The power industry is inherently high-risk, with workers exposed to electricity, hazardous materials, heavy machinery, heights, and confined spaces. Around 1,000 electric workplace accidents are reported to the UK’s Health and Safety Executive annually. Globally, power line repair workers are especially vulnerable, with the Electrical Safety Foundation International finding that overhead power line contact caused 43% of US workplace electrical fatalities between 2011 and 2023.
Power companies can receive hefty fines, penalties, lawsuits, and reputational damage for health and safety negligence. In September 2023, National Grid was fined £3.2m ($3.9m) after a safety failure left a worker replacing step bolts on a pylon with life-changing injuries.
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Internet of Things (IoT) describes the use of connected sensors and actuators to control and monitor the environment, the things that move within it, and the people that act within it. IoT is a key technology that will help tackle the challenge of health and safety across the power industry.
How IoT can improve health and safety in the power industry
IoT-based predictive maintenance allows power maintenance teams to detect and fix potential equipment failures before they escalate into serious incidents threatening workers, as well as wider public safety. For example, IoT temperature sensors can monitor battery assets in power plants to limit battery fires, a pertinent issue following a battery fire that broke out at a California power plant housing one of the world’s largest battery energy storage systems (BESSs) in January 2025. Edge computing should be integrated with IoT-based predictive maintenance wherever feasible to facilitate local processing of sensor data, which reduces latency and therefore allows for faster responses to critical equipment failures. IoT edge-based predictive maintenance is especially important in facilities such as nuclear power plants, where rapid detection and intervention are essential to prevent catastrophic failures from equipment breakdowns.
IoT-based environmental monitoring is vital for maintaining safety at power plants and manufacturing sites. IoT sensors can continuously track environmental variables such as temperature, humidity, and hazardous gases, enabling early detection of unsafe working conditions. IoT actuators can trigger automated responses such as adjusting ventilation or shutting down assets to keep workers out of harm’s way. IoT sensor data can also assist with early wildfire detection, which may be especially beneficial for preventing catastrophic explosions at sites hosting BESSs. Korea Electric Power (KEPCO) has implemented an AI IoT-based mountain fire monitoring system into its operations since February 2024. The system uses security cameras for heat-sensitive imagery. KEPCO is working with local authorities to install the system nationwide.
Wearable tech offers targeted safeguards for power industry workers. IoT-enabled wearables such as smartwatches, glasses, and helmets enable real-time monitoring of workers’ vital signs, fatigue levels, locations, and nearby environmental hazards. Wearables can trigger alerts when workers are at increased risk of accidents or need to leave the frontline urgently. For example, smart helmets can notify field personnel of potential danger when approaching live electrical components. Wearable IoT data can be transmitted to supervisors for improved safety oversight. These devices also enhance emergency recovery by enabling emergency teams to quickly pinpoint the locations of workers needing rescue in real-time.
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By GlobalDataWearable devices integrated with augmented reality (AR) support hands-free remote technical assistance for frontline workers, minimising accidents from distractions and reducing the need for experts to travel to maintenance locations. TotalEnergies and the State Grid Corporation of China have deployed RealWear’s AR smart glasses to this effect. Wearables support a proactive safety approach and should complement broader IoT safety systems. While the power industry’s adoption of these devices currently lags industries such as construction and mining, this gap will close as underlying technologies improve and awareness of their benefits grows.
Utilities must implement safeguards to limit IoT-related cybersecurity risks
Despite boosting health and safety across the power industry, IoT also introduces cybersecurity risks. Compromised IoT networks could lead to false alarms and disabled safety mechanisms. A zero-trust security framework, AI-driven anomaly detection, and encrypted IoT communications are essential to ensure the resilience of safety-critical IoT applications.
As the industry moves forward, integrating IoT into safety strategies is essential. By prioritising both physical and digital safeguards, power companies can better protect their workers, enhance their operational efficiency, and shield their reputations.
