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Process plants, watched for leaks, fires and emissions.

Chemical and process plants handle substances that can leak, ignite or reach the neighbours. Fixed gas detection, thermal cameras, stack emission monitors and site weather, joined in one record, let operators find leaks sooner, prove permit compliance and tell emergency services where a release is heading.

Industry

Industry

Measurements

5

Sources cited

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1. Industry · Chemical and process plants

   Hazards inside the fence, neighbours outside

   Chemical and process plants handle substances that can leak, ignite or drift toward homes and schools. The law asks them to prevent major accidents, limit consequences and keep emissions within their permits. Gas, fire, emissions and weather watched together make every one of those duties easier to meet.

2. What is measured

   Gas, heat, stacks and wind

   Fixed detectors measure flammable and toxic gases at units, tank farms and fence lines. Thermal cameras watch units and storage for hot spots, automated systems measure stack emissions, and a weather station measures the wind and stability that decide where a release goes.

   Instruments

   Gas detectors · Thermal cameras · Stack emission monitors · Weather station

3. The base node

   Where is it heading?

   The node joins gas readings with wind to estimate where a release is heading, confirms alarms with thermal images, computes emission averages against permit limits as they accumulate and keeps a signed record that the regulator can inspect. Every value is signed at the node before it leaves.

4. Radio and links

   Fibre, behind a gateway

   Plants have fibre, and monitoring rides it to the control room and the environment team through a security gateway that keeps it apart from the control system. A private cellular network reaches temporary detectors during shutdowns. When one path fails, the other carries the data.

   Links

   Fibre · Private LTE

5. How it works

   From a leak to a safe muster

   A flange leaks in a tank farm at night. Two detectors alarm, the thermal camera shows no fire, and the node estimates the plume heading toward the east fence on a light wind. Operators isolate the line, the east muster point is avoided, and emergency services are told the direction.

6. From order to operation · Order

   Scope with the safety report

   The scope reads the site’s safety report, emissions permit, existing detection and stack monitors, emergency plans and the control system architecture. Nexus Observatory Inc. returns the monitoring design, joins to existing systems, security design and a price per site and per year.

   Plan a deployment

7. From order to operation · Survey

   Survey units and fence lines

   Crews survey units, tank farms, stacks and fence lines with the site’s safety and environment engineers: detector positions for each hazard, camera views, weather station siting and network paths. Hazardous area classifications set what equipment may go where. Findings shape the kit for each site before anything is built.

8. From order to operation · Permits

   Permits to work

   All work follows the site’s permits to work and hot work rules, equipment in hazardous areas is certified for its zone, and connecting monitoring to the network goes through the site’s change control. Every permit is kept with the site record.

9. From order to operation · Build

   Build and certify

   Detectors, cameras and gateways are configured, certified equipment is checked against its zone, nodes are hardened and enrolled with their identities, and the whole system is tested with simulated alarms before it ships. Nothing ships until the whole kit has passed its tests together.

   Open the Station Builder

10. From order to operation · Install

    Install during planned work

    Crews install detectors, cameras and the weather station during planned work, connect gateways and the node behind the security gateway, and photograph every point. Existing detectors and stack monitors are joined through their interfaces. Crews follow the site safety plan throughout the work.

11. From order to operation · Commission

    Commission with gas tests

    Each node proves its identity. Every detector is bump-tested with calibration gas, cameras are checked with a heat source, stack monitor data are compared with the latest quality assurance results, and alarm routes are tested. Acceptance is recorded with the owner before handover.

12. From order to operation · Operate

    One record for safety and permits

    Operators see gas, fire, emissions and weather together. Leaks are found and fixed sooner, emission averages are tracked against limits in real time, and in an incident emergency services receive where the release is heading. Every alert and action is kept on the record.

