Introduction to Explosion-Proof Surveillance Cameras

As surveillance professionals working in Canada's industrial sector, you understand that installing cameras in hazardous environments requires more than standard CCTV expertise. When your clients operate in oil and gas facilities, chemical processing plants, or manufacturing environments where flammable gases, vapors, or combustible dust are present, the stakes couldn't be higher. One spark from improperly rated equipment could lead to catastrophic consequences.

In this article, we explain the basics of explosion-proof surveillance cameras, from their key features to certification requirements. This will help you better understand this type of product and offer your customers superior solutions, whether you're new to installations in hazardous environments or looking to expand your expertise.

How Do Explosion-Proof Cameras Work?

In some industrial sectors, explosive substances and gases that promote combustion are external factors difficult to control. Therefore, the mere presence of electronic devices and equipment unsuited to these environments can act as a source of combustion and cause explosions. That's why some devices, such as surveillance cameras, must comply with regulations regarding explosive atmospheres to prevent this from happening.

An essential component of commercial security camera systems, explosion-proof cameras are meticulously designed to operate in hazardous environments without risk. Unlike standard cameras, these specialized units feature robust engineering that prevents any potential ignition sources from interacting with hazardous atmospheres. For installers, understanding this type of product and the systems involved is of paramount importance - not just for proper implementation but also for ensuring compliance with Canadian Electrical Code (CEC) requirements and maintaining the safety standards your industrial clients depend on.

Design and Construction of Explosion Proof Cameras

• Stainless Steel Enclosures

The foundation of explosion-proof cameras lies in their sophisticated enclosure designs. These housings are typically constructed from marine-grade 316L stainless steel, featuring precision-engineered flame paths and robust walls, with thickness exceeding 3.5 mm, that can withstand internal explosions. If an ignition occurs inside the camera, the sealed housing contains it while simultaneously preventing the ignition of external hazardous gases or dust.

The flame paths - carefully calculated gaps in the housing joints - serve a critical purpose. They allow any explosion inside the enclosure to cool as it escapes, ensuring that by the time gases reach the external atmosphere, they are below the ignition temperature of the surrounding hazardous materials. This design principle, known as flame-proof protection, is fundamental to their safe operation.

• Protection Against Harsh Environments

Enclosures of CCTV explosion-proof cameras offer superior resistance to chemical corrosion, salt spray, and industrial pollutants. Their material's durability ensures long-term integrity in harsh environments, from offshore oil platforms to chemical processing facilities. The smooth, polished surface also prevents dust accumulation and simplifies maintenance.

• Cleaning and Defrosting Capabilities

Canadian industrial environments often experience extreme weather and temperature variations. Some advanced explosion-proof cameras incorporate integrated features like wipers, as well as heating elements that prevent condensation and frost formation on the optical window. These heaters maintain optimal operating temperatures without compromising the enclosure's explosion-proof integrity. Some models can function reliably in temperatures ranging from -40°C to +60°C, which is essential for our country's diverse climate conditions.

• Shock and Vibration Resistance

Industrial environments often subject equipment to constant vibration and potential impacts. Explosion-proof cameras feature reinforced mounting systems and internal shock absorbers to maintain stable imaging even in high-motion areas. This robust construction ensures reliable surveillance in environments with heavy machinery or frequent mechanical disturbances.

Important Certifications

Certifications are non-negotiable when it comes to explosion-proof CCTV cameras used in Canada and around the world. Each camera should meet global and national standards for safety and reliability.

• ATEX (European Union): Sets the benchmark for equipment used in explosive atmospheres, defining essential safety requirements and conformity assessment procedures.
• IECEx (International): Provides a globally recognized certification system under the IEC 60079 standard for equipment used in explosive atmospheres, facilitating international trade while maintaining safety standards.
• CSA (Canadian Standards Association):  Indicates that a product complies with rigorous Canadian safety and performance standards of the CEC (Canadian Electrical Code).
• UL (Underwriters Laboratories): Confirms that products have been thoroughly tested for fire and explosion safety based on standards described in the National Electrical Code (NEC).

Other Certifications & Ratings

• C5-M: Explosion-proof cameras tested to ISO 12944-2 are C5-M certified, indicating that product materials meet the strict anti-corrosion standards required for harsh environments.
• NEMA 4X (National Electrical Manufacturers Association): Specifies that equipment enclosures are built to resist corrosion and withstand harsh environmental conditions.
• IP Rating (Ingress Protection): Defines the level of protection against dust and water ingress. For example, an IP66 rating means the camera is dust-tight and protected against powerful water jets, while an IP67 or IP68 rating offers even higher water resistance with submersion protection.
• IK Rating (Impact Protection): Measures the camera's resistance to mechanical impact, as defined by IEC 62262. IK10 is the highest level of impact resistance and is often associated with explosion-proof cameras, indicating superior resistance to vandalism and harsh industrial environments.

Classifications of Hazardous Environments

Explosion-proof cameras are not universal, i.e., they are not suitable for all types of hazardous environments. The Canadian Electrical Code has adopted a three-class system of hazardous environments. Each camera is identified according to the environment for which it is suitable. This information is available from manufacturers to facilitate selection. Here are the three classes, each with numerous divisions and subdivisions.

• Class I – Gas and Vapor Environments: Areas where flammable gases or vapors are present in concentrations sufficient to cause an explosion.
• Class II – Dust Environments: Locations where combustible dusts are present in the air in sufficient quantities to pose an explosion risk. These areas require equipment that prevents dust ingress and minimizes the potential for ignition.
• Class III – Fibers and Flyings Environments: Areas where ignitable fibers or flyings are present, though typically not in amounts that can form explosive mixtures under normal conditions.

