flightizers, autoloaders, and other technological equipment is conducted.
The speed of working out a full working cycle is several seconds, therefore, only by viewing the video archive can many violations of this technological cycle be recorded.
Due to the territorial dispersion of the plant's workshops and the current lack of a single fiber-optic data transmission network (the Plant is in the development stage), Fort-Security Engineering solved the Customer's problems by creating 3 local systems for each of the listed workshops.
The VideoInspector Professional systems from ISS Company were used as the software platform for each of the sections.
However, at the next stages of work, they will all be combined, and systems from other production facilities will be added to them.
It is planned to include at least 5 more video servers in the single system and connect more than 120 video cameras.
Thanks to the new capabilities of the VideoInspector Professional system, one of which is support for network distributed systems with a multi-server configuration, the planned development within the framework of this project will not be difficult for the installation company and will not require financial costs from the Customer.
When implementing a video surveillance system at the Orekhovo-Zuevsky Glass Factory, the Fort-Security Engineering team had to carefully select equipment and consumables.
The production conditions defined specific requirements, deviation from which could turn the system from highly efficient and fault-tolerant into a «burden», the maintenance of which in working condition would cost the customer more than its implementation.
The project was carried out in truly extreme conditions.
The ambient air temperature in the machine shop reaches 70 degrees Celsius. In the glass batch preparation shop, there is a constant suspension of small particles in the air.
The work was organized in shifts, with a longer rest period, with the strictest observance of safety measures and regulations.
The software of the VideoInspector Professional system is installed on video servers with an uninterruptible power supply system, which are located in telecommunication wall cabinets.
In one of them, excess pressure is organized to prevent the airborne charge mixture from getting into the equipment.
For work in aggressive environments, the glass batch preparation shop is equipped with high-resolution analog black-and-white video cameras in hermetic housings with an additional function of continuous external blowing of the front glass, implemented by the team of the Fort-Security Engineering company.
In the machine shop at the hot production stage, analog black-and-white high-resolution video cameras in double thermal housings with a heat-insulating layer of one-component polyurethane foam sealant are used, also developed by Fort-Security Engineering.
In the machine shop at the cold production section, analog black-and-white high-resolution video cameras and dome robotic color video cameras are installed, «monitoring» the operation of process equipment and recording the exact time of the duration of operating modes.
The software of the VideoInspector Professional system made it possible to organize the required number of workstations (2, 5, 4 URM-M in different workshops) to monitor the technological processes of container glass production in real time and work with the generated video archive.
The delivery set (without additional payment) of the VideoInspector Professional system already includes 5 remote monitoring workstations and 1 administration workstation.
A coaxial cable and a copper twisted pair were used to transmit data in this project.
RAID arrays for storing video archive data are organized on each of the three video servers. The total disk space capacity of the video server is about 8 TB and is designed to store a video archive for a full calendar month.
A remote division of the Orekhovo-Zuevsky Glass Factory is located in Moscow.
For the Management of the enterprise working in the Moscow office, URM-Ms have been organized via a VPN connection to monitor technological processes.
Remote access is provided from mobile devices connected to the Internet.
Introduced by Fort-Security Engineering The video system designed to control the technological processes of container glass production is only a stage in the construction of a comprehensive security system for the Glass Factory.
Currently, an ACS is being implemented at this facility (the estimated number of entry points is 64).
A security video surveillance system will also be created in the workshops, on the intra-factory area, and along the perimeter of the facility.
This system will be integrated with the ACS to ensure the purposes of monitoring the movement of personnel and their visual identification.
The implementation of such a comprehensive project is possible thanks to the new capabilities of the VideoInspector Professional system.
Now, on the VideoInspector system platform, it is possible not only to organize video surveillance, but also to create integrated solutions with support for fire alarm systems and ACS.