13. From order to operation · Maintain

    Test, calibrate, report

    Detectors are calibrated and bump-tested on schedule, stack monitors follow their quality assurance cycle, cameras are cleaned and software patched in rings. Annual emissions reports and incident records come from the same signed record. Maintenance history stays with each site for its whole life.

    Book field services

14. Data products

    For control rooms, environment and regulators

    Control rooms and emergency response teams receive gas and fire alarms with location; environment managers receive emission averages against permit limits; emergency services receive release direction in incidents; regulators receive emissions and incident reports, each signed and tied to unit and time.

    See the data products

15. Evidence

    Safety report, permit and record

    Monitoring supports the major-accident hazards directive and industrial emissions permits, stack measurements follow the European quality assurance standard, gas detectors follow the international selection and maintenance standard, and the network follows the industrial security series. Every alarm and average is signed and kept.

    Drawn against

    Directive 2012/18/EU · Directive 2010/75/EU · EN 14181 · IEC 60079-29-2 · IEC 62443

16. What you get

    Mine, plant and port site monitoring

    Slope radar, tailings monitoring, dust and water, and site connectivity for operations and closure. Delivered as managed service and hardware + software, for mining, heavy industry, ports. Scale: Site portfolios. Service levels are written as numbers you can measure on your own dashboard.

    Talk to sales

17. Next step

    Plan chemical and process plants with us

    Tell us the site, the measurements and the rules it answers to. We reply with a survey proposal, a design and a scope for chemical and process plants. An engineer replies with a survey proposal and a scope, and the plan grows from one site to the network you need, at your pace.

    Plan a deploymentOpen the Station BuilderOpen the Studio

01The place and its hazards

Where it runs, and what can go wrong.

Operating contextEstablishments holding dangerous substances must prevent major accidents and limit their consequences under the major-accident hazards directive, large installations operate under industrial emissions permits with automated stack measurements quality-assured to the European standard, and flammable gas detectors are selected, installed and maintained to the international standard.

Hazards

• Leaks of flammable and toxic gases
• Fires spreading between units
• Stack emissions above permit limits
• Releases drifting toward homes and schools
• Monitoring networks that are themselves a cyber entry point

02What must be measured

What, where, how often, and under which rules.

Each measurement names where it is taken, how often, and the public standard or regulation behind it. Numbers in the sources column open the cited source below.

03The observation stack

From one base unit to a network.

The same blocks at every scale: instruments and a base node, a site with its radio, a fleet run as one, and a network federated on the open protocol.

1. 01

   Base unit

   A unit point: gas detectors, a thermal camera and a weather sensor on an industrial gateway with an edge node.

   Build a station →
2. 02

   Site

   A site: every unit, tank farm, stack and fence line on one node behind a security gateway, with fibre backhaul.

   Plan a site →
3. 03

   Fleet

   Every site of an operator on one safety and environment view.

   Managed offers →
4. 04

   Network

   Operators share emissions and incident records with regulators and emergency services through agreed formats.

   The open protocol →

• 01Gas detector (industrial)
• 02Thermal camera
• 03Compact weather station
• 04OT gateway (OPC UA, Modbus)
• 05Edge node (Wedge)
• 06Zero-trust gateway
• 07Fibre terminal

Radio and links

Fibre

Plants have fibre; monitoring rides it to the control room and the environment team.

Radio and links

Private LTE

A private cellular network reaches temporary detectors during shutdowns and in units without cabling.

Edge computeThe node joins gas readings with wind to estimate where a release is heading, confirms alarms with thermal images, computes emission averages against permit limits and keeps a signed record for the regulator.

PowerMonitoring runs from the plant’s uninterruptible supply, so it keeps reporting during the power loss that may accompany an incident.

04How it works

From the instrument to the product.

One observation’s path, tier by tier, with the interface on every link and a bill of materials below; then how the one node grows to a site, a fleet and federated networks.

05From order to operation

Every step, from the first call to a running site.

The same crew and the same record carry the work from scope to maintenance.

1. 01 Order

   Scope with the safety report

   The scope reads the site’s safety report, emissions permit, existing detection and stack monitors, emergency plans and the control system architecture. Nexus Observatory Inc. returns the monitoring design, joins to existing systems, security design and a price per site and per year. 23

2. 02 Survey

   Survey units and fence lines

   Crews survey units, tank farms, stacks and fence lines with the site’s safety and environment engineers: detector positions for each hazard, camera views, weather station siting and network paths. Hazardous area classifications set what equipment may go where. Findings shape the kit for each site before anything is built. 1

3. 03 Permits

   Permits to work

   All work follows the site’s permits to work and hot work rules, equipment in hazardous areas is certified for its zone, and connecting monitoring to the network goes through the site’s change control. Every permit is kept with the site record. 5

4. 04 Build

   Build and certify

   Detectors, cameras and gateways are configured, certified equipment is checked against its zone, nodes are hardened and enrolled with their identities, and the whole system is tested with simulated alarms before it ships. Nothing ships until the whole kit has passed its tests together. 5

5. 05 Install

   Install during planned work

   Crews install detectors, cameras and the weather station during planned work, connect gateways and the node behind the security gateway, and photograph every point. Existing detectors and stack monitors are joined through their interfaces. Crews follow the site safety plan throughout the work.

6. 06 Commission

   Commission with gas tests

   Each node proves its identity. Every detector is bump-tested with calibration gas, cameras are checked with a heat source, stack monitor data are compared with the latest quality assurance results, and alarm routes are tested. Acceptance is recorded with the owner before handover. 14

7. 07 Operate

   One record for safety and permits

   Operators see gas, fire, emissions and weather together. Leaks are found and fixed sooner, emission averages are tracked against limits in real time, and in an incident emergency services receive where the release is heading. Every alert and action is kept on the record. 23

8. 08 Maintain

   Test, calibrate, report

   Detectors are calibrated and bump-tested on schedule, stack monitors follow their quality assurance cycle, cameras are cleaned and software patched in rings. Annual emissions reports and incident records come from the same signed record. Maintenance history stays with each site for its whole life. 4

06Data products and integration

What it delivers, to whom, and into which systems.

Data products

• Gas and fire alarms with locationControl rooms and emergency response teams
• Emission averages against permit limitsEnvironment managers
• Release direction for incidentsEmergency services
• Emissions and incident reportsRegulators

Integration

• Control systemAlarms reach the control room through the site’s own interfaces; monitoring never writes to the control system.
• Environmental reportingEmission records feed the permit reports.
• Emergency servicesRelease direction is shared through agreed channels.

Exchanged through OPC UA, Modbus, MQTT.

07Questions buyers ask

Before you scope it.

Does it replace our safety systems?

No. Safety systems stay as they are; this joins monitoring into one record.

Is the equipment certified for hazardous areas?

Yes, for the zone where it is installed.

Can it show where a release goes?

It estimates direction from gas readings and wind.

Is it secure?

The monitoring network is separated and secured to the industrial security series.

08Resources

The sources behind this page.

Public standards, regulations and guidance, cited where they apply. Each applies only where its jurisdiction or scope does.

1. 1IEC 60079-29-2: Gas detectors, selection, installation, use and maintenance of detectors for flammable gases and oxygenInternational Electrotechnical Commission
2. 2Directive 2012/18/EU on the control of major-accident hazards involving dangerous substances (Seveso III)European Union · 2012
3. 3Directive 2010/75/EU on industrial emissionsEuropean Union · 2010
4. 4EN 14181: Stationary source emissions, quality assurance of automated measuring systemsEuropean Committee for Standardization
5. 5IEC 62443: Security for industrial automation and control systemsInternational Electrotechnical Commission

09Related

Use cases and solutions.

10Industry: specialized fields

Other fields of this industry.

Bring us the site.

Plan a deployment, configure a station, model it in the Studio or talk to sales. The form names who receives your details.