Efficient CCTV monitoring in control rooms of the future

SUMMARY

There is no doubt that future control rooms will have access to extensive amount of cameras, visually connecting operators to the process. To keep operators alert and at the same time well informed about the process is in sharp contrast, a problem that needs attention. Constant camera feeds in multiple displays easily create confusion and an overload of irrelevant information that constantly needs attention and analysis.

With a good strategy for integration and prioritization of cameras within the process control system, utilizing built-in camera abilities for analysis, the operator can receive relevant and timely camera feed, upon request or pushed for view by the system.

INCREASE SAFETY AND PRODUCTIVITY WITH EXTENDED VISIBILITY

Humans have five senses; smell, taste, touch, sight and hearing. We use as many as possible in each situation to interpret, understand and take action. When we cannot be in the process of a plant and hear a fault, smell something burnt, see smoke from fire, or people in danger, we need increased support from the automation system, to interpret, understand and take the correct action.

Sight is one of the strongest senses and one that we rely on the most. In a control room the view of the process can be empowered with images from cameras. They can give provide information that are crucial to resolve or confirm actions taken or considered. If there´s an alarm, the operators immediate access to the right view of the situation can make a large impact on process safety and productivity.

Since the 70´s cameras have become very common in the process industry. As part of the digital evolution, technology has become affordable and reliable for decision making. The common solution when a camera feed is needed, is to add a screen in the control room. Leaving operators with little, or no control of the camera. More stressful than camera control; In a critical situation they need to move attention from the process control, make sure to find the right screen and object for visual guidance before they take action in the process control system.

The evolution will continue to add camera feeds to operators. They will have better quality and control, but it´s not wise to constantly increase the number of screens to monitor. Consolidation of control rooms is another industry trend pushing the need for smart camera feed. Creating control centers further away from the process reduces sensibility for the process, which often is compensated with large video walls to visualize what´s in control. It´s neither an ergonomic or collaborative environment for operators to perform in.

USE INTELLIGENT CAMERA FEED

Operators should be in control of cameras and get automatically notification when attention is needed. Ensuring that correct camera is viewed, when needed, reduces the response time dramatically, especially in critical situations. Connect the cameras to the process control system by object or section with continuous recording, or with automatically recording upon an event or an alarm. The recording can be used as documentation for efficient error analysis or for educational purposes to avoid reoccurring mistakes.

Modern cameras provide more than an image to view. Intelligent cameras has built in image analysis and are becoming contact less sensors which can measure or monitor thermal development, motion, object size, speed, pattern deviation and much more. Combine a couple of variables and use the powerful analysis to replace or reinforce fence with video that can notify operators or shut down the process when an object moves within a particular zone. Analysis can also be made over time to measure changes over time or to a set threshold. Conveyor belts can be monitored with a thermal camera. If friction occurs a heat signature will be visual and if not noticed in time subject for a costly repair or fire hazard.

A standard infrared camera measures temperature differences of 0.05 degrees and can transfer the image, temperature data, heat spot as an alarm or warning in the process control system.

IMAGINE EFFICIENT VISUALIZATION

When avoiding constant camera feed, in multiple displays, the brain can handle other information more efficient. Studies show that after 15 minutes of exposure to multi screen with surveillance cameras, operators misses about 45% of the events that they are supposed to react upon. Categorize your cameras and display them properly to eliminate confusion and an overload of irrelevant information.

Different Cameras should have relevant priority. A steam-dome camera monitoring the pressure must always be visible for the operator, while a conveyor belt is only necessary momentarily. Let´s categorize cameras from classification, priority and then choose method of presentation:

1. Mission critical cameras; Should always be in the operators field of view, in fixed position embedded in the workplace. Example; boiler domes, burners, flares, feeders etc.
2. Process related cameras; Normally hidden and recording, letting the operator choose to view the camera when needed or review recordings after an event. This category could also be analytical cameras, sending a signal to the operator that something needs their attention. With a PTZ camera it´s possible to cover multiple objects or sections with predefined settings, ensuring fast access for the operator and a security that the process object in the video feed is correct. Example; Tanks, storage, conveyors, pumps, motors, grinders etc.
3. Situational awareness cameras; Show proximity areas not affecting the process. These cameras can be shown with live feed on separate monitors or video walls, or combined as process objects if control of the camera or related object should be handled by the operator. Example; Gates, parking, entrances, storage areas etc
4. Mobile cameras; When the operator moves away from production and into the control room, there will always be dead spots not visible with the fixed mounted cameras. With semi-mobile and fully mobile cameras even these spots can be covered temporarily. A semi-mobile camera, i.e. a temporary camera on a stand for a limited time period, can be used to resolve a reoccurring issue or monitoring personal safety during maintenance. A fully mobile camera, i.e. a service engineer can use his smart phone camera to allow the operator, or other expertise, to be involved and cooperate to quickly solve upcoming issues.

CONCLUSION

Striving to provide a better overview with CCTV support for the operators, can result in massive amount of screens in the control room. It´s important to use many different cameras to cover large areas but without overwhelming the operator. A good strategy for camera information, both concerning what, when and how it will be presented as well as utilizing new technology is important. Reducing constant camera streams to the most critical ones, also increase focus from the operator. Make a proper CCTV and control system integration to benefit the most from the recent technology development around analytical cameras.