Design and Development of Intrinsically Safe Lightning Arrester System for Firework Industries

The fireworks production process is highly risky for lightning-related accidents due to the presence of explosive substances and exposure to severe weather conditions. The existing fire protection system depends on ineffective surge and grounding management techniques without any automated emergency service in real-time. This article discusses the design and implementation of a fundamentally safe, affordable, IoT-enabled lightning protection and early alert system developed for the fireworks industry. This model combines environmental sensing, artificial lightning modeling, electrical fault monitoring, fire detection and automated fire control. Weather conditions such as temperature, humidity, rainfall, noise levels and water levels are continually monitored to detect the irregular variations caused by simulated lightning strikes using voltage and current sensors. The experimental results show fire detection (~0.3s), automated fire protection activation within 1.5s, reliable cloud data updates every 15s, and WhatsApp alert notifications sent within 6–8s. This system operated continuously for 8 hours with stable performance and achieved AI-based weather risk prediction accuracy of approximately 82%. These results confirm that the proposed work is an effective smart safety measure for improving lightning-related fire protection in fireworks manufacturing industries.