Safety
Gas and Chemical Plant: Proactive Safety with AI
- Monitoring
- Safety Observations
- Closure
The problem
Most safety programmes only hear about serious incidents. Unsafe acts, unsafe conditions and near misses — the leading indicators that predict them — rarely get reported. OSHA recorded about 3.7 fatalities per 100,000 full-time workers in 2022; data on leading indicators is largely missing.
The challenge
A leading gas and chemical manufacturer in Mumbai had strong HSE practices and several reporting tools, but still couldn’t see everyday unsafe behaviour clearly enough to act on it.
The analysis
Awiros worked with the plant’s HSE and operations teams to find the most frequent issues in existing reports:
- PPE not worn in PPE zones.
- Walkways not followed.
- Traffic rules broken inside the plant.
The session also mapped why these went under-reported:
The conclusion: leading indicators improve through behaviour, and behaviour improves when spotting and reporting no longer depend on someone deciding to raise it.
The solution
HD cameras went up where most hazards were reported — the main gate, walkways, weighbridge, gas filling station and perimeter. Awiros trained models on that footage for PPE, anomalies, and vehicle and people movement, then ran them in production for a month. The results:
- 10x more safety observations, with 24x7 analysis instead of relying on an observer being present.
- Rule-based alerts that take subjective risk judgement out of reporting.
- Action on 100% of alerts through an escalation workflow.
More leading indicators, reported consistently, let management act before serious incidents happen.
The impact
Operational Compliance MonitoringAutomated checks and timely alerts keep operations running without disruption.
Man-Machine SegregationReal-time audio alerts whenever people get too close to machines.
Hazardous Area Access ManagementLess unauthorised access: safer people, fewer stolen materials.
PPE Matrix ComplianceReal-time alerts raised PPE compliance and cut accident risk.
Road SafetyBetter gate, traffic and speed compliance with 24x7 monitoring.Book a demo
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