Extreme ambient conditions, fluctuating temperatures, dust, and salt spray, make monitoring offshore and onshore drilling rigs extremely difficult. Not just in offshore and onshore drilling rigs, a reliable surveillance system is a necessity in all industries where safety and security are a constant concern. In hazardous areas where toxic chemicals or inflammable materials exist, explosion-proof CCTV or hazardous area cameras allow operators to remain safe while monitoring the site. The ability to monitor and control activities, applications and processes plays an important role in providing a safe work environment and preventing accidents, injuries, and equipment damage. Industries like the oil and gas industry, chemical processing plants, aircraft refuelling and hangars, coal mines, oil refineries, sewage treatment plants, grain handling, sugar refineries, etc. have facilities or sections that are regarded as hazardous zones. Around such facilities, it is common to see flammable gases, vapour, and sparks that can cause accidents and fatal injuries.
Every environment is unique, with specific characteristics that depend on the nature of the atmosphere and the elements present. Hazardous areas are generally defined as any locations where explosive or flammable substances may be present in quantities that require special precautions for the construction, installation, and use of electrical equipment to prevent ignition. To classify an environment as an explosive atmosphere, three components are required:
A Flammable Substance: This includes gases, vapours, or dust that can ignite and cause an explosion.
Oxygen: Oxygen must be present in high quantities to support combustion.
An Ignition Source: This could be a spark, high heat, or any other source capable of igniting the flammable substance.
Some industrial zones require additional surveillance to maintain safety and efficiency. These sites often have extreme conditions, varying in temperature, atmosphere, and other factors, necessitating specific monitoring and equipment. Below listed are some of the most common conditions encountered regularly in high-risk industries.
• Enclosed areas prone to explosion
• Abnormally low or high temperatures
• Ships and areas with high corrosion levels
• Gas or toxins
• Irregular weather patterns
Governing bodies have designated zones based on the associated risk of explosions, defined by characteristics such as lower and upper explosive limits, equipment layout, relative density, ventilation, and the grade of the source of release. The level of risk is defined by the frequency and duration of the occurrence of an explosive atmosphere. They include:
Zone 0: An area where a flammable atmosphere is continuously present or present for long periods.
Zone 1: An area where a flammable atmosphere is likely to occur during normal operation.
Zone 2: An area where a flammable atmosphere is not likely to occur in normal operation but, if it does, will persist for a short period only.
Similarly, for dust-associated risks and exposure, zones include:
Zone 20: An area where combustible dust is present continuously or for long periods.
Zone 21: An area where combustible dust is likely to occur during normal operation.
Zone 22: An area where combustible dust is not likely to occur in normal operation but, if it does, will persist for a short period only.
In 2022 alone, large-scale industries recorded 5,486 fatal work injuries. OSHA outlines some key factors that contribute to such alarming statistics, including, improper processing of explosive materials, inadequate training of the crew, industrial malpractices, improper management of emergencies, lack of real-time data for monitoring, etc.
Thus, surveillance in hazardous areas is critical for both safety and operational efficiency. The primary reasons for implementing stringent surveillance measures with different types of outdoor CCTV cameras include:
Early Detection: Surveillance systems can detect potential hazards early, such as gas leaks or dust accumulation, which can prevent accidents before they escalate.
Real-time Monitoring: Continuous monitoring ensures that any changes in the environment are quickly identified and addressed.
Compliance with Regulations: Surveillance helps ensure compliance with safety regulations and standards, minimising legal risks and enhancing overall safety.
Minimising Downtime: Early detection of issues allows for prompt intervention, reducing downtime and maintaining production schedules.
Maintenance Optimization: Regular surveillance data can inform maintenance schedules, ensuring equipment is serviced before failures occur.
Resource Management: Effective monitoring helps in the optimal use of resources by identifying areas where improvements can be made, thereby enhancing productivity and reducing waste.
By understanding the specific risks associated with hazardous areas and implementing robust surveillance systems, industries can significantly enhance safety and efficiency. The integration of advanced technologies, such as sensors and real-time data analytics, further strengthens the ability to monitor and manage these environments effectively.