Types of Explosion-Proof Cameras

Explosion-proof CCTV cameras are all designed for hazardous environments. However, each design offers unique advantages and specialized features to meet diverse surveillance needs. Here are some common design types.

Explosion-Proof Bullet Cameras

• Characterized by their cylindrical, streamlined form factor
• Ideal for long-range, directional monitoring of specific areas
• Excellent for perimeter surveillance and monitoring pipelines
• Typically feature built-in sun shields to prevent glare and overheating
• Cost-effective solution for fixed-direction monitoring - optimal for mounting on walls or poles where a specific area or corridor needs constant monitoring.

Discover our explosion-proof bullet caméras.

Explosion-Proof Dome Cameras

• Features a hemispheric housing that provides discrete surveillance
• Superior vandal resistance due to their robust dome construction
• Offers wide viewing angles ideal for area monitoring
• More challenging to determine camera direction, which enhances security
• Perfect for indoor installations in processing areas

Explosion-Proof PTZ Cameras

• Provides 360-degree coverage through remote-controlled movement
• Zoom capabilities allow detailed inspection of distant objects
• Programmable preset positions for automated patrol functions
• Reduces the total number of cameras needed for comprehensive coverage
• Ideal for large areas requiring dynamic surveillance

Discover our explosion-proof PTZ cameras.

Main Benefits of Using Explosion-Proof Cameras

As you'd expect by now, using surveillance cameras specifically designed for hazardous environments has many benefits for your clients. Here are just a few.

• Enhanced safety: These cameras prevent internal sparks or heat from igniting flammable materials, which reduces the chance of explosions in volatile environments.
• Continuous remote monitoring in harsh conditions: Explosion-proof cameras allow industries to monitor hazardous areas closely and continuously without putting workers' lives at risk.
• Compliance with standards and regulations: Explosion-proof security cameras meet stringent safety standards, which ensure compliance with industry regulations.
• Durability: Made from tough and tested materials, these cameras can withstand harsh conditions, temperature changes, and impacts.
• Advanced analytics: Modern explosion-proof cameras often include built-in video analytics, which helps detect unusual activity, smoke, gas leaks, and unauthorized entries.
• Cost-effective: Although more expensive initially, explosion-proof surveillance cameras are cost-effective in the long term, thanks to their longer service life and low maintenance requirements.

Industries Requiring Explosion-Proof Cameras

Many Canadian industries benefit from installing explosion-proof CCTV cameras outside and inside their facilities. Here are just a few of them.

• Oil and Gas: Monitoring drilling sites, refineries, and pipelines to detect leaks or unauthorized access.
• Chemical Processing: Ensuring safety in facilities handling volatile substances.
• Mining: Surveillance in areas with combustible dust.
• Manufacturing: Overseeing processes in environments where flammable materials are present.
• Food Processing: Ensuring hygiene and safety in potentially explosive atmospheres.

Choosing the Right Explosion-Proof Camera

As an installer, working closely with your customers helps you make sure you understand their needs and the environments they wish to monitor. This is even more important in hazardous environments. Here are some key factors to keep in mind when selecting reliable explosion-proof cameras for your next project.

1. Assessment of the Installation Environment

 With your client's help, evaluate the site's specific hazards—be they extreme temperatures, flammable gases, or dust. Always verify that the camera's certification matches both the hazardous location classification and the site's specific environmental conditions. This includes checking zone classifications, gas groups, and temperature codes against the camera's ratings.

2. Considering the Right Coverage Option

Determine whether a fixed camera or a PTZ (Pan-Tilt-Zoom) model best meets your client's surveillance needs. This decision will affect both the camera’s placement and its ability to cover critical areas.

3. Reviewing Technical Specifications

Focus on features such as high-resolution imaging, the appropriate lens type, and options like thermal imaging. These technical details ensure the camera can deliver clear, actionable footage even in challenging conditions.

4. Confirm Certification Compliance

Ensure the camera meets IECEx certifications so you can confidently install equipment that is proven safe and compliant in explosive atmospheres.

5. Consider Additional Functionalities

Look into cameras with optical zoom, universal mounting options, and advanced analytics. These features can enhance your installation’s flexibility and overall monitoring capabilities.

Case Study - Oil Depots

Let's say your client owns an oil depot where comprehensive surveillance is essential for safety and operational efficiency. Based on a thorough assessment of your client's facility, you could consider the following strategic deployment.

1. Loading and Unloading Zones: These high-activity areas involve the transfer of flammable materials, which presents significant risks. For dynamic monitoring, you could recommend installing explosion-proof PTZ cameras to allow for the adjustment of the camera view remotely.
2. Storage Tank Areas: Storage tanks contain large volumes of flammable substances. Fixed explosion-proof bullet cameras can ensure continuous and reliable monitoring of these areas.
3. Control and Monitoring Rooms: These areas serve as the depot's operational hubs, housing sensitive equipment and personnel. Installing explosion-proof dome cameras here provides comprehensive coverage with a discreet profile.

Conclusion

Explosion-proof surveillance cameras are essential components for monitoring industrial sites where the risk of ignition is omnipresent. Their rugged design and impact resistance ensure safe, reliable performance even under the most challenging conditions. 

If you're an installer wishing to specialize in the installation of video surveillance systems in hazardous environments, you'll first need to familiarize yourself with the various types of environments and their specific requirements and regulations. This will help you choose not only the proper type(s) of camera(s) but also the other components of your system that are subject to similar regulations.

Noctoptics offers installers a wide range of products, including explosion-proof cameras, to build reliable, high-performance, and safe commercial security camera systems for their clients. Contact us to learn more about our explosion-proof cameras and other innovative products.