Thermal imaging is transforming industrial safety. Whether it’s detecting overheating equipment or monitoring critical processes, thermal cameras help prevent disasters, protect workers, and keep operations running smoothly. In high-risk industries like oil and gas, chemicals, and LNG, even small issues can escalate quickly, making reliable thermal monitoring an essential safeguard.
At Industrial Video & Control (IVC), we’ve developed a Class I Division 1, 316 stainless steel IP thermal camera specifically engineered for demanding environments such as refineries, chemical plants, and LNG facilities. Manufactured in the U.S., IVC’s AFV-3543-7 features high-resolution thermal imaging and delivers reliable performance in extreme temperatures.
Here are real-world examples that illustrate how we can help companies prevent disasters, protect workers, and improve operational safety.
Remote Tank Level Monitoring: A Smarter, Safer Alternative
The Challenge:
Industrial tanks storing crude oil, chemicals, or liquefied natural gas (LNG) pose significant risks due to their explosive and toxic contents. Traditional methods like manual inspections or mechanical sensors can introduce critical safety and reliability issues:
- Manual inspections put workers in direct contact with hazardous substances, increasing risks from toxic fumes and potential explosions.
- Mechanical sensors often fail because of wear and tear from constant exposure to hazardous materials..
- Ignition risks are high, as even a tiny electrical spark from a faulty sensor can ignite vapors in a CID1 environment.
How Thermal Imaging Helps:
- Remote Detection: Our AFV-3543-7 camera measures liquid levels safely from a distance by detecting subtle temperature differences, completely removing the need for in-tank sensors.
- Explosion-Proof Construction: Certified Class I, Division 1, our camera’s rugged design eliminates ignition risks, ensuring it’s safe to use near hazardous substances.
- Reliable Performance: Capable of functioning in extreme temperatures, fog, and total darkness, it provides consistent monitoring in any environment.
Flare Monitoring: Keeping Invisible Hazards in Check
The Challenge:
When industrial flares fail, dangerous gases begin accumulating unnoticed, creating serious explosion risks. In addition, with over 80 times the warming power of CO₂, methane is a potent greenhouse gas. Inefficient flares can release harmful gases directly into the atmosphere.
Why Traditional Methods Fall Short:
- Gas sensors alone can lag in detection, missing early signs of danger.
- Visual checks are unreliable due to daylight glare or poor visibility conditions like rain or fog.
Thermal Advantage:
- Real-Time Confirmation: The AFV-3543-7 instantly confirms flare status by clearly distinguishing between hot (active flare) and cool (no flame) conditions.
- Real-Time Alerting: Combined with IVC’s video management software, operators receive instant notifications.
- Regulatory Compliance: Helps operators meet strict environmental regulations by ensuring proper methane destruction.
- Explosion-Proof Build: Rated Class I, Division 1, the AFV-3543-7 safely operates near highly combustible areas without sparking.
According to the EPA, flare failures contribute to over 200,000 tons of unnecessary emissions annually. Effective thermal monitoring could prevent a significant portion of these events.
Detecting Invisible Fires: Preventing Hydrogen Fire Catastrophes
The Challenge:
Hydrogen fires pose a unique safety risk because they burn invisibly, without smoke or visible flames. In 2023, an undetected hydrogen fire at a California facility burned for nearly half a day, resulting in over $500 million in damage.
Why Conventional Detection Falls Short:
- Smoke Detectors Miss Hydrogen Fires: Without smoke or flame, traditional detectors fail completely.
- Visual Checks are Impossible: Workers simply cannot detect a fire that’s invisible to the human eye.
Thermal Solution:
- Instant Detection: Our AFV-3543-7 thermal camera clearly identifies the intense heat signature from hydrogen combustion.
- Early Intervention: Immediate detection means fires are extinguished before spreading, dramatically reducing risks and potential damage.
- Worker Safety: Remote monitoring reduces worker exposure to hazardous areas during emergencies.
Why the AFV-3543-7 CID1 Thermal Camera Stands Apart
The AFV-3543-7 sets a new standard in industrial safety by enabling remote monitoring of dangerous chemicals, ensuring flare reliability, and detecting invisible hydrogen fires in hazardous areas.
- Explosion-Proof & Rugged: Designed to safely function in hazardous environments without sparking ignition.
- All-Conditions Reliability: Operates reliably from -40°F to 140°F, day or night, even in severe weather.
- Proactive Safety: Enables early detection, significantly reducing emergency response times and preventing costly shutdowns.
Ready to learn more about protecting your operations and your team with thermal imaging technology? Contact us to schedule a consultation or demo today.
Jarred Melendez is a senior channel sales director at Industrial Video and Control has been with the company since 2015. To get in touch with Jarred directly, email him at jmelendez@ivcco.com.