Chennai Petroleum Corporation Limited (CPCL) has taken a major step towards modernising its safety and security infrastructure by deploying an AI-powered video analytics system developed by Vehant Technologies. This strategic move supports the Make in India and Digital India initiatives, demonstrating how artificial intelligence is transforming critical national infrastructure.
Tackling Legacy Surveillance Challenges
Operating in a high-risk environment, CPCL’s refinery previously relied on traditional surveillance systems that lacked real-time detection and analytical capabilities. Key gaps included:
*Inability to detect unauthorised access or loitering
*Missed PPE (Personal Protective Equipment) violations
*No alerts for fire hazards or abnormal vehicle movement
*Camera failures going unnoticed
*Manual monitoring that was time-consuming and prone to errors
These limitations posed serious safety risks and hampered compliance with industrial regulations.
AI-Driven Surveillance: A Game-Changer
To address these issues, CPCL implemented a customised AI-based video analytics platform from Vehant Technologies. Tailored for industrial environments, the system delivers:
*Real-time intrusion and motion detection
*Automated PPE compliance monitoring
*Instant fire risk alerts
*Vehicle tracking using Automatic Number Plate Recognition (ANPR)
*Camera health checks to flag tampering or disconnections
These capabilities enable faster incident response and significantly reduce the dependency on manual oversight.
Advanced Features Built for Industrial Scale
The system’s smart algorithms are integrated through a layered dashboard architecture, combining a central master dashboard with multiple contextual views. This enables safety officers to focus on priority alerts and take immediate action.
Notable capabilities include:
*PPE detection for helmets, jackets, masks, and safety shoes
*Fire risk alerts based on abnormal heat or smoke patterns
*Intelligent motion sensing in restricted zones
*Camera functionality monitoring for uninterrupted visibility
Customised for CPCL’s Needs
The platform has been custom-fitted to CPCL’s operational conditions. For example, PPE detection algorithms were trained to identify the specific gear used onsite. Field of View (FoV) for legacy cameras was also optimised to support AI functionality. Furthermore, the system is modular and scalable, allowing for expansion or replication across other refinery sites with similar risk profiles.
Ensuring Regulatory Compliance
Fully aligned with Indian industrial safety norms, including:
*The Factories Act, 1948
*Oil Industry Safety Directorate (OISD) Guidelines
The AI platform helps CPCL enforce compliance by automatically recording violations and creating digital logs for audit trails and investigations—improving both accountability and transparency.
Measurable Improvements in Safety and Efficiency
Since its deployment, CPCL has observed clear improvements in:
*Response times to potential hazards
*Reduction in manual errors
*Enhanced situational awareness for safety officers
*Digital documentation for audits and inspections
Although no major incidents have occurred since implementation, the AI system is credited with elevating the overall safety culture at the refinery.
Strong Return on Investment
The AI solution has delivered quantifiable value by:
*Reducing compliance violations
*Automating repetitive surveillance tasks
*Minimising downtime through early detection
*Lowering manpower requirements for routine monitoring
As reported by manufacturingtodayindia.com, the return on investment reinforces the case for further digital adoption across industrial operations.
Industry Benchmark for AI-Enabled Safety
“This deployment represents a major step in CPCL’s safety transformation,” said Shailendra Kumar Singh, Business Unit Head – SSE Business, at Vehant Technologies. “Our AI-powered video analytics system offers real-time, site-specific monitoring that’s both scalable and proactive. With similar successes at IOCL and GAIL, we’re helping set a new benchmark for industrial safety across India,” Singh added.