Traditional camera systems are not well-suited to sustain the challenging conditions of explosive environments. Areas that are prone to explosion such as chemical processing plants, the oil and gas industry, etc. need camera systems that are able to withstand the blast and pressure that could arise in the high-risk industries. Explosion-proof CCTVs, with their rugged and flameproof casing, are viable options for explosive zones. Below listed are the four reasons why your company need to invest in explosion-proof CCTVs:
Accident Prevention
The best way to deal with a disaster is to lower the risk factors to site safety and security. Hazard area cameras allow for increased safety as employee practices can be observed in real-time. A supervisor can promptly view the live feed when any dangerous activities are observed, even at night or low-light conditions.
Security
Companies that deal with hazardous materials need to be on guard against sabotage and intrusion threats at all times. By monitoring the video constantly you can easily spot any trespassers or illicit activities to avert a catastrophe, should other security measures fail to identify the threat.
Remote Accessibility
The video feed of ex-proof CCTVs can be viewed from anywhere, both live or recorded. This is extremely beneficial since it eliminates the need for 24x7 on-site monitoring and supervision. In an emergency situation, an experienced personnel member can be called in to consult and best handle the situation, since HD cameras provide real-time insights on an ongoing operation or incident.
Video Playback
In case of an accident or questionable activity, the explosion-proof CCTV captures the footage of the incident to provide a factual explanation, offer a basis for future safety measures to prevent repeated occurrence, and present evidence for legal proceedings, especially the ones involving insurance during site accidents.
When selecting an explosion-proof CCTV, it is essential to consider certain features and specifications to ensure optimal performance and safety in hazardous environments. High-resolution imaging, a wide field of view, robust durability, and compliance with safety standards are the cornerstones of an ideal explosion-proof CCTV. With these attributes, you can achieve reliable surveillance and enhance safety in your operations. Below listed are some important considerations and features for the industries looking to invest in reliable ex-proof CCTV:
High-Resolution Imaging with a Wide Field of View (FOV):
An ideal explosion-proof CCTV should offer high-resolution imaging to capture clear and detailed footage. Look for cameras with at least 1080p resolution for their superior image quality in the ex-proof category. Furthermore, a wide field of view is essential for comprehensive surveillance coverage in large industrial zones, to ensure that no blind spots are left unchecked.
Robust Design with High Ingress Protection (IP) Rating
Explosion-proof CCTVs must be constructed from durable materials such as stainless steel or aluminium to withstand harsh environments. Additionally, the CCTVs must be tested for their resistance against corrosion, high temperatures, dust, water, and physical impacts for uninterrupted industrial monitoring. A high IP rating ensures the camera is protected against dust and water ingress. Ideally, explosion-proof CCTVs should have an IP66 or IP67 rating, indicating robust protection against dust and powerful water jets or immersion.
Compliance with Safety Standards
Compliance with safety standards is crucial for explosion-proof CCTVs. ATEX certification is a must for cameras used in explosive atmospheres within the European Union. This certification indicates that the camera meets stringent safety requirements to prevent ignition in hazardous areas. Similarly, IECEx certification is an international standard ensuring that the camera is safe for use in explosive environments. Both ATEX and IECEx certifications provide assurance that the CCTV can operate safely in hazardous locations without posing a risk of explosion.
Infrared (IR) Features
The infrared (IR) feature equips the ex-proof CCTVs with night vision ability for monitoring in dark or low-light conditions. IR technology allows these cameras to capture clear and detailed images even in complete darkness, enhancing security and operational efficiency. This feature is particularly useful for worksites that are operational 24x7, including oil and gas and marine industries.
Remote Monitoring and Control
The ability to remotely monitor and control the camera is essential for maintaining safety without putting personnel at risk. Explosion-proof CCTVs should support various connectivity options such as Ethernet, Wi-Fi, or 4G/5G for seamless integration with existing surveillance systems. This allows the managers to survey the operations without putting the personnel at risk.
There are three primary types of CCTV cameras designed to suit the unique needs of every industry and its respective zones. These categories include Fixed, Pan-Tilt-Zoom (PTZ), and Zoom IR CCTV Cameras.
Fixed explosion-proof CCTVs are designed to offer constant surveillance over a specific area. These cameras are ideal for monitoring high-risk zones without the need for movement or zoom adjustments. They typically feature high durability and are constructed from materials like stainless steel to withstand harsh conditions. SharpEagle hosts a Fixed Type Dome Camera model in this category.
