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Connected safety for petrochemical workers.



The importance of the petrochemical industry is often overlooked —but petrochemical products are all around us. From the production of chemicals, plastics, car components. gasoline, asphalt, synthetic rubber and fertilizer to name just a few, the petrochemical industry is booming and expected to grow at a CAGR of 6.2% from 2022 to 2030, rapidly approaching a USD 1 trillion market size.

There are significant hazards petrochemical workers may face that range from toxic gas exposure to confined space and the risk of fire or explosion from combustible gases. Particularly concerning is the safety of lone workers and potential gas exposures, such as:

Exposure to these gases can occur during the production, transportation, storage, and use of petrochemical products. It is important for workers to be trained on the hazards associated with these gases and stay protected by wearing PPE, including personal gas detectors.

oil worker petrochemical gas detection

Connected gas detection and lone worker safety for the Petrochemical industry.

Blackline provides the petrochem industry with safety solutions that connect, protect and enable workers to get the job done confidently, efficiently, and most important, safely so they return home after every shift. Our connected wearable gas detectors protect workers, improve compliance and increase operational efficiencies, and include lone worker safety features, such as fall and no motion detection and an SOS latch.

Personal Gas Detection Area Monitoring
gas detectors for petrochemical industry

G7 EXO area monitor

G6 and G7 wearable devices protect workers during turnarounds, shutdowns, unforeseen outages, and every other day on-site. With various gas hazards in the petrochemical industry and confined space entries, workers need a connected safety solution to ensure they are always protected.


Monitor the safety and atmospheric hazards of your facilities whether it be a refinery or chemical plant. G7 EXO deploys in minutes and delivers reliable connectivity for 100+ days, even in the harshest conditions. You can always rely on the G7 EXO to perform when you need it the most. 


Petrochemical Toxic and Combustible Gas Hazards

  • Main gas hazards
  • Flammable hydrocarbons are present in crude oil, treating operations, transfer and loading operations, heat exchangers, and more.
  • Exposure to toxic gas during cracking, combining and reshaping fractions (feedstocks) can lead to short and long-term health conditions. 
  • Rearranging and combining processes like reformation and alkylation can release CO, as can heat-generating flares, boilers, and furnaces.
  • During the production of electricity or heating (when coal or oil is burned) workers may be exposed to SO2. Specific examples are flares, treating operations, and cracking unit regeneration.
  • NO2 can be released from flares and boilers.
  • Cracking operations, liquid wastes, pumps, and crude towers, along with rearranging and combining processes can present a hazard of H2S exposure.
  • Confined space entries are a common undertaking refinery and petrochem plant workers need to perform. Whether it be an entry into reactors, tanks, vessels, or ducts—oxygen deficiency or otherwise dangerous atmospheres are a risk.
  • Hot work operations such as welding cutting, soldering, brazing, etc. which have the potential to create heat, a spark, or hot slang can ignite flammables nearby.

Explosion from a pipeline leak of alkylation reaction material in Petrochemical plant kills five and seriously injures eight in Liaoning, China - Jan. 2023

(Hazardex, 2023)

Petrochemical Lone Worker Risks

  • Inhaling dust or other dangerous substances can increase the risk of burns, loss of consciousness, and asphyxiation.
  • Unreliable cell coverage at certain worksites can put workers at risk. Satellite-connected gas detectors, such as G7x/Bridge, are critical to ensure worker safety.
  • Turnarounds, shutdowns or unexpected stoppages of work due to maintenance, cleaning, or unforeseen circumstances bring additional workers to plants. Contractors unfamiliar with the facility may not be aware of lone worker hazards or areas that are out of sight and sound if help is needed.
  • Plant operators and technicians risk falling, slipping, and tripping-related injuries from uneven terrain or slippery areas experienced on sites.
  • Noise from equipment, machinery, fans and heaters can drown out a call for help. Wearing devices with lone worker safety features, like those in G7, can instantly notify safety monitors of a call for help with the simple pull of the SOS latch.
  • Heavy machinery and equipment can trap or severely injure workers that may need urgent help. Safety devices need to have no motion, fall detection and two-way push-to-talk features to keep the lines of communication open.

The connectivity and software to further protect your team.

Blackline’s connected safety and robust software offering provide the petrochem industry with solutions that offer ultimate protection from worksite hazards and help you run a more efficient operation.

Next-level safety – The Blackline Live online portal allows you to manage your G7 connected safety devices, monitor your facility and your workforce’s well-being in real-time, respond to emergencies and report on collected data. Simple compliance is no longer good enough.

Unmatched visibility – Blackline Analytics provides a complete view of your connected safety fleet’s compliance, usage and alert data in a single, easy-to-use tool. Analyze real-time and historical data to anticipate potentially dangerous situations and prevent incidents from happening.

Enhanced productivity – Connected devices deliver data that can uncover opportunities to increase operational efficiency, offering the potential to save millions in lost revenue.

Optimized responses – Comprehensive safety monitoring and mass notifications give you complete and swift control of evacuation and emergency management.

Always at the ready – Blackline’s in-house Safety Operations Center is staffed 24/7 with professionally trained monitoring agents focused exclusively on ensuring the safety of your people.

The connected devices you need for unparalleled safety.

With Blackline’s comprehensive suite of safety devices, you get a complete ecosystem that leaves no aspect of worker or worksite safety to chance. Whether you need personal safety monitoring, gas detection or area monitoring, every G7 solution offers turn-key connectivity and versatility.

Trustworthy protection – Poison-immune combustible gas monitoring with broad spectrum LEL detection

Efficient execution – Connect in minutes wherever the device is placed or worn

Built for extremes – Face tough and rugged conditions, on any worksite, anywhere in the world

Ready and reliable – The G7 EXO’s100+ days of battery life allows devices to remain in operation longer, reducing the manpower needed to swap batteries or devices and the number of permits required

Direct-to-Cloud connectivity – Industry-leading cellular and optional satellite connectivity for remote areas (e.g. bring the magnetic satellite bridge with you from your truck to your ATV), streaming all data directly to the cloud

Low cost of ownership – G7 EXO’s extra-long battery life eliminates the need to purchase extra monitors, saving tens of thousands of dollars. And with connected wearables, you can easily locate a lost device

Immediate Awareness - Text and email alerts keep you fully aware of device status and active situations

No nonsense – Eliminate the need for LEL correction factors, minimizing unnecessary and costly evacuations from false readings

Maximum flexibility – Thousands of gas detection configurations available in single-gas to five-gas detectors with or without a pump

Uncompromised safety – Extensive person down safety features such as fall detection, missed check-in alarms, an S.O.S. latch to call for immediate assistance and no-motion detection, two-way communications and push-to-talk functionality.



Leveraging data to create a proactive and efficient safety program

Connected gas detection isn’t the tech of the future anymore. It’s right here, right
now, and more money-saving, sustainable and simple than you think.




Evacuation management is a necessary element of safety planning for oil and gas operations. It is critical to be prepared to quickly and safely evacuate personnel in the event of an emergency, as every second counts when lives are on the line.



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