IoT Based Smart Industrial Safety System

Advanced workplace safety monitoring with real-time alerts

Abstract

This project presents an IoT-based industrial safety system designed to enhance workplace safety by monitoring environmental hazards such as temperature, gas leaks, smoke, and flames using an ESP32 microcontroller. The system integrates multiple sensors to collect real-time data, processes it through a central controller, and triggers notifications through buzzer, LED, Firebase, and Blynk platforms. Emergency contacts, including fire stations and hospitals, are automatically informed through Twilio services, ensuring rapid hazard identification and response with comprehensive data visualization on a dashboard.

Technologies Used

Software

  • Arduino IDE
  • Blynk Platform
  • Firebase
  • Twilio API

Hardware

  • MQ-135 Air Quality Sensor
  • MQ-2 Gas Sensor
  • Flame Sensor
  • DHT11 Temperature/Humidity
  • ESP32 Microcontroller
  • Buzzer & LED Alerts

Case Study 1: Gas Detection

Advanced Gas Monitoring

The MQ-2 gas sensor continuously monitors air quality, detecting harmful substances like carbon monoxide, ammonia, and volatile organic compounds (VOCs). The system provides real-time readings to the microcontroller and triggers immediate alerts when dangerous gas levels are detected, preventing inhalation risks and potential explosions.

Key Features: Continuous monitoring, Real-time alerts, Multi-gas detection
Gas leak detection setup Gas sensor in action

Case Study 2: Fire & Smoke Detection

Comprehensive Fire Safety

Our dual-sensor approach provides complete fire detection coverage:

  1. Flame sensor detects infrared radiation from open flames
  2. Smoke sensor identifies airborne particles indicating early fire stages

When fire or smoke is detected, the system immediately triggers signals to the control unit, enabling rapid response to prevent fire spread.

Fire detection system Smoke sensor setup

Remote Alert Systems

Blynk Dashboard

Blynk interface

Real-time monitoring dashboard featuring:

  • Air quality (ppm)
  • Gas levels (ppm)
  • Temperature & Humidity
  • Fire status indicators
  • Buzzer controls
  • GPS coordinates

SMS Alerts

SMS notification

Automated SMS alerts sent via Twilio API to registered emergency contacts including fire stations, hospitals, and authorities. Ensures immediate notification of critical safety events.

Emergency Response: Instant notifications to multiple stakeholders