Ingevity UK CCTV System (Warrington)
Ingevity commissioned AIS Security to implement a state-of-the-art CCTV system at their 1.3 million sq. ft industrial complex in Warrington.
AIS has a wealth of experience designing, installing, and maintaining bespoke factory and industrial CCTV systems that address the specific needs and challenges of extensive, muti building facilities.
Ingevity CCTV System Requirements
After an initial consultation with the key personnel at the site, we established a list of key objectives that the new system needed to include:
Equipment / Process Monitoring – the ability to allow the monitoring of ATEX & hazardous areas with ATEX certified CCTV cameras.
Production / Logistics Monitoring – this is a large facility with operations spread out over multiple buildings. The office building stands apart from the manufacturing/warehousing area, causing a disconnect between logistics and administration. A CCTV system was required to give the management team a clear oversight of logistical and production operations in all buildings and key external areas.
Improvements to Quality Control – the new system needed to provide a visual record of the time, date and condition of goods leaving the facility.
Improve site safety – CCTV was required to ensure adherence to health and safety policies by all people on-site and help to identify potential accident blackspots. This is a busy site, with 100’s of vehicles entering/leaving the area.
Monitoring Goods In / Out – there was a requirement to closely monitor all goods in/out of the site.
Improve external security – the new system was required to provide evidential quality footage of key exterior areas in all lighting conditions.
Installation of Security Control Room – a full specification security control room needed to be designed and installed, allowing the site’s 24/7 security team to monitor and control all activity on the site.
CCTV System Specification
Working closely with the team at Ingevity UK, AIS carried out a detailed survey. We identified a comprehensive list of their requirements, identified areas of the site of particular interest, identified the best locations for the cameras and switches, etc. We then determined the best CCTV cameras for each position to ensure the best possible result.
The resulting system design comprised of the following equipment:
2 x Network Video Recorders (with 240TB data retention)
35 x 8MP cameras
3 x ATEX explosion-proof cameras
2 x 8ch 4K video decoders
1 x Touch Screen Network Keyboard
8 x POE switches
The installed system allows up to 128 cameras to be recorded simultaneously (the system will record 180 days before overwriting). All AIS installed systems are network-enabled, enabling key staff with appropriate password permissions to access footage from any location with a network connection. The CCTV system was configured with multiple monitoring stations, allowing key personnel to have a customised view of the camera feeds relevant to them.
The static cameras in this installation utilise the very latest 4K image quality (8 Megapixels). They have a wide dynamic range, providing excellent image quality across various lighting conditions. The cameras have inbuilt IR and can see in the dark up to 40M. The external cameras can record at 4K in full colour at night.
In addition to the excellent image quality, the cameras have built-in intruder analytics with face capture, line crossing detection, intrusion detection, region entrance detection, and region exiting detection. This ensures that the system can be used to notify a monitoring company of any potential intruders outside of regular business hours.
In addition to the standard cameras, we were commissioned to supply/install cameras in some ATEX areas at the site. The Explosion-Proof ATEX Cameras used in this installation are constructed from 316L stainless steel. They have an ATEX rating of:
II 2 G Ex db IIC T6 Gb
II 2D Ex tb IIIC T80°C Db IP68
The cameras were connected using galvanised steel wire braid ethernet cable with a polyurethane sheath, suitable for the petrochemical industry (tested to BS EN13617-1:2004).
We designed and installed a control room with the focal point being a video wall allowing all camera feeds to display simultaneously and for scenes of interest to display on a primary viewing screen at the touch of a button.
Installation
Before the commencement of the installation, AIS carried out a RAMS and submitted all relevant documentation (insurance, IPAF, Enhanced DBS certificates etc.).
Due to the nature of the operations at the site, all AIS Engineers undertake regular safety training specific to the customer, and AIS provide the client with ongoing support and maintenance of the system.
Immediate Tangible Results
The system had an immediate positive impact enabling the monitoring of operations, and the feedback from all interested parties at the site has been overwhelmingly positive.
