4K Clarity in All Conditions for Mexico Refinery

The Dos Bocas Refinery in Tabasco, Mexico, is one of the region's most important critical infrastructure projects in the last 40 years.

Developed as part of Mexico’s National Refining Plan, which aims to reduce reliance on fuel imports from the US, the PEMEX-operated site already produces approximately 20% of the country’s daily gasoline requirements.

The site has extremely complex safety and security monitoring needs, and it comprises multiple plant areas that produce diverse products – from gasoline and low-sulphur diesel to propylene, LPG, and Coke. Mathieson Elco, the integrator appointed by lead contractor Samsung Engineering, knew precisely where to turn for the right surveillance solution.

“Having worked with Synectics before”, comments Sam Mathieson at Mathieson, “we knew their COEX camera stations would offer the clarity, reliability, and durability needed for this challenging project.”

Hazardous-area monitoring made simple  

COEX C3000 4K PTZ camera stations provide 24/7 monitoring across plant areas. Extreme temperatures, risk from hazardous gases and liquids, and harsh tropical conditions such as humidity and high winds are all ‘business-as-usual’ scenarios across the site. Hence, the cameras have much to contend with.

As Darren Alder, Head of Oil and Gas at Synectics, explains, this is no problem for the technology used by many of the world’s largest oil and gas projects. “Our C3000 4K PTZ camera stations are rigorously tested to global certification standards to ensure they operate reliably and safely in potentially explosive environments and all-weather conditions.

“In addition to being explosion-proof and fully operational at ambient temperatures as high as 70ºC, these cameras are also designed to seamlessly integrate with any video management systems, including our Synergy platform. Essentially, we make it easy for organisations like PEMEX to leverage COEX cameras' capabilities by ensuring they are compatible with existing surveillance and IT infrastructure.”

4K performance protecting all areas

Synectics’ COEX camera stations were chosen for their clarity and durability. 4K capabilities mean operators can zoom significantly further into areas of interest without risk of image quality degradation. This makes deeper levels of image interrogation (of live and recorded footage) possible, allowing surveillance operators at Dos Bocas to identify even the finest detail. Sharp image quality like this is essential when monitoring complex equipment and processes.

However, detail is also vital for non-hazardous areas such as asset security and worker safety. This is why Dos Bocas also uses Synectics 4K IP cameras for office areas, control rooms, and other zones where continuous situational awareness is required. In addition to the high image quality delivered, using these cameras rather than HD alternatives means fewer cameras are needed. This is due to the improved coverage area that 4K delivers.

Precise PTZ control for super stability

PTZ control is a critical factor for complex process monitoring. Operators must be able to move cameras with extreme precision to capture different fields of view and zoom with absolute accuracy. Additionally, cameras need to return to pre-set positions – whether this process is manual or automated – with the same precision and image stability.  

At Dos Bocas, these requirements are all in play and addressed by the proprietary drivetrain technology developed for COEX camera stations. Featuring a ‘zero-backlash’ worm drive and a high-precision stepper motor, the technology compensates for any lost movement when changing directions to deliver smooth, highly responsive control – even at high zoom. It also features automatic locking so that, for example, the camera cannot unintentionally be forced out of position even in gale-force winds.

Mathieson’s Sam Mathieson adds: “PEMEX have had trouble with cameras from different manufacturers in the past, with belt and gear mechanisms failing or frequently needing maintenance due to harsh operating conditions resulting in wear and tear. The technology in COEX cameras eliminates this risk while guaranteeing the level of control required.”

Cost-efficient solutions that don’t compromise performance

Cost efficiency is also a critical factor for vast oil and gas projects. Finding ways to use existing infrastructure or innovative solutions that avoid implementing unnecessary devices and processes can make a big difference.

The integrated junction box used with the COEX C3000 cameras deployed at Dos Bocas is an excellent example of this principle in action. The box safely houses both fibre optics and power conversion for mains connectivity. In addition to allowing the cameras to utilise more cost-effective single-mode fibre over 1GB, the solution avoids the need for separate Exd junction boxes that would otherwise be necessary for making mains power ‘camera suitable’.