IoT-based Industrial Safety and Monitoring System with Real-Time Alert Mechanism

Manufacturing sites, chemical plants, and power plants as the major components of industrial settings are often at the risk of exposure to harmful conditions such as gas leakages, fire outbreaks, sudden temperature rises, and equipment failures. Conventional safety systems have mainly focused on monitoring and alarm generation. Still, they have heavily relied on humans who during emergencies tend to respond slowly thereby delaying the critical response times. In case of an emergency, the IoT, enabled industrial safety and monitoring system here proposed can hazard detection and perform the functions necessary to eliminate or mitigate the risk autonomously. This system uses an ESP32 microcontroller along with several sensors that help to determine temperature, humidity, gas concentration, flame presence, and human approach. Upon sensing these conditions, the system without human intervention turns on the Automatic Shutdown System that first disconnects power to the critical loads and then gives Smart Emergency Routing instructions which is a way of guiding workers away from danger to the nearest safe exit. Furthermore, an incident data logger is used to keep records of the sensor readings and event data, which can later be used for event analysis. The data via Wi, Fi are transmitted to a cloud platform for remote monitoring and instant alerting. Results of experimental evaluations reveal that the system being put forward enables quick responses, dependable hazard detection, and safety improvement in an industrial setting through intelligent and automatically made decisions based on data.