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Customer application December 5, 2022

Safe Filling in Hazardous Areas

As a solution provider for explosion-proof cameras in process and system monitoring, TTS Automation has developed a system for safe loading processes. The intelligent industrial camera allows tank loading processes to be monitored and anomalies detected early. As an intelligent interface for image analysis, TTS relies on the IoT Box from WAGO.

TTS Automation and WAGO:

  • Intelligent industrial camera and WAGO IoT Box for process monitoring

  • Early detection of anomalies and irregularities

  • Safety in the Ex area for people, machines and the environment

  • Modular design for green and brownfields

Detect events before they become dangerous

In 2009, TTS Automation developed the first camera system for Ex areas. The idea was born out of the fact that industries in which hazardous and explosive atmospheres occur in the form of mixtures of air and combustible gases, vapors or mists are subject to explosion protection. When it came to developing an explosion-proof solution for tank loads, the company based in Neustadt an der Weinstraße faced a major challenge: tank loading processes are complex because they go beyond mere process and plant monitoring. Irregularities in the loading must be quickly recognized and remedied. “Our experience has shown that leaks at loading fittings are often preceded by events such as jerking of the pipeline or slumping of the tank vehicle. So we wanted to develop a solution for tank loading that would detect dangers before they arise," recalls Michelle Striegel, who is responsible for marketing and project management at TTS Automation.

It soon became clear that the camera needed intelligence to detect and evaluate potential dangers preventively. For this purpose, controlling the functional sequences must be required on the system side. In search of a suitable system, TTS Automation found the solution at WAGO. “The WAGO IoT Box was exactly the right component for an intelligent camera system,” recalls Wolfgang Laufmann, Global Key Account Manager Digital Plant at WAGO and contact person in the project for TTS Automation.

WAGO IoT Box:

  • A complete ready-to-use solution

  • Expandable hardware/software

  • Customizable

  • Flexible connection via ETHERNET, WLAN or mobile network

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Protecting People, Equipment and the Environment

With the intelligent, automated industrial camera, TTS Automation aims to contribute to the safe and quality-enhancing tank loading in Ex areas. In doing so, the company manages to cover safety on three levels: protect people, equipment and the environment. For this purpose, the intelligent system camera films the entire workflow at different points: When a truck to be loaded drives onto the company premises, the vehicle license plate is scanned by the first camera at the gate or the barrier.

This matches the loading documents with the SAP order and assigns the vehicle to a loading zone. The tank train to be loaded travels into the loading zone assigned to it, and a new scan of the identification occurs. With the second license plate scan, the system is unlocked and incorrect tank loading is prevented.

MM-386849_GWA_Reference-TTS-ATL-Station_1S7A4217_2000x1125.jpg

The vehicle license plate is scanned by the intelligent camera.

The truck driver then places the grounding pliers on the vehicle. After starting the loading process, the driver returns to the safe area of the measuring station and does not have to stay in the hazardous area as they once did. Then the intelligent system camera from TTS automatically zooms in on the tank loading area. Anomalies or irregularities are identified before they become hazardous. If an anomaly is detected, the camera triggers a warning on the screen in the measurement station. The system reacts even before the system fails or stops. The loading process can be stopped automatically via the WAGO IoT Box, and an alarm is triggered. Leaks of explosive or chemical substances are prevented, thus averting fatal environmental and system damage.

MM-386849_GWA_Reference-TTS-ATL-Station_1S7A4278_2000x1125.jpg

The truck goes into the loading zone, the second camera detects the license plate and unlocks the system.