Installing explosion-proof cameras is a vital step toward enhancing safety in hazardous industrial environments. From oil refineries to chemical plants and fuel storage depots, these specially designed cameras allow businesses to monitor high-risk zones without creating ignition sources. However, despite the growing awareness around explosion-proof equipment, many installations still fall short due to common and avoidable mistakes.
Here are the five most frequent errors made during explosion-proof camera installations — and how to avoid them for full safety and compliance.
1. Using Non-Certified Equipment in ATEX Zones
The Mistake:
Some companies mistakenly install regular industrial or weatherproof cameras in ATEX-certified zones, assuming rugged construction is enough.
Why It's a Problem:
Only ATEX- or IECEx-certified equipment is safe for use in potentially explosive atmospheres. Non-certified devices can emit heat, sparks, or arcs—turning them into potential ignition sources.
The Fix:
Always ensure the camera and all associated components (cables, connectors, housings) carry the required ATEX, IECEx, or equivalent certifications. Double-check the zone classification (Zone 1, Zone 2, Zone 21, Zone 22) before selection.
2. Improper Cable and Gland Sealing
The Mistake:
Installing explosion-proof cameras using standard cable glands or open conduits can allow flammable gases or dust to enter.
Why It's a Problem:
A camera is only as safe as its weakest connection. Improper seals around cabling can compromise the explosion-proof integrity of the unit.
The Fix:
Use explosion-proof-rated cable glands and junction boxes. Install with sealed conduit systems and regularly inspect for wear or breaches. All entry points must be completely gas- and dust-tight.
3. Poor Mounting Location
The Mistake:
Installing the camera in a location where it's exposed to vibration, corrosive elements, or extreme heat without adequate protection.
Why It's a Problem:
Over time, poor positioning leads to damage, misalignment, or visibility obstruction. This reduces effectiveness and can create maintenance or safety issues.
The Fix:
Select a strategic mounting point that provides clear visibility of the target area, avoids extreme conditions, and allows for maintenance access. Use vibration-resistant brackets and weatherproof mounting poles where necessary.
4. Lack of Integration with Safety Systems
The Mistake:
Treating explosion-proof cameras as standalone systems, without linking them to alarms, control rooms, or emergency protocols.
Why It's a Problem:
Cameras offer real-time insights, but without integration, they can't support proactive safety or automated alerts when something goes wrong.
The Fix:
Connect explosion-proof cameras to SCADA systems, fire/gas detection alarms, and central monitoring hubs. Enable automated event recording, motion detection, or heat mapping where possible to get maximum safety value.
5. Neglecting Maintenance and Inspection Protocols
The Mistake:
Once installed, many facilities forget to inspect or maintain explosion-proof cameras, assuming they're maintenance-free.
Why It's a Problem:
Even ATEX-certified units require regular inspection to ensure seals remain intact, housings aren't compromised, and lenses stay clear of debris or corrosion.
The Fix:
Create a maintenance schedule that includes visual inspection, system testing, cleaning, and certification checks. Use cameras with remote diagnostics when possible to reduce human exposure during maintenance.
Final Thoughts
Explosion-proof cameras play a critical role in safety, but their effectiveness depends heavily on proper installation and maintenance. Avoiding the five common mistakes above ensures your investment doesn't just meet regulatory standards, but actively prevents accidents, improves visibility, and protects both workers and infrastructure.
For companies in oil & gas, chemical manufacturing, food processing, and hazardous warehousing, working with a specialist provider like SharpEagle Technology ensures every component—from hardware selection to installation—is ATEX-compliant and field-proven.
Safety starts with smart installation. Don't let simple errors turn into costly oversights.