Technical Specifications:
Applications:
Best suited for environments where continuous, stable monitoring is required, such as in chemical plants and storage facilities. They are particularly effective in stable terrains where the CCTV’s field of view does not need frequent adjustments
PTZ CCTV cameras offer dynamic surveillance capabilities, allowing operators to pan, tilt, and zoom to cover wide areas and focus on specific points of interest. These cameras are essential for environments requiring flexible monitoring and detailed inspections. SharpEagle hosts two models in Ex-Proof PTZ CCTV cameras - PTZ Type Dome Camera and PTZ Camera with IR.
Technical Specifications:
Applications:
Ideal for large, dynamic environments such as oil rigs, mining operations, and offshore platforms. They excel in terrains where comprehensive, adjustable surveillance is crucial, allowing for the monitoring of wide areas and specific, detailed inspection points.
Zoom IR CCTV cameras combine high-resolution imaging with infrared capabilities, making them perfect for low-light and night-time surveillance. They are equipped with powerful zoom functions to capture distant details clearly, even in low-light conditions. SharpEagle hosts IP and analogue variants in Zoom IR Ex-Proof Cameras.
Technical Specifications:
Applications:
Suited for environments with fluctuating lighting conditions, such as refineries and chemical processing plants. They are particularly effective in terrains with poor visibility, ensuring detailed and clear images are captured day or night
Considering the type of hazardous operation that needs to be overseen, SharpEagle can provide different types of CCTV cameras which are reliable safety and security solutions for your operations. Explore our complete range of explosion-proof CCTVs to learn more.
Explosion-proof CCTVs are designed to withstand the challenging conditions in hazardous industries. However, experts at SharpEagle recommend additional installation and maintenance tips to extend the durability of the hazard cameras and ensure their optimum functioning.
Site Assessment
Conduct a thorough assessment of the installation site to identify hazardous zones and ensure compliance with safety standards like ATEX. This step helps determine the best CCTV model and placement for optimal coverage and safety.
Proper Mounting
Use explosion-proof enclosures and certified mounting hardware to securely install the CCTVs. Ensure the mounting location provides a clear view while protecting the camera from potential impacts or environmental hazards.
Wiring and Connections
Utilise explosion-proof conduits and junction boxes for wiring to prevent ignition risks. Ensure all electrical connections are secure and compliant with relevant safety standards, avoiding any potential sources of sparks in explosive environments.
Regular Inspections
Schedule regular inspections to check for signs of corrosion or damage to ex-proof CCTVs. Ensure all components of the device, including enclosures and wiring, are intact and compliant with safety regulations.
Cleaning the CCTV
Keep camera lenses and enclosures clean to maintain clear image quality. Use appropriate cleaning agents that do not compromise the integrity of the explosion-proof CCTV.
Professional Servicing
Engage certified professionals for periodic servicing and maintenance. They can perform thorough checks, repairs, and replacements of any faulty components, ensuring the CCTV's long-term reliability and safety compliance.
Our team at SharpEagle provides end-to-end safety consultation for your ex-proof solutions, including site inspection, recommendations, designing, manufacturing, installation, and maintenance. We constantly upgrade our designs with the latest technology to systematically target the safety gaps in the hazardous industries today. Our robust build, ATEX certifications, and on-time maintenance ensure durability of our ex-proof solutions for reliable monitoring of hazardous zones, improved situational awareness, and adherence with the prescribed safety regulations.
“I highly recommend SharpEagle's explosion-proof cameras for any high-risk industrial environment. These cameras provide durability and exceptional video quality. Their advanced features ensure that our safety and security measures are top-notch, protecting both our equipment and our team.”
“The night vision capability of SharpEagle's explosion-proof cameras is outstanding. Even in complete darkness, the clarity of the footage is impeccable. This has significantly enhanced our ability to monitor and respond to potential safety threats around the clock.”
“Implementing SharpEagle’s ex-proof cameras on our site has significantly improved our surveillance capabilities. The clarity and durability of these cameras are unmatched, making our workplace much safer and secure.”
Team SharpEagle believes in constant research and innovation, which reflects in our different types of CCTV camera solutions from the ex-proof range. Acknowledging our decade of providing unparalleled safety solutions, SharpEagle has received several awards, including, Corporate Vision’s Industrial Safety Solutions Provider 2024 - UK, UAE Business Awards’ Best Safety & Security Technology Company 2024 - Middle East, and UAE Business Awards’ Most Impactful Safety Solutions Provider 2024. As a result, today SharpEagle is recognised as a leading safety solution provider in the GCC and the UK.
Collaboration with SharpEagle Technology ensures:
To get customised safety recommendations for your industry, book a free consultation call with our experts today!
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