Chemicals.
Offshore-grade process-safety pedigree carries directly into downstream chemical operations.
Refineries and chemical plants combine confined spaces, restricted zones and atmospheres cameras can’t see. SecureSafety pairs video detection with gas and environmental sensing for a fuller safety picture.
Why this sector is demanding.
Chemical and process facilities operate under a regime of regulatory requirements — DSEAR, COMAH, PSSR and the permit-to-work system — that recognises the potential for catastrophic consequences from process safety failures. The hazard profile is unlike most industrial environments: the risks include not just struck-by and falls, but fire, explosion, toxic atmosphere and confined-space emergency, several of which can develop rapidly and without visible warning.
Permit-to-work compliance is a structural challenge in chemical environments. Hot work permits, confined-space entry permits and electrical isolation certificates create a complex matrix of authorisations that must be checked at the point of entry, by the right person, at the right time. In practice, these checks are performed by humans under shift pressure and can be incomplete. Camera-based zone access monitoring provides an independent enforcement layer that does not depend on every check being performed correctly.
Confined-space entry represents one of the highest-consequence single-event risks in the sector. A worker who becomes incapacitated in a confined space due to atmospheric contamination may not be discovered before their condition becomes fatal. SecureSafety combines camera monitoring of confined-space entries with wearable gas detection and man-down alerting to close the gap between entry log and confirmed safety of the worker inside.
The problems AI solves here.
DSEAR-area access and hot-work zone control
ATEX-rated zones in chemical facilities carry strict access rules that are enforced through permit-to-work, but permit compliance at the physical boundary is difficult to verify continuously. SecureSafety monitors zone boundaries in real time, alerting when personnel enter without the correct authorisation or RPE and logging every entry for permit audit.
Confined-space monitoring and personnel tracking
Confined space entry requires a continuous thread between the entrant, the standby person and the control room. The platform combines camera monitoring of the entry point with wearable gas detection and man-down alerting worn by the entrant, providing automatic notification if check-ins are missed or a man-down event is detected.
RPE and specialist PPE compliance
Chemical environments require RPE, chemical-resistant gloves, face shields and specialist footwear in defined zones — requirements that are more complex and more consequential than standard PPE rules. The platform verifies each item at zone entry and monitors compliance throughout the task, alerting when RPE is removed prematurely or the wrong equipment type is worn.
SecureSafety was built in the offshore process environment — high-pressure systems, ATEX-rated areas and atmospheres that cameras cannot detect — before moving downstream. The process-safety discipline of the drill floor carries directly into chemical and refinery operations, with the same sub-0.05% error rate.
Questions from chemicals.
Can cameras operate in ATEX-rated zones within our facility?
Where intrinsically safe camera equipment is not already in place, SecureSafety works with your electrical area classification to identify monitoring positions outside the ATEX boundary that still provide effective zone access coverage. ATEX-rated cameras can be integrated where required.
How does the system handle gas hazards that cameras cannot detect?
The platform integrates wearable multi-gas monitors and fixed IoT gas sensors alongside camera detection. Gas readings are surfaced on the same control room dashboard as camera alerts, and a gas alarm can trigger the camera review automatically so the control room sees both the atmospheric and visual picture simultaneously.
Can the system support permit-to-work verification at zone entry?
Camera-based access monitoring provides the physical enforcement layer: it confirms that the person entering the zone is wearing the required PPE for that permit class. Integration with permit-to-work management systems to cross-reference permit status with entry events is available and is scoped during the Discovery phase.
Does the platform support COMAH and DSEAR compliance reporting?
The platform logs every zone entry, PPE compliance event and alert with timestamp, camera reference and personnel data. This record supports COMAH major accident prevention policy documentation, DSEAR risk assessment evidence and HSE audit. Specific reporting requirements are configured during implementation.
Does the system support COMAH major accident hazard (MAH) documentation requirements?
Yes. The continuous detection log, alert record and compliance data generated by the platform supports the monitoring evidence requirements of a COMAH safety report. The data demonstrates that behavioural controls (zone enforcement, PPE checking, permit verification) are operational and effective, which is a specific requirement of the COMAH preventive measures documentation.
How does the system handle ATEX-classified zones — does the hardware need to be ATEX-rated?
The edge compute hardware is installed outside ATEX zones in a safe area. Camera connections use the existing cable infrastructure; new camera installations in ATEX zones require ATEX-rated cameras with appropriate cable glands. The camera specifications for ATEX zones are reviewed during Discovery and the correct equipment is specified for each zone classification.
Can the platform integrate with the process safety information system to adjust zone rules based on process state?
Integration with process control systems for dynamic zone activation based on process state is available via the platform's API. A zone that is restricted when a specific process is running and open when the process is shut down can be linked to a process state signal from the DCS or SCADA system, automatically activating and deactivating the zone without manual control room intervention.
Tell us the hazard. We'll detect it.
Book a demo and we'll show SecureSafety running in a chemicals environment. Then scope your site with a fully-costed Discovery phase.