According to recent statistical reports, the chemical industry has been found to be one of the most hazardous industries globally. Owing to numerous air-borne and waste toxins released as by-products during the manufacturing process, several crucial zones in the industry are extremely prone to explosions and the associated fatalities. Upon closer investigation, several risk factors have been identified that threaten the safety of the crew and equipment in chemical industries, including improper transportation and release of chemicals, inadequate workforce training, and inefficient risk management during crises.
With a rising wave of technology, automation has profoundly impacted the chemical industry, revolutionising its safety regulations and standards one step at a time. Maintenance tasks have been greatly facilitated by using sensors and actuators, enhancing both their efficiency and safety. However, another crucial component has emerged in this transformation — security cameras and in particular, explosion-proof cameras.
Conventional CCTV camera models don’t have the robustness and resilience to sustain in explosive areas. Explosion-proof cameras are now largely used in chemical industries to ensure enhanced security.
Recently, there has been a spike in the demand for explosion-proof security cameras as must-have equipment in the niche. These advanced hazardous area cameras are specifically designed to operate in inaccessible areas where human presence is restricted due to the presence of hazardous and flammable chemicals.
Accidents in the chemical industry can become extremely costly for the business, in terms of finances, equipment, and human resources. A report from 2021 suggested that in 2016 a refinery fire cost nearly €800 million in damages and an explosion in a steel factory in 2016 cost €80 million.
Such incidents emphasise on the use of a device like ex-proof cameras to record and store the data for analysis.
The construction of explosion-proof cameras implies the incorporation of specialised enclosures specifically designed for use in explosive environments. This design ensures that any internal sparks generated by the camera are contained and prevented from interacting with the surrounding elements. Thereby, it eliminates the risk of potential explosions in hazardous environments where substances like propane, methane, or other flammable gases are present.
Explosion-proof camera systems address the following limitations of conventional camera systems:
Equipped with a sturdy and robust design, these hazardous area cameras ensure individual's safety and provide enhanced security measures. By providing situational awareness with enhanced visibility, these cameras enable comprehensive monitoring of the entire manufacturing process, alleviating the burden on human resources and reducing the need for continuous on-site surveillance. With a 15-day storage capacity, ex-proof cameras offer ample time to back up critical data, ensuring the preservation of sensitive information.
Here are some pain points in chemical plants that necessitate the use of explosion-proof security cameras:
A case study of a UAE-based chemical plant outlines the key issues in safety and security after a serious trespassing incident a fortnight before. Besides the manual oversight in security, the footage procured using traditional cameras had several glitches, rendering it useless for legal purposes and identification of the perpetrator.
After the incident, the company partnered with SharpEagle for their explosion-proof PTZ cameras. In a single year, the statistics showed a sharp decline in security breaches due to AI-automated detection of unidentified personnel. The smart integration of different security systems reduced the risk of false alarms and allowed the operators to maximise their situational awareness with auto-focused and glitch-free surveillance feed. Even the fatality rates of the industry dropped from 23% to 12% from 2017 to 2018, indicating the establishment of a safer and more secure work environment in the chemical industry.
Versatility is a hallmark of SharpEagle explosion-proof cameras, as they can be effortlessly installed in various even the tightest spots around your facilities. Beyond safeguarding the well-being of your personnel, they act as vigilant protectors of your valuable equipment and assets, deterring theft and unauthorised access. Furthermore, these cameras possess exceptional night vision capabilities, providing comprehensive situational awareness even in complete darkness.
Struggling with monitoring hazardous areas in your chemical plant? Explore our explosion-proof cameras today!
Crafted with a strong emphasis on durability and resilience, these cameras are constructed using top-quality materials such as aluminium, stainless steel, or high-grade fibreglass. This choice of robust materials ensures that the cameras are highly resistant to fire and capable of withstanding extreme temperatures while still delivering clear and high-quality footage under any circumstances.
Additionally, the sturdy casing acts as a protective barrier, preventing gases and chemicals from infiltrating the camera and interfering with its electrical components. This crucial feature guarantees that the cameras are not at risk of triggering any explosions or hazardous incidents.
