A Practical Engineering Guide to Selecting Explosion-Proof Cameras for Zone 1 & Zone 2 Industrial Environments

Introduction

Hazardous industrial locations such as petrochemical plants, refineries, gas terminals, offshore rigs, paint and coating facilities, fertilizer processing, and solvent handling environments require continuous visual monitoring for operational and safety integrity. Standard CCTV cameras cannot be used in such environments due to risk of ignition from electrical sparks, IR LED heat, and internal component failure.

Flameproof (Ex d) CCTV cameras are engineered to contain internal ignition and prevent flame propagation outward, ensuring safe monitoring in Zone 1 and Zone 2 hazardous atmospheres.

For foundational knowledge of zone definitions: A Comprehensive Guide to Zone 0, Zone 1, Zone 2 & Zone 3 – Read here

Why Standard CCTV Cameras Cannot Be Installed in Hazardous Areas

1. Sparks from electronics can ignite flammable gas or vapours
    
2. Motorized zoom modules create friction sparks
    
3. IR LEDs produce high surface temperature at glass interface
    
4. Plastic housings melt during ignition
    
5. Non-sealed devices allow gas ingress and internal detonation
    

See detailed explanation of protective concepts:

1. Difference Between Explosion-Proof & Flameproof
2. What Is Flameproof Equipment?

Zone 1 vs Zone 2 – Camera Selection Requirements

Explore certified housings: Explosion-Proof Camera Enclosure

IR Performance & Glass Reflection Control

IR performance is critical for 24/7 monitoring.
  In explosion-proof cameras, thick Ex d glass can reflect IR light back into the lens, causing glare and fogging. Flameproof Instrumentation has surmounted this challenge!

Recommendation: Split-Window or Dual-Window Design

A Split-Window camera design physically separates the lens window from the IR LED window, using two separate optical panels.
  Benefits include:

1. Zero IR bleed or reflection distortion
    
2. High clarity in fog, smoke, steam, or vapour
    
3. Superior night performance and contrast

Lens Type Selection

IR Range Selection

Why IP (PoE) Camera Is Better Than Analog in Zone 1

PoE Single-Cable Advantage

Analog cameras require:

1. Coaxial cable for video
    
2. Separate cable for power
    

Meaning:

1. Two cable entries
    
2. Two expensive Ex d cable glands
    
3. Two independent leak or spark risk points
    

IP PoE cameras use only one cable for both power and data, resulting in:

1. 50% reduction in cable glands
    
2. Fewer wall penetrations
    
3. Easier sealing and certification
    
4. Lower installation labour cost
    

For Zone 1, this advantage is significant.

Comparison of Flameproof Camera Types

Browse enclosure solutions here: Explosion-Proof Camera Enclosure

Frequently Asked Questions

Can I place a standard CCTV inside a flameproof enclosure?
  Only if enclosure is certified and cable entry follows Ex d rules.

Is PTZ allowed in Zone 1?
  Yes, if complete assembly is tested as Ex d.

Can I retrofit wiper later?
  No. Must be certified as part of the camera assembly.

Conclusion

Selecting a flameproof CCTV camera is a critical engineering decision that affects real-time visibility, emergency response speed, compliance performance, and worker safety.

Evaluate certification, optical design, IR capability, material durability, PoE wiring advantages, and installation environment before finalizing equipment.

Explore certified industrial monitoring solutions here:Flameproof Camera Enclosure & CCTV Systems