Saudi Aramco
Smart Site Safety Solution (4S) Monitoring with LoRaWAN Smart Helmets, AI Analytics, Weather Stations
End-to-end site safety monitoring for MAPA Construction along the PS-2 to PS-3 right-of-way using LoRaWAN smart safety helmets, A.I video analytics and industrial weather stations.
- Main Contractor
- Saudi Aramco
- Main Client
- MAPA
- Industry Type
- Oil and Gas
- Company Size
- Large
- Number of Employees
- 65,000
- Location
- Riyadh, Saudi Arabia
The Master Gas System-3 Package 4 (MGS-III PKG-4) is a critical component of Saudi Aramco's massive expansion of its domestic natural gas network. This phase (MGS-3) is designed to increase the network's capacity and shift the Kingdom's power generation from liquid fuels to cleaner-burning natural gas. Creation Source is working on this project along with MAPA who are the official contractors for this project.
The project is a large-scale, site-based safety and monitoring initiative designed to improve worker safety, operational visibility, and incident response across active project sites.
The core objective of the project is to create a connected ecosystem where safety-critical information is available in real time, enabling faster decision-making, proactive risk mitigation, and structured incident reporting. The solution is designed to be scalable, reliable, and suitable for harsh outdoor and industrial environments.
Connectivity Approach
LoRaWAN macro gateways blanket 60 km of desert ROW without a single fiber trench, streaming helmet telemetry, weather data, and AI-camera alerts over resilient dual-SIM backhaul.
Sensor Integration
Smart PPE, PTZ video, and 11-parameter weather probes converge in one timeseries engine: delivering heat-stress, fall, and intrusion insights in under two seconds.
Edge AI
GPU-powered trailers run PPE and fall detection models right at the work front, pushing only actionable metadata to the Safety Command Center to slash bandwidth by 95%.
Cellular Backup
A web-first 4S dashboard and supervisor mobile app give HSE leads real-time headcount, geo-fenced alerts, and one tap SOS escalation; anywhere from laydown yard to boardroom.
Permit System
LoRaWAN micro-climate stations feed live heat-index and wind-gust thresholds straight into the digital permit engine, pausing hot-work and lifting ops automatically.
Solution Scope and Deployment Model
The IoT solution by Creation Source is deployed on a site-based model, where each project site operates as an independent monitoring unit while still being connected to a centralized platform. All components described in this case study are part of the MGS-III PKG-4 solution scope as defined in the project technical proposal. All devices are deployed and configured to operate continuously, ensuring uninterrupted data availability.
The deployment includes:
Smart Helmets
Wearable safety devices for personnel monitoring
Environment Sensors
Environmental sensing infrastructure
Gateways
Gateways and communication components
Smart Site Safety Platform
A centralized platform for monitoring, alerts, and reporting
IoT Architecture Overview
This architecture ensures scalability, fault tolerance, and secure data flow from the field to decision-makers. The integrated IoT architecture follows a layered approach:
Device Layer
Sensors and smart helmets are provided to personnel at site locations
Connectivity Layer
LoRaWAN and cellular communication for data transmission
Gateway Layer
Aggregation of sensor data and forwarding to the cloud
Platform Layer
Data processing, storage, visualization, and alerting
Application Layer
Dashboards, reports, and incident management tools
Equipment Integrated from Vendors
Central Safety Command Center
- Design, Installation and Integration
- A.I Analytics on 36 Cameras
- 5 Modules for A.I Video Detection
1
Trailers
15
Weather Stations
1
Cameras
36
Personnel Safety Monitoring
The VCT Smart Safety Helmet is a key component of the safety solution. A total of 1000 smart helmets are included in the MAPA solution, ensuring wide coverage across active sites. Data collected from the helmets is transmitted to the central platform via APIs, where it is visualized on dashboards and used to trigger alerts when abnormal conditions are detected.
1,000
VCT Smart Helmet
Deployed to monitor the real-time location and vital parameters of personnel working on-site. The helmet integrates positioning technology and health monitoring capabilities, enabling continuous tracking of worker movement and physical status
Environmental Monitoring
Environmental conditions play a critical role in site safety and operational planning. To address this, MAPA includes a Weather Station, QR Code / RFID Based Equipment Tracker, and Vehicle Trackers for vehicle and heavy equipment tracking and monitoring.
By integrating weather data into the MAPA platform, site managers can correlate environmental conditions with safety events and operational decisions. The digitally mapped QR / RFID Equipment Tracker is designed to improve asset visibility and control across MAPA project sites. Vehicle and heavy equipment tracking enables real-time monitoring of fleet movement, utilization, and safety. The solution supports both light and heavy vehicles and enhances operational control across MAPA sites.
1
Milesight EM-500-UDL Environment Monitoring Sensor
A multi-parameter environmental sensor designed for outdoor industrial use. The EM-500-UDL continuously measures and reports key environmental parameters, enabling proactive risk management related to weather conditions.
19
QR Code / RFID Based Equipment Tracker
Designed to improve asset visibility and control across MAPA project sites. Each tracker is uniquely identified and digitally mapped, enabling instant access to asset information and improving inventory accuracy
226
FMC-130 Vehicle Tracker
Enables real-time monitoring of fleet movement, utilization, and safety. The solution supports both light and heavy vehicles and enhances operational control across sites.
Site Control Trailer
The Site Control Trailer serves as a mobile and self-sufficient operational unit, acting as a localized control and monitoring hub for MAPA sites.
- Acts as an on-site command and communication unit
- Supports rapid deployment in remote or temporary sites
- Houses critical monitoring and networking equipment
- Designed for harsh and power-constrained environments
15
HikVISION DS-2DF A.I-Based CCTV HD Site Camera
The AI-based CCTV solution provides intelligent visual monitoring to enhance workforce safety, detect unsafe behavior, and support real-time site surveillance.
15
Cisco Wireless Gateway
These Cisco Gateways act as the central communication bridge between LoRaWAN devices deployed on-site and the cloud platform, ensuring reliable and scalable data transmission.
15
Site Control Enclosure
The Site Control Enclosure provides secure housing and autonomous power for all on-site MAPA equipment, ensuring continuous operation even in remote or power-limited environments.
1
Edge Compute IoT Server
The Edge Compute IoT Server enables local data processing and decision-making at the site level, reducing latency and minimizing dependency on cloud connectivity.
Solution Scope and Deployment Model
The Safety Command Center (SCC) is the central operational and decision-making facility of the MAPA project. It operates 24/7 and integrates workforce data, video surveillance, environmental monitoring, and vehicle tracking into a single, secure environment. The SCC enables real-time monitoring, rapid incident response, and compliance with safety and environmental standards.
- Centralized hub for safety monitoring and incident management
- Operates continuously during project hours
- Designed according to ergonomic and safety standards
- Integrates data from all MAPA IoT subsystems
- Supports proactive risk identification and mitigation
Proposed SCC renders (helps stakeholders visualize SCC setup)
Video Management Server
We utilized a high-performance 16-channel NVR to provide centralized video management. The system supports 4K resolution and 40 TB of reliable storage, integrating advanced AI analytics like intrusion detection to ensure comprehensive, high-resolution site security.
Video Analytics Server
We deployed a high-performance analytics server featuring dual CPUs, 96 GB RAM, and an NVIDIA A5000 GPU. This powerful architecture enables real-time AI processing, pattern detection, and event classification to identify site anomalies and improve safety protocols.
Workforce Data Management
SCC includes a centralized management system that tracks workforce attributes, including location, occupation, and safety training records. This provides real-time personnel visibility, ensuring strict compliance with safety regulations.
Work Permit Management
SCC integrates work permit data with real-time tracking to ensure only authorized personnel and equipment enter designated zones. By linking permits to location and time, the system enhances operational control and automates safety enforcement.
Vehicle and Equipment Monitoring
SCC provides real-time tracking for vehicles and heavy equipment, integrating operator certifications and maintenance records. This improves fleet utilization and safety oversight while supporting incident investigations and audit readiness.
Environmental Data Monitoring
SCC utilizes specialized weather stations to continuously monitor wind speed, temperature, humidity, and lightning. By generating automated alerts for unsafe conditions, it supports informed decision-making for high-risk activities, effectively preventing incidents.
Hazard Identification
SCC identifies high-risk activities by correlating work permits, environmental data, and operational schedules. This allows for the prediction of hazardous scenarios and the recommendation of mitigation measures, enabling proactive safety planning to reduce incident likelihood.
Surveillance System (AI-Enabled CCTV)
SCC utilizes AI-based surveillance to detect unsafe behaviors and conditions in real time. It supports behavioral analysis and recorded monitoring while using clear signage to ensure transparency, ultimately strengthening safety compliance and accountability.
Security Measures
Strict security controls are implemented to protect SCC operations and sensitive data.
- Restricted physical access
- Entry limited to authorized personnel only
- Mandatory ID verification
- No photos or recordings without approval
- Controlled operational environment
Reporting and Analysis
The SCC supports continuous improvement through structured reporting and data analysis.
- Weekly review by HSE team
- Identification of trends and violations
- Regular reporting to client for action and closeout
Reports include:
- Safety observations
- HSE incidents
- Rule violations
- Weather conditions
- Site manpower
- Vehicle data
- Environmental monitoring results
Technical Specifications
Video Management Server
Video Analytics Server
Network Infrastructure
Real-Time Dashboards
The MAPA platform provides real-time dashboards that present critical safety and operational information in an intuitive format. Alert mechanisms notify relevant stakeholders when thresholds are exceeded, enabling immediate corrective action.
Overview of Personnel and their details
Overview of a Personnel's Vitals
Conclusion
The MAPA IoT case study demonstrates how a comprehensive, site-based IoT solution can significantly enhance safety, visibility, and operational control. By combining wearable technology, environmental monitoring, robust connectivity, and a centralized platform, MAPA delivers a scalable and future-ready safety ecosystem that can be easily understood, managed, and expanded.