AI for Petrochemical — PPE, Corrosion, Flare & Leak Detection

Petrochemical Challenges

Five fronts where worker, process and asset risks slip past on a live petrochemical plant — fugitive emissions, H2S exposure, hot-work near live flare, confined-space entry, perimeter breach at remote plots — and why CCTV watched by people alone cannot keep up across a 24/7 site.

A · PPE & gas safety

FR suit

A worker without a flame-resistant coverall standing near hot process equipment

Flame-resistant suit missing

H2S

A worker without a personal H2S monitor entering a sour-service process area

H2S monitor not worn

Respirator A worker without a full-face respirator near a chemical loading arm

Full-face respirator absent

B · Process & asset threats

Leak

Flange & gasket leak

Flare

Off-spec flare combustion

Smoke

Uncontrolled smoke plume

C · Zone & space hazards

Confined space A worker opening a manhole on top of a process vessel without a permit posted

Unpermitted confined-space entry

Restricted A worker crossing a barrier into a restricted hot-process area

Restricted-zone breach

Open manhole An open vessel manhole left uncovered with no attendant watching

Unattended open manhole

D · Perimeter & security

Perimeter

Remote-plot perimeter breach

Lone worker A single worker isolated inside a flare radiation zone with no attendant

Lone worker in flare zone

Vehicle

Vehicle in live piperack

E · Inspection, compliance & monitoring gap

Corrosion

Corrosion under insulation

Reporting

Manual inspection rounds

Night

Tank-farm night blind spots

Solutions for Petrochemical

Every gap above has an answer below: how the AI sees flare, corrosion and PPE, what it detects across the plant, how alerts become action, the analytics you get, and a deployment that fits your existing cameras, drones and Saudi data rules.

A · How the AI sees

Detection

Workers on a process unit each outlined by a translucent segmentation mask following their silhouette

Instance segmentation, not boxes

Pose

Pose & action recognition

PPE

A worker with the FR suit and H2S monitor highlighted by separate segmentation masks

Per-worker FR & H2S check

B · What it detects

A worker with FR suit and respirator highlighted by AI segmentation masks, process-worker detection

Process-Worker PPE

Flare flame and smoke plume highlighted by an AI segmentation mask, process-condition detection

Flare, Flame & Smoke

A corroded pipe joint and visible drip highlighted by an AI mask, integrity and leak detection

Corrosion & Leak Detection

C · From alert to action

Real-time

A shift supervisor receiving a process-safety alert on a smartphone in the control room

Tiered, real-time alerts

Verified

Operators in a modern control room verifying process and PPE alerts on a video wall

Operator-verified

Intervene

A public-address speaker on a pole at a plant for live talk-down warnings

On-plant intervention

D · See it & prove it

Dashboard

Live operations dashboard

Analytics

A screen showing a unit map with colour-coded corrosion and leak hot zones

Corrosion & Leak Trends

Reporting

A tablet showing KPI gauges and charts for a process-safety and integrity report

ISO 45001 & Integrity reporting

E · Fits your plant

Integration An existing CCTV camera on a tank farm with a small edge-AI box beside it

Works on existing CCTV & thermal

Edge

Edge, hybrid or cloud

Residency

A secure on-premises server rack keeping data inside the Kingdom at a refinery

KSA data residency

AI Technology

Built for petrochemical plants: data-driven video analytics, computer vision that watches live feeds and understands what it sees — flare colour, corrosion rust-bleed, FR suit and H2S monitor on a worker, a vapor cloud, a vehicle at a piperack. The same AI runs across any input you bring: your existing CCTV, thermal cameras, drones, autonomous robot dogs and smart helmets, all connected into one platform and one app, and processed on-site inside the Kingdom. We keep the engine proprietary; what follows is how it works for your plant.

Any input, one platform

AI Video Analytics

The brain behind every source: computer vision analyses each frame in real time and flags flare drift, corrosion rust-bleed, missing FR suits and unpermitted vessel entries the moment they appear.

Existing fixed, PTZ and thermal CCTV cameras on a tank farm and process unit

Your Existing CCTV & Thermal

Runs on the cameras you already have, fixed, PTZ, explosion-proof and thermal, with no rip-and-replace in most units.

A survey drone flying over a refinery checking flare and tank roofs

Drones & Aerial

Drones carry the same AI across flare stacks, tank roofs, pipe racks and remote plots, from above, including thermal sweeps for hot equipment.

An autonomous quadruped robot dog patrolling a process unit and flare area

Autonomous Robot Dog

A four-legged robot walks pipe racks, vessel farms and flare radiation zones on its own, taking the AI where fixed cameras cannot reach.

Smart Safety Helmet

Worker-worn helmets with an on-board camera add a first-person view and lone-worker protection in flare zones, vessel interiors and remote plots.

An on-site edge AI server appliance with status lights in a control room

On-Plant Edge AI

All analysis runs on a secure unit at your plant, so footage and process data stay inside the Kingdom, in line with PDPL and plant cyber rules.

A unified plant app on a phone showing every connected camera, thermal feed and drone

One Unified App, every camera & device

Every fixed, PTZ, thermal, drone, robot and helmet feed a single platform and one app, one place to watch flare, vessels, piperacks, tank farms and remote plots, verify alerts and act. Add a new device and it simply appears in the same view.

Integration with Your Systems

We adapt to your plant, you don't rebuild for us. The AI runs on the cameras, thermal sensors and monitoring systems you already have at the process unit, tank farm and perimeter: a small on-site unit pulls the video, your cameras and VMS keep running untouched, and in most plants nothing is replaced.

Works with what you already have on site

A mix of existing fixed and PTZ CCTV cameras on an industrial building

No rip-and-replace

In 70–80% of sites your existing cameras are reused as they are. We connect over standard RTSP / ONVIF, compatible with virtually any IP camera.

A small edge-AI appliance plugged in beside an existing network switch

Plugs in alongside

A small on-site sidecar unit pulls the camera streams. Your cameras and current VMS keep running exactly as they do today, no disruption.

A technician surveying a CCTV camera with a tablet before deployment

Survey before spend

A pre-deployment camera survey (included) checks each camera's resolution, angle and lighting, so you know exactly what qualifies before buying anything.

Connects to your monitoring systems

Milestone XProtect Genetec Security Center Hikvision / HikCentral Dahua DSS Axis Camera Station

We integrate with the leading VMS platforms used in the Kingdom, pushing events and alerts straight into the system your control room already uses. Not on the list? The edge unit also runs fully standalone over direct RTSP, no VMS required.

Camera requirements

Parameter	Minimum	Recommended
Resolution	2 MP (1080p)	4 MP or higher
Frame rate	10 fps	15–25 fps
Low light	IR / night capable	True WDR
Detail on target	head ≥ 20 px	≥ 40 px for PPE
Compression	H.264	H.265 (½ the bandwidth)

Network & footprint

Light on bandwidth, a few Mbps per 1080p or thermal stream; H.265 halves it.
Only alerts leave the edge, short event clips and metadata, never full 24/7 process video.
Processed on-site, a plant VPN or private APN covers remote plots and tank farms; data stays in the Kingdom.
No new software for your operations team, the dashboard is browser-based; nothing to install on the DCS network.

Use Cases

The same AI runs across petrochemical plants, refineries and downstream terminals — flagging PPE and H2S gaps, corrosion and leaks, flare & smoke, confined-space entries, spills and perimeter intrusion on your live cameras and drones with a pixel-precise segmentation mask, never a crude box.

PPE & gas safety

AI segmentation mask on a worker wearing a flame-resistant coverall near a process unit — Flame-Resistant Coverall

AI segmentation mask on a worker wearing a hard hat with face shield at a chemical plant — Hard Hat + Face Shield

AI segmentation mask highlighting chemical-resistant gloves on a worker handling solvents — Chemical-Resistant Gloves

AI segmentation mask on a full-face gas respirator worn by a worker at a loading arm — Full-Face Respirator

AI segmentation mask on a personal H2S monitor clipped to a worker's chest harness — H2S Personal Monitor

AI segmentation mask on a hi-vis flame-resistant coverall with reflective stripes — Hi-Vis FR Coverall

