Industrial Safety · MI-IS-03
Connected PPE & Lone-Worker Gas Safety
Wearable gas detectors and man-down badges send gas and no-motion alarms with location; a missed check-in auto-escalates.
Industrial Safety · MI-IS-03
Wearable four-gas detectors and man-down badges for two workers, connected harness and PPE sensors, an outdoor gateway and a lone-worker dashboard with automatic check-in escalation.
- ₹1,12,500pilot BOM · hardware only
- 5 – 8 daysto a live pilot
- Advancedintegration level
- 3validated providers
Why a local gas alarm is not enough
The problem
Confined-space entries, tank cleaning, paint shops and chemical stores rely on a buddy at the hatch and a portable gas meter that only the wearer can see. A lone worker in the yard at night has a phone and a hope. Alarms that nobody hears are not alarms.
- Gas alarms are local to the wearer; the control room hears nothing
- Man-down and no-motion events go unnoticed for minutes
- Harness and PPE use in confined spaces is unverified
- Lone-worker check-ins are a radio call that is easy to skip
The solution
Each worker carries a connected four-gas detector (O₂, CO, H₂S, LEL) and a man-down badge with a no-motion timer and SOS; a clip-in sensor confirms the harness is attached and PPE present. A LoRaWAN outdoor gateway covers the yard and tank farm. The dashboard shows live gas readings and location, escalates gas, man-down and SOS alarms to the control room, and auto-escalates a missed check-in.
- Live gas readings visible to the control room, not only the wearer
- Man-down, no-motion and SOS alarms with location
- Harness and PPE presence confirmed before entry
- Scheduled check-ins with automatic escalation
Validated service providers
Validated by TwoElectrons and ranked by validation score: verified credentials, completed jobs on the platform and client ratings.
- Sample Provider P — Mumbai · Connected PPE & helmets · ★ 4.8 · 8 jobs
- Sample Provider Q — Vadodara · Gas safety & lone worker · ★ 4.7 · 10 jobs
- Sample Provider R — Bengaluru · Wearables & worker health · ★ 4.6 · 5 jobs
Provider listings are samples pending live registrations.
Pilot BOM and cost
Reference hardware to run the pilot. Unit costs are indicative Indian market prices for the component class.
| Qty | Item | Unit cost | Line |
|---|---|---|---|
| 2× | Wearable 4-gas detector with BLE/LoRa O₂, CO, H₂S, LEL | ₹32,000 | ₹64,000 |
| 2× | Man-down / lone-worker badge no-motion timer, SOS, LoRaWAN | ₹10,500 | ₹21,000 |
| 2× | Connected PPE sensor harness clip-in / glove & vest presence | ₹4,500 | ₹9,000 |
| 1× | LoRaWAN outdoor gateway yard and plant coverage | ₹18,500 | ₹18,500 |
| 1× | Lone-worker dashboard & check-in app | Free tier / open source | — |
| Pilot BOM total | ₹1,12,500 |
POC BOM cost only — hardware for a pilot. Installation, integration and provider services are quoted separately. Request for Quote
How connected gas and lone-worker safety works
- Equip. Issue gas detectors, badges and PPE sensors to two workers.
- Cover. Mount the outdoor gateway over the yard and tank farm.
- Rules. Set gas limits, no-motion time and check-in interval with EHS.
- Drill. Simulate a gas alarm and a man-down; time the control-room response.
Pilot architecture
Gas detectors + man-down badges + PPE sensors (O₂ · CO · H₂S · LEL · IMU) → LoRaWAN outdoor gateway (yard & tank-farm coverage) → Safety cloud (alarm rules · check-ins) → Control-room dashboard (live gas · escalation)
Detector readings and events leave the worker over LoRa, so the control room sees what the wearer sees.
Business case: response time, PPE compliance, check-ins
Ranges are typical figures reported for this class of solution; your pilot establishes the numbers for your plant.
- Seconds from gas or man-down alarm to control room (versus an unheard local alarm)
- 100% of confined-space entries with PPE confirmed (harness clip-in logged)
- Zero missed check-ins without escalation (automatic timers)
- 5 – 8 days to a live pilot (two workers)
Who this is for: EHS and process-safety heads, Utilities, water and effluent plants, Chemicals, paints and coatings, Oil depots and tank farms, Confined-space contractors, Any site with lone or confined-space work.
Illustrative case study
Illustrative scenario · not a client reference
An effluent-treatment plant with sump and tank entries in Ankleshwar (illustrative)
Set-up. Two operators equipped for the night shift; gateway on the ETP mast; control room on the dashboard; check-ins every 30 minutes; a drill on day two.
What happened. During a tank inspection the H₂S reading crossed the alarm limit and the control room saw it at the same moment as the wearer, calling the entry off before the worker felt symptoms. A missed check-in in week three, caused by a flat radio, was escalated automatically and resolved in four minutes.
- Pilot budget: ₹1,29,500 hardware
- Alarm to control room: seconds
- Missed check-in resolved: 4 min
FAQ
Are the gas detectors certified for hazardous areas?
Intrinsically safe (ATEX/IECEx) variants are specified for hazardous zones; the pilot quotes the rating your areas require.
What if there is no LoRaWAN coverage in a tank?
Detectors alarm locally regardless; the badge buffers events and the gateway coverage is verified in the pilot, with a repeater added if needed.
Can it integrate with our permit-to-work system?
Yes — PPE confirmation and check-in status can be shown against the open permit in a scale-up phase.
What does the ₹1,29,500 cover?
Two gas detectors, two badges, two PPE sensors and an outdoor gateway on a free-tier dashboard. Calibration, hazardous-area variants and provider services are quoted after a Request for Quote.