Explosion-proof cameras are just one component of our robust system and its carefully engineered design. Equally important are the holders that support these security cameras, designed with the capability to withstand up to 10 times the weight of the camera itself. These mounts are not only bulletproof but also shock resistant, ensuring that the camera remains securely fixed in place even in the event of an explosion occurring nearby.
SharpEagle's cameras are meticulously crafted to adhere to rigorous design principles that prioritise heavy-duty explosion-proof capabilities. A flame-proof cylindrical joint serves as an internal safeguard, effectively directing potentially ignitable particles into a conduit, ensuring the utmost security.
Our hazardous area cameras are ATEX-certified, meeting the stringent requirements for operation in the most hazardous zones. Even in the unlikely event of an internal explosion, the ATEX camera's design ensures that the sparks remain contained and avoid releasing any harmful substances into the surrounding environment.
Nevertheless, the advantages of deploying these cameras for chemical facility security extend beyond their robust construction. Here are some of the additional benefits they offer:
SharpEagle's cameras offer another valuable feature for the chemical plant security — optics protected by explosion-proof white tempered glass.
Moreover, both the camera's enclosure and lens are designed to withstand air pressures of up to 10,000 psi, surpassing the requirements of virtually all explosive environments. This remarkable capability ensures that these cameras remain steadfast in the face of potential catastrophes, providing an additional layer of reliability and peace of mind.
Chemical industries have high-temperature areas that can cause moisture build-up around the lens. This is not an issue with explosion-proof CCTV cameras, as the devices are manufactured with built-in blowers or dryers that operate as and when required to dissipate moisture. This ensures that the camera’s picture quality is always razor-sharp.
Real-time monitoring and alerts in explosion-proof cameras offer continuous, high-resolution surveillance in hazardous environments. These systems use advanced motion detection and analytics to identify potential threats. Instant alerts are sent to operators via integrated communication protocols, enabling immediate action. This rapid response capability prevents incidents from escalating, ensuring safety and operational integrity in volatile areas by allowing for quick intervention and risk mitigation.
Remote access and control of explosion-proof security cameras enable operators to monitor and manage surveillance from a safe distance via secure networks. This feature is crucial in hazardous environments, reducing the need for physical presence and minimising risk to personnel. Benefits include real-time video feed access, camera angle adjustments, and system diagnostics, all performed remotely. This enhances safety, operational efficiency, and ensures uninterrupted surveillance and quick response to incidents.
Explosion-proof cameras can integrate seamlessly with other safety systems, such as fire alarms, gas detectors, and access control systems, creating a comprehensive security solution. This integration enables synchronised responses to emergencies, like automatic shutdowns, alerts, and evacuation procedures. By providing real-time video feeds and data to central control systems, these cameras enhance situational awareness, facilitate coordinated actions, and ensure a robust safety and security infrastructure in hazardous environments.
Explosion-proof cameras are designed for versatility, making them suitable for diverse chemical processing environments, including refineries, storage facilities, and production plants. They are built to withstand extreme temperatures, corrosive chemicals, and flammable atmospheres, ensuring reliable performance. With features like high-resolution imaging, durable enclosures, and specialised coatings, these cameras provide continuous monitoring and security across various hazardous settings, enhancing safety and operational efficiency in critical chemical processes.
High-resolution imaging in explosion-proof cameras delivers exceptional video quality, essential for detailed monitoring and incident analysis. With high-definition clarity, operators can detect fine details, identify potential hazards, and monitor intricate processes accurately. This precision enhances the operator’s situational awareness, supports thorough incident investigations, and aids in regulatory compliance. The superior image quality ensures critical areas are monitored effectively, contributing to improved safety and operational efficiency in hazardous environments.
Explosion-proof cameras with wide-angle and zoom capabilities offer extensive coverage of large areas, providing comprehensive surveillance with fewer cameras. Wide-angle lenses capture broad scenes, minimising blind spots, while zoom features enable close-up inspection of distant objects or specific details. These capabilities enhance situational awareness, allow for detailed monitoring of critical areas, and facilitate quick identification and response to potential hazards, significantly improving safety and security in expansive hazardous environments.
Explosion-proof cameras are built with robust materials like stainless steel and reinforced glass, designed to resist extreme weather and physical impacts. Their durable construction ensures reliable operation in harsh conditions, including high humidity, dust, and corrosive environments. Weatherproof seals and protective coatings enhance longevity and performance. This durability ensures continuous, dependable surveillance, safeguarding hazardous areas from potential risks while maintaining functionality in the most challenging conditions.
Explosion-proof mini IR camera undergoes rigorous testing for its ATEX camera certification, assuring safe deployment in Zone 1 and 2 environments. Despite its small size, the design of the camera is resilient with bulletproof and shock-resistant qualities, ensuring unwavering durability in the most demanding conditions.
Unfazed by extreme temperatures, this camera is capable of enduring challenging climates without compromising the image quality. Equipped with powerful night vision capabilities, it provides the versatility of selecting between 2MP and 5MP resolution options, tailoring the visual clarity to meet your specific needs.
Explosion-Proof PTZ Camera is ATEX and IECEx-approved camera with full HD resolution for superior image quality. It offers 360° continuous rotation and 30x zoom, providing comprehensive surveillance coverage. Enjoy high-quality images with efficient H.264 video compression. The camera is IP68 waterproof standard compliant and features up to 100 metres of IR illumination.
The camera is built with durable stainless steel 304 or 316L enclosure, making it suitable for gas zone 1 & 2 and dust zone 21 & 22. Based on the specific industrial requirements, one can choose between DC12V or AC220V power supply. The camera is ideal for long-distance monitoring with the intelligent long focal speed limit. Additionally the camera also ensures reliable day/night vision with infrared lights. Designed for tough environments, including resistance to hydrofluoric acid areas and intelligent window defroster, ex-proof PTZ camera is a recommended investment for chemical industries.
Explosion-proof fixed-type camera is crafted with a formidable stainless steel enclosure. Its ingenious design contains sparks, mitigating the risk for camera or power-related explosions. The camera's sleek dome body adds a touch of sophistication to the camera’s design.
Engineered by the IP68 standard, this camera excels in durability, making it a stalwart choice for demanding hazardous environments. Furthermore, its night vision capability empowers effortless surveillance, rendering it a dependable and trustworthy solution for a wide range of applications.
With flexible installation options like a wall bracket or universal joint, setting up an explosion-proof zoom IR camera is quite hassle-free. Its waterproof and shock-resistant characteristics guarantee exceptional durability, enabling it to thrive in even the most demanding conditions.
Embracing versatility, this camera is available in both IP and analogue variants, offering compatibility for a wide range of systems. Equipped with intelligent technology, it effortlessly transitions to the infrared mode when visibility is compromised, ensuring clear and reliable surveillance.
Following are the benefits provided by explosion-proof cameras to help you monitor hazardous incidents and take preventive measures:
The introduction of explosion-proof cameras has revolutionised safety in the chemical industry. These provide essential protection in hazardous environments where flammable chemicals are present. By containing sparks and preventing explosions, they mitigate the risk of costly accidents and ensure the safety of personnel.
Explosion-proof cameras offer numerous benefits to chemical plants. They enhance security by providing improved visibility and enabling prompt alarm notifications. With comprehensive monitoring capabilities, they reduce the need for continuous on-site surveillance and offer ample storage for critical data. Learn more about the recommended ex-proof camera solutions on our SharpEagle website or book a free consultation call with our experts today!
These cameras allow for continuous monitoring of processes and areas that are potentially dangerous. They help in identifying risks, ensuring safety protocols are followed, and detecting early signs of malfunction or chemical leakage that could lead to explosions.
Explosion-proof cameras are often designed to operate in extreme temperatures, both high and low, which is common in chemical processing environments.
In case of an incident, these cameras provide real-time monitoring and recording, which is crucial for emergency response teams to assess the situation remotely and plan their intervention safely and effectively.
While the basic design principle of containing internal explosions is consistent, some cameras may have specific features or materials suited for certain types of chemicals or environments.
Installation should be done by professionals with expertise in hazardous area equipment. It typically involves secure mounting and ensuring that all electrical connections are safe and compliant with safety standards.
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