Safe Filling in Hazardous Areas

With the intelligent, automated industrial camera, TTS Automation aims to contribute to the safe and quality-enhancing tank loading in Ex areas. In doing so, the company manages to cover safety on three levels: protect people, equipment and the environment. For this purpose, the intelligent system camera films the entire workflow at different points: When a truck to be loaded drives onto the company premises, the vehicle license plate is scanned by the first camera at the gate or the barrier.

This matches the loading documents with the SAP order and assigns the vehicle to a loading zone. The tank train to be loaded travels into the loading zone assigned to it, and a new scan of the identification occurs. With the second license plate scan, the system is unlocked and incorrect tank loading is prevented.

The truck driver then places the grounding pliers on the vehicle. After starting the loading process, the driver returns to the safe area of the measuring station and does not have to stay in the hazardous area as they once did. Then the intelligent system camera from TTS automatically zooms in on the tank loading area. Anomalies or irregularities are identified before they become hazardous. If an anomaly is detected, the camera triggers a warning on the screen in the measurement station. The system reacts even before the system fails or stops. The loading process can be stopped automatically via the WAGO IoT Box, and an alarm is triggered. Leaks of explosive or chemical substances are prevented, thus averting fatal environmental and system damage.

Julian Loesch, Senior Project Manager Automation and Computer System Validation at Pitzek GMP Consulting, planned the project. It was important for him to create added value for potentially explosive areas, in which the loaders and unloaders no longer must be in the danger zone: “The early detection of events via the intelligent system interface between camera and system ensures greater personal safety, contributes to environmental protection and increases the quality of the systems. By solving the optical process monitoring with the TTS Automation system integrator and the connected WAGO system control, nothing stood in the way of technical implementation.”

The Palatine company left nothing to chance when developing the new camera. It developed a housing technology that is exceptionally durable and can withstand all atmospheres – the robust camera can also endure dramatically fluctuating conditions such as temperature differences. The front window of the camera is very smooth and thus prevents cracks, brittle dirt or condensation. But that's not all: The camera's small design makes it possible to use in green and brownfields. “The small size of the camera means that it takes up little space in the hazardous area and can be quickly and easily installed anywhere,” explains Julian Loesch. In addition to the small size, TTS Automation has opted for a modular design. “The combination of optical process monitoring and the WAGO IoT Box makes this industrial camera compatible with existing systems, and it can be retrofitted at any time,” says the senior project planner.

With the intelligent industrial camera, TTS Automation has brought meaningful innovation to the Ex area market. Further development of the system is already well under way. “Camera control will no longer run through a separate system; the entire process will be controllable via a uniform process control system,” says Michelle Striegel proudly. “Whether it's enlarging the picture, starting and stopping charging processes or entering parameters, everything is possible via a process control system.” Even though new areas are being explored, much is already planned. “For example, thermal monitoring of reactors is conceivable for detecting anomalies in temperature trends,” says the marketing manager. One thing is certain, though: Whether for trucks, rail vehicles or ship loading and anywhere critical or dangerous process applications occur, intelligent process monitoring and control can make an enormous contribution to human, environmental and system safety in the future.