Switchyard Hotspot Temperature Real-Time Monitoring System

Overview

A leading private transmission & distribution (T&D) company in India is associated with the city’s public transportation network. Given its role, the reliability of electrical switchyards spread across multiple locations is of the utmost importance. Any unplanned downtime of critical switchyard assets will directly impact the transport operations, halting all operations and damaging the business’s reputation, while incurring substantial financial losses. Most cases of asset damage and unpredictability were a result of overheating during peak-load seasons, i.e., extreme summers and monsoons. Thus, to overcome these challenges, the T&D company sought to digitize its maintenance strategies and adopt Rugged Monitoring’s enterprise-level asset performance management (APM) suite, RM EYE.

The Challenge

The lack of real-time visibility and access to long-term historical data has left the T&D company unable to identify gradual degradation trends in hotspots.

High-Hotspot Density

Challenge to monitor and maintain hotspots spread across an entire ecosystem.
Manual Data Collection

Prone to errors, missed data, or incorrect inputs in unsafe or risky environments.
Lack of Predictive Visibility

Absence of real-time monitoring hindered timely and accurate decision making.
Safety risks

Increased risk of fires or explosions endