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