REAL-TIME INDUSTRIAL SAFETY SURVEILLANCE USING ESP32 AND LORA

Abstract

Industrial settings, such as refineries, chemical plants, and mining sites, often face situations where gas leaks, overheating, and fire risks can occur unexpectedly. Providing continuous monitoring and quick detection of such dangers remains a significant challenge, especially in areas with dense metal structures that interfere with wireless signals. Traditional short-range technologies like Wi-Fi, ZigBee, and Bluetooth usually have limited coverage, face high interference, and require more power, making them unsuitable for larger or obstructed industrial spaces. This highlights the need for a communication system that is long-range, energy-efficient, and reliable for realtime safety alerts. To meet this need, this project presents an Industrial Safety Monitoring System based on LoRa (Long Range) communication. LoRa is an LPWAN protocol known for its long-range communication and low power consumption, offering an effective way to monitor hazardous sites spread over large areas. The system combines ESP32 microcontrollers with Reyax LoRa modules to create strong wireless connections between sensor units and a central receiver. The sensing unit includes an MQ-2 module for detecting combustible and toxic gases, along with a DHT11 sensor for measuring temperature and humidity. Local alert systems such as a buzzer, LED indicators, an LCD display, and an emergency button allow workers to receive immediate feedback and send alerts when necessary. At the receiving end, an ESP32-LoRa module processes incoming data, displays environmental readings on an LCD, and activates alarms when unusual conditions are detected. Cloud connectivity is also included, allowing supervisors to access live sensor data and historical records through remote dashboards for better monitoring and decision-making. Performance testing shows that the system can maintain reliable communication over distances from 1 to 5 kilometers with a power consumption of about 0.75 W. These results show that the proposed design is a scalable and cost-effective solution for industrial safety monitoring. Future improvements could include using machine learning for predictive analytics, switching to LoRaWAN for better network support, and using solar power for remote or off-grid installations. Index Terms—IoT, ESP32, LoRa, Industrial Safety, Sensor Networks, Real-Time Monitoring.