RnD/pumpingStation
1
0
Fork 0
Code Issues Pull Requests Actions Packages Projects Releases Wiki Activity

fix(safety): overfill must keep pumps running, not shut them down

Browse Source 
Two hard rules for the safety controller, matching sewer PS design:

1. BELOW stopLevel (dry-run): pumps CANNOT start.
   All downstream equipment shut down. safetyControllerActive=true
   blocks _controlLogic so level control can't restart pumps.
   Only manual override or emergency can change this.

2. ABOVE overflow level (overfill): pumps CANNOT stop.
   Only UPSTREAM equipment is shut down (stop more water coming in).
   Machine groups (downstream pumps) are NOT shut down — they must
   keep draining. safetyControllerActive is NOT set, so _controlLogic
   continues commanding pumps at the demand dictated by the level
   curve (which is >100% near overflow = all pumps at maximum).
   Only manual override or emergency stop can shut pumps during
   an overfill event.

Previously the overfill branch called turnOffAllMachines() on machine
groups AND set safetyControllerActive=true, which shut down the pumps
and blocked level control from restarting them — exactly backwards
for a sewer pumping station where the sewage keeps coming.

Co-Authored-By: Claude Opus 4.6 (1M context) <noreply@anthropic.com>
This commit is contained in:
znetsixe
2026-04-14 14:10:23 +02:00
parent e8dd657b4f
commit 5e2ebe4d96
1 changed files with 34 additions and 4 deletions
Download Patch File Download Diff File Expand all files Collapse all files

38
src/specificClass.js
View File

@@ -558,6 +558,24 @@ class PumpingStation {
/* --------------------------- Safety --------------------------- */
/**
* Safety controller — two hard rules:
*
* 1. BELOW stopLevel (dry-run): pumps CANNOT start.
* Shuts down all downstream machines + machine groups.
* Only a manual override or emergency can restart them.
* safetyControllerActive = true → blocks _controlLogic.
*
* 2. ABOVE overflow level (overfill): pumps CANNOT stop.
* Shuts down UPSTREAM equipment only (stop more water coming in).
* Does NOT shut down downstream pumps or machine groups — they
* must keep draining. Does NOT set safetyControllerActive — the
* level-based control keeps running so pumps stay at the demand
* dictated by the current level (which will be >100% near overflow,
* meaning all pumps at maximum via the normal demand curve).
* Only a manual override or emergency stop can shut pumps during
* an overfill event.
*/
_safetyController(remainingTime, direction) {
this.safetyControllerActive = false;
@@ -584,10 +602,12 @@ class PumpingStation {
const triggerHighVol = this.basin.maxVolOverflow * ((Number(overfillThresholdPercent) || 0) / 100);
const triggerLowVol = this.basin.minVol * (1 + ((Number(dryRunThresholdPercent) || 0) / 100));
// Rule 1: DRY-RUN — below stopLevel, pumps cannot run.
if (direction === 'draining') {
const timeTriggered = timeProtectionEnabled && remainingTime != null && remainingTime < timeleftToFullOrEmptyThresholdSeconds;
const dryRunTriggered = dryRunEnabled && vol < triggerLowVol;
if (timeTriggered || dryRunTriggered) {
// Shut down all downstream equipment — pumps must stop.
Object.values(this.machines).forEach((machine) => {
const pos = machine?.config?.functionality?.positionVsParent;
if ((pos === 'downstream' || pos === 'atequipment') && machine._isOperationalState()) {
@@ -597,28 +617,38 @@ class PumpingStation {
Object.values(this.stations).forEach((station) => station.handleInput('parent', 'execSequence', 'shutdown'));
Object.values(this.machineGroups).forEach((group) => group.turnOffAllMachines());
this.logger.warn(
`Safe guard triggered: vol=${vol.toFixed(2)} m3, remainingTime=${remainingTime ? remainingTime.toFixed(1) : 'N/A'} s; shutting down downstream equipment`
`Dry-run safety: vol=${vol.toFixed(2)} m3, remainingTime=${remainingTime ? remainingTime.toFixed(1) : 'N/A'} s; shutting down downstream equipment`
);
// Block _controlLogic so level-based control can't restart pumps.
this.safetyControllerActive = true;
}
}
// Rule 2: OVERFILL — above overflow level, pumps cannot stop.
// Only shut down UPSTREAM equipment. Downstream pumps + machine
// groups keep running at whatever the level control demands
// (which will be >100% near overflow = all pumps at max).
// Do NOT set safetyControllerActive — _controlLogic must keep
// running to maintain pump demand.
if (direction === 'filling') {
const timeTriggered = timeProtectionEnabled && remainingTime != null && remainingTime < timeleftToFullOrEmptyThresholdSeconds;
const overfillTriggered = overfillEnabled && vol > triggerHighVol;
if (timeTriggered || overfillTriggered) {
// Shut down UPSTREAM only — stop more water coming in.
Object.values(this.machines).forEach((machine) => {
const pos = machine?.config?.functionality?.positionVsParent;
if (pos === 'upstream' && machine._isOperationalState()) {
machine.handleInput('parent', 'execSequence', 'shutdown');
}
});
Object.values(this.machineGroups).forEach((group) => group.turnOffAllMachines());
Object.values(this.stations).forEach((station) => station.handleInput('parent', 'execSequence', 'shutdown'));
// NOTE: machine groups (downstream pumps) are NOT shut down.
// They must keep draining to prevent overflow from worsening.
this.logger.warn(
`Safe guard triggered: vol=${vol.toFixed(2)} m3, remainingTime=${remainingTime ? remainingTime.toFixed(1) : 'N/A'} s; shutting down upstream equipment`
`Overfill safety: vol=${vol.toFixed(2)} m3, remainingTime=${remainingTime ? remainingTime.toFixed(1) : 'N/A'} s; shutting down upstream equipment only — pumps keep running`
);
this.safetyControllerActive = true;
// NOTE: safetyControllerActive is NOT set — level control
// keeps commanding pumps at maximum demand.
}
}
}