Industrial & Manufacturing Facilities Communication Solutions

Metallurgical plants are high-risk environments characterized by high temperatures, heavy dust, and strong electromagnetic interference, as well as safety hazards such as gas leaks and molten steel splashes. In emergencies, an efficient and reliable emergency communication system is essential. This solution integrates IP dispatch consoles, SIP microphones, and other devices to build a "highly reliable, strongly interference-resistant, and easy-to-maintain" emergency communication system.

Project Background

Metallurgical plants are high-risk environments characterized by high temperatures, heavy dust, and strong electromagnetic interference, as well as safety hazards such as gas leaks and molten steel splashes. In emergencies, an efficient and reliable emergency communication system is essential. However, current communication systems face challenges including weak anti-interference capability of traditional analog systems, high equipment failure rates in high-temperature conditions, low efficiency in multi-process coordination, and difficult maintenance in dusty environments.

This solution integrates IP dispatch consoles, SIP microphones, and other devices to build a "highly reliable, strongly interference-resistant, and easy-to-maintain" emergency communication system. The system complies with metallurgical industry standards and leverages wired communication technology to ensure real-time and stable communication in both routine production and emergency scenarios, establishing a robust digital communication safeguard for safe production in metallurgical plants.

Requirements Analysis

Rapid Emergency Response

In emergencies such as gas leaks or blast furnace explosions, the system must achieve a "30-second emergency communication chain activation": the management center dispatch console can trigger a high-priority emergency broadcast across the entire plant with one button; gas detection alarms automatically activate regional broadcasts issuing evacuation instructions; on-site personnel can communicate with the management center in real time via emergency call phones for feedback.

Harsh Environment Adaptability

Equipment must meet strict environmental requirements: IP65 protection rating (dust and water resistance); operating temperature from -40℃ to +70℃ (to withstand high temperatures); ExdIICT6 explosion-proof certification (suitable for explosive environments); ISO10816-3 vibration resistance standard (to endure equipment vibrations).

Seamless Coverage Across All Areas

Ensure no communication blind spots: terminals placed every 200 meters in key zones such as raw material processing and molten iron handling areas; dust-resistant intercoms deployed on elevated platforms like blast furnace platforms; mobile terminals installed on vehicles for dynamic communication coverage.

Multi-System Collaborative Integration

Deep integration with existing systems: interface with gas detection system (GDS) to automatically trigger regional broadcasts upon alarm; linkage with fire alarm system (FAS) to switch to emergency evacuation broadcasts during fire events; compatibility with manufacturing execution system (MES) to obtain equipment data for decision support during emergencies.

Easy Operation and Efficient Maintenance

Adapted to operational characteristics: terminals equipped with one-touch alarm/call function for rapid use in high-temperature environments; modular equipment design to facilitate maintenance and replacement in dusty conditions; system supports remote monitoring to reduce manual inspections in high-temperature zones.

Design basis

This solution is strictly designed in accordance with current national standards and the actual needs of the project
site, ensuring full compliance throughout system design, equipment selection, installation, and acceptance testing.
The main references include:

Explosion-Proof Safety Standards

Complies with GB3836.1-2021 "Explosive Atmospheres — Part 1: Equipment General Requirements," with equipment explosion-proof rating of ExdIICT6; adheres to AQ2007.1-2006 "Basic Safety Standardization for Metallurgical Enterprises — Rolling Steel Enterprises," ensuring safe use of equipment in hazardous areas; meets the corrosion protection requirements for hydrogen sulfide environments in SY/T7352-2016 "Technical Specifications for Oil & Gas Field Communication System Engineering," analogous to corrosion conditions caused by metallurgical dust.

Environmental Adaptability Standards

Protection level meets GB/T4208-2017 IP65 standard, resisting dust ingress and water spray; high-temperature endurance references MIL-STD-810G Method 501.5, supporting cold start at -40℃ and continuous operation at +70℃; vibration resistance complies with ISO10816-3 "Mechanical Vibration — Evaluation," with equipment mounted on vibration isolation bases having a natural frequency ≤15Hz.

Communication Protocol Standards

Voice codec adopts ITU-T G.711A standard, with end-to-end latency ≤80ms to meet real-time emergency command requirements; IP network follows RFC3261 (SIP protocol), supporting seamless integration with office communication systems; wireless communication uses IEEE 802.11n protocol, compatible with existing Wi-Fi infrastructures.

Electromagnetic Compatibility Standards

Equipment interference immunity complies with GB/T17626.5-2019 "Surge Immunity Test"; electromagnetic radiation emissions meet GB9254-2008 "Limits and Methods of Measurement of Radio Disturbance Characteristics of Information Technology Equipment" Class A requirements; grounding system design follows GB50169-2016 "Grounding Device Construction and Acceptance Specification," with grounding resistance ≤1Ω.

Solution Design and System Architecture

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System features

Emergency event grading response

The system implements a three-level response mechanism to adapt to different metallurgical emergency scenarios: first level response (gas leakage), second level response (blast furnace abnormality), and third level response (daily emergency).

Adaptation to the entire scene environment

High temperature environment, dust environment, vibration environment

Multi system collaborative linkage

Gas monitoring system, rolling mill control system, overhead crane management system.

Anti interference and reliability guarantee

Hardware anti-interference, software anti-interference, reliability.

Full process recording and tracing

Recording function: Record all calls, broadcasts, and associated device data, synchronized with the factory clock (error ≤ 50ms); Support multi condition (region/time/device type) retrieval; Encrypt storage for at least 12 months.
Traceability analysis: Automatically associate recordings with production logs to generate event timelines; Support playback of communication records for retrospective analysis; Real time recording of equipment operating parameters (temperature/voltage/signal strength; automatic backup of data 10 minutes before equipment failure; automatic generation of equipment maintenance files.

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Industrial & Manufacturing Facilities Communication Solutions

Project Background