At a large-scale Oil & Gas project site in the Middle East, site safety and workforce accountability are critical. The site required a system that could continuously monitor weather conditions, alert workers about environmental risks, and record their attendance with minimal manual intervention.

To address this, the site operator partnered with Innobayt to develop a distributed weather monitoring and worker notification system. The solution integrates real-time environmental data collection, multi-channel alert dissemination, and RFID-based check-in/out tracking—delivered across 50 smart notification poles deployed site-wide.

The Challenge

Managing safety for hundreds of on-site workers across a vast area presents several challenges:

• No real-time weather awareness, increasing the risk of unplanned exposure to extreme heat or high wind conditions.

• Lack of automated alerts, requiring manual announcements during weather events.

• Limited visibility into worker presence, as manual attendance tracking lacked precision and reliability.

• Disparate systems, with no centralized dashboard for monitoring environmental data, alerts, and workforce logs.

• No way to verify equipment status across dozens of distributed notification poles.

The site needed a resilient, connected, and automated system that could unify these functions and provide real-time insights to site administrators.

The Solution

Innobayt engineered a full-stack solution that combines IoT sensors, edge computing (Raspberry Pi), RFID readers, cloud-hosted services, and a centralized admin dashboard.

1. Weather Monitoring and Alerting

• Sensor Collection: A weather station captures wind speed, temperature, humidity, and radiant heat (black globe) data every 5 minutes.

• Cloud Transmission: Data is sent via GSM to a cloud backend where thresholds are evaluated in real-time.

• Alert Distribution: Weather alerts are pushed to 40 master notification poles via GSM and then relayed to 10 slave poles using LoRa connectivity.

• Multi-Sensory Warnings: Poles activate RAG (Red/Amber/Green) lights and play audio alerts to warn workers of hazardous conditions.

2. Worker Attendance via RFID

• RFID Check-In/Out: Workers tap RFID cards on any pole to register attendance.

• Real-Time Sync: Data is sent to the cloud (via master poles) and mapped to pole ID and timestamp, ensuring location-based traceability.

• Offline Tolerance: Slave poles cache attendance logs and forward them via their connected master poles when back online.

3. Centralized Admin Panel

• Threshold Configuration: Admins define safe limits for each weather parameter.

• Live Monitoring: Real-time dashboard displays weather conditions, alert events, and online/offline status of poles.

• Attendance Viewer: Filterable logs allow for quick audits by date, time, and location.

• Audio Alert Management: Upload and assign unique audio files for different weather parameters.

4. Cloud Infrastructure & Hosting

• Cloud-Hosted Backend: Deployed in the client’s preferred cloud environment, supporting HTTPS, API key management, and auto-scaling.

• Data Storage: Secure storage for weather logs, RFID records, and alert audio files.

Technology stack

• Edge Devices: Raspberry Pi (RPi), LoRa modules, GSM modules

• Sensors: Anemometer, Black Globe, Temperature, Humidity

• RFID: Card readers integrated into each pole

• Cloud Backend: REST APIs with threshold and notification engines

• Web Dashboard: HTML/CSS/JavaScript admin panel hosted in secure cloud

• Audio Management: Custom uploads for localized and multilingual alert sounds

Business Impact

The system delivered measurable improvements in worker safety, operational efficiency, and real-time visibility:

• Worker Safety: 60% reduction in weather-related incident risk due to proactive alerts

• Attendance Tracking: 99.5% logging accuracy across 50+ remote locations with RFID-based check-ins

• Operational Oversight: Real-time visibility of 100% critical zones via a centralized monitoring dashboard

• Efficiency: Reduced manual alert handling time by 80%, saving ~15 hours per site per month

• Resilience: Maintained 100% communication uptime during 3 power/network outages using LoRa fallbacks

• Customizability: Enabled over 200 dynamic audio alert combinations and real-time threshold adjustments for evolving field conditions