Corrosion & integrity

AI segmentation mask on external corrosion and rust staining on an overhead pipe — Pipe External Corrosion

AI segmentation mask on shell corrosion and pitting on a storage tank wall — Tank Shell Corrosion

AI segmentation mask on flange face corrosion and bolt thread rust — Flange Face Corrosion

AI segmentation mask on coating disbondment and blistering on a process pipe — Coating Disbondment

AI segmentation mask on rust bleeding through pipe insulation cladding — Insulation Rust Bleed

AI segmentation mask on a visible hydrocarbon drip and puddle under a flanged joint — Visible Leak Drip

Flare, flame & smoke

AI segmentation mask on a tall flare stack flame at a refinery — Flare Stack Flame

AI segmentation mask on a dark smoke plume rising from a process unit — Dark Smoke Plume

AI segmentation mask on a steam vent from a pressure safety valve — PSV Steam Vent

AI segmentation mask on a low-lying vapor cloud drifting from a process leak — Vapor Cloud

AI segmentation mask on an off-spec black smoke and lazy flame from a flare tip — Off-Spec Flame

AI segmentation mask on a flare tip with no visible pilot flame — Pilot Flame Out

Confined-space entry

AI segmentation mask on an open manhole on top of a process vessel — Open Vessel Manhole

AI segmentation mask on a worker entering a vessel through a side opening — Worker Entering Vessel

AI segmentation mask on a standby attendant watching the confined-space opening — Standby Attendant

AI segmentation mask on a gas tester sampling atmosphere before vessel entry — Pre-Entry Gas Test

AI segmentation mask on a tripod and winch set up over a vessel manhole — Tripod & Winch

AI segmentation mask on a retrieval lifeline attached to an entrant inside a vessel — Retrieval Lifeline

Spill & environmental

AI segmentation mask on a hydrocarbon pool spill spreading on plant concrete — Hydrocarbon Pool Spill

AI segmentation mask on a tank bund overflowing with process liquid — Bund Overflow

AI segmentation mask on a chemical drip tray filling up at a pump skid — Drip Tray Filling

AI segmentation mask on a foam blanket released from a fire monitor — Foam Blanket

AI segmentation mask on an oil sheen spreading on a process-water pond — Oil-on-Water Sheen

AI segmentation mask on an uncontrolled hydrocarbon release from a flange — Uncontrolled Release

Perimeter, thermal & restricted

AI segmentation mask on a person breaching the perimeter fence of a remote plant plot — Perimeter Fence Breach

AI segmentation mask on a person walking between live piperacks — Person in Piperack

AI segmentation mask on a vehicle entering a process unit without escort — Vehicle in Process Unit

AI segmentation mask on a thermal hotspot on a pump bearing in a thermal overlay — Equipment Hotspot

AI segmentation mask on a thermal anomaly at a substation transformer — Substation Heat Anomaly

AI segmentation mask on a person crossing into a restricted zone with no permit — Restricted-Zone Entry

Not limited to these These are our standard library, we also train custom detection classes for the hazards, equipment and processes specific to your site.

How We Do It

01

Existing CCTV cameras on a pole overlooking a process unit

Ingest

We pull live video from your existing CCTV and thermal over RTSP and ONVIF, no new cameras in most units

02

A compact edge GPU appliance processing video on a refinery site

Edge AI

Inference runs on a small on-plant GPU appliance, so video and process data stay inside the Kingdom

03

A monitor showing workers and process equipment segmented by AI masks on a live plant feed

Detect

A three-stage cascade segments people, FR & H2S PPE, flare, corrosion and confined-space entries on every frame

04

A control-room screen showing an AI reasoning check on a flagged plant event

Validate

A vision-language model reasons over plant context to confirm or suppress each alert, killing false alarms on flare and rust

05

Alert

Tiered alerts reach the control room, shift supervisor phones and WhatsApp within seconds

06

Confirm

For non-critical events an operator confirms with a clip and scene description before any field team is dispatched

07

Dashboard

Every camera, unit, zone and live alert appears on one dashboard, on a control-room screen or a phone

08

An automatically generated process-safety and integrity report with charts and an audit trail

Report & audit

Shift, daily and integrity reports, KPIs and an immutable audit trail are generated automatically for ISO 45001 and PDPL

The Monitoring Platform

One console for the petrochemical operations and HSE team. Overview, events, cameras, units, zones, integrity, reports and live AI inspection, all in a single app. Every alert traces back to the camera that raised it, the process unit it sits in, the moment it happened, and the confidence the AI gave it. Live today at viewkeepersa.com/VisualDefectDemo/hse.

HSE app overview: process-safety score, flare and corrosion breakdown, hottest units and 3D plant map

HSE Monitoring · Overview

Live AI detection: FR & H2S PPE, flare drift, vapor cloud, corrosion drip, confined-space entry, perimeter breach
your PTZ, fixed, thermal and explosion-proof cameras on one live plant wall
Per-camera health, link status and unit / zone routing
Operator verify, dispatch, and false-alarm workflow for process and integrity events
Owner-ready daily, monthly, and incident-evidence reports for plant and HSE
Runs in the on-plant control room, no foreign cloud, PDPL-aligned

Platform Walkthrough — Page by Page

07 · A

Seven pages, live in our HSE app today. The images below come straight from the running build. These are the same screens your plant operations and HSE teams will open on day one.

viewkeepersa.com/VisualDefectDemo/hse

01 · Overview

The whole plant, one screen

The plant HSE landing page. A live process-safety score, FR & H2S compliance, open integrity findings and critical incidents run across the top, next to cameras online and mean response time. Below sits a 24-hour hazard breakdown, the hottest flare and corrosion zones ranked, and a 3D plant map of every unit and tank farm.

Plant Safety ScoreFlare & CorrosionHottest Units3D Plant Map

viewkeepersa.com/VisualDefectDemo/hse/events

02 · Events

Every process event, triaged

The working queue of process and integrity events. Each one tagged by type, with the camera, unit and zone that caught it, a severity, a confidence score and a status. An officer verifies, assigns or closes, and the response clock keeps the team honest.

36 Event TypesUnit RoutingEvidence SnapshotResponse Clock

viewkeepersa.com/VisualDefectDemo/hse/cameras

03 · Cameras

The plant camera fleet, at a glance

Every connected fixed, PTZ, thermal and explosion-proof camera by unit and zone, with live thumbnails, online status and the flare, corrosion or PPE events it raised. A technician sees what needs attention before the morning round.

Live ThumbnailsPer-UnitOnline StatusLast Event

viewkeepersa.com/VisualDefectDemo/hse/workers

04 · Workers

Plant crews, FR & H2S watched

Workforce safety built for petrochemical plants: heat-stress risk levels, the summer midday-work ban window, FR-suit and H2S-monitor compliance per crew, lone-worker flags in flare and vessel areas, so the rules MHRSD audits are kept automatically.

Heat StressMidday BanFR & H2SLone Worker

viewkeepersa.com/VisualDefectDemo/hse/zones

05 · Zones

Process & flare zones, enforced

Plant zones drawn on the unit plan and the 3D model: flare radiation radii, vessel and tank envelopes, restricted hot-process areas. Each zone carries its own rules, and any intrusion shows up in Events with the unit and zone attached.

Zone Rules3D Plant ModelFlare RadiiIntrusion Link

viewkeepersa.com/VisualDefectDemo/hse/reports

06 · Reports

Ready for the audit

Shift, daily and integrity summaries, FR & H2S compliance exports, corrosion-trend reports and incident evidence packs, generated automatically and exportable for ISO 45001 and PDPL reviews. One click, and the record is in your inbox.

Shift SummaryFR & H2S ExportEvidence PackISO 45001

viewkeepersa.com/VisualDefectDemo/hse/inspect

07 · Inspect

Point the AI at any scene

A live AI scan page: drop in footage or pick a plant camera, and the engine outlines people, FR & H2S PPE, flare, corrosion and confined-space entries on the spot. The fastest way to see the detection quality on your own plant scenes.

Live ScanAny FootageInstant MasksYour Plant