Critical busbar joints and terminations are the "silent" risk centers of an industrial plant, where undetected loose connections or oxidation lead to overheating, catastrophic fire hazards, and unplanned downtime. Traditional reliance on periodic manual thermography often misses intermittent hotspots that develop between inspection cycles, leaving assets vulnerable and maintenance teams reactive. Our wireless, battery-powered solution provides continuous thermal surveillance at every critical junction, delivering real-time alerts that allow maintenance teams to drive proactive maintenance and intervene long before a thermal runaway event occurs
Continuous monitoring of high-voltage joints, terminations, and critical busbar junctions
Real-time visibility via thermal heat maps to identify hotspots before they escalate
Proactive alerts delivered via SMS and email to prevent equipment failure and fire hazards
Operational and safety improvements achieved through continuous thermal visibility
Upto 30% Less Unplanned Downtime
Detect thermal anomalies early to prevent sudden power failures and costly production halts across the facility
Automated Thermal Audits
Replace manual periodic thermography with 24/7 digital monitoring for consistent and reliable asset oversight
Mitigate of Fire Risks
Drastically reduce the threat of electrical fires and arc flashes by catching runaway events in early stages
Improved Personnel Safety
Minimize technician exposure to high-voltage zones by removing the need for manual scans on energized equipment
Solution Highlights
Key capabilities enabling early detection and proactive electrical maintenance
One-Stop Dashboard
Effective heat map interface to quickly visualize and analyze thermal data across the entire plant
Wireless & Self-Powered
Sensors require zero cabling and offer an industry-leading battery life of 4–5 years
33kV Line Compatibility
Engineered and tested to operate safely and accurately on high-voltage lines up to 33kV
Smart Proactive Alerts
Automated SMS and email notifications that trigger the moment thermal thresholds are breached
Standalone Architecture
Independent system operation requiring no complex interfacing with existing plant networks
Unique Engineering
A specialized, one-of-a-kind solution designed specifically for busbar thermal monitoring challenges
Why Faclon Labs
Core strengths that ensure reliable and scalable busbar monitoring deployments
End-to-End Implementation
Complete ownership from sensor installation to final user data delivery
Smart Design for 10+ Year Life
Hardware engineered for long-term reliability in harsh industrial settings
Proven Industrial Experience
Validated across cement, metals, and chemicals with multiple success stories
Prebuilt Analytical Dashboards
Ready-to-go tools for faster deployment and immediate thermal visibility
Customizable Site Reporting
Tailored configurations to align with specific plant and safety requirements
Dedicated Customer Success Team
Quality support ensuring high system upkeep and rapid organizational adoption
CASE STUDY - BUSBAR TEMPERATURE MONITORING
Preventing Catastrophic Failures: Thermal Monitoring for a Cement Leader
We implemented a real-time thermal monitoring system covering over 200 critical locations across 3 plants for a leading cement manufacturing company to replace infrequent manual thermography. This continuous digital safety net ensures high-voltage junctions are monitored 24/7 to identify overheating before catastrophic failure occurs. The system empowers maintenance teams with a centralized diagnostic hub to visualize power distribution health in real-time
5+ Major Anomaly Detections prevented potential fire hazards and equipment failures
Reduced Manual Audit Dependency for all critical high-voltage locations across sites
Ongoing Scale-up to additional locations across the group's assets is currently underway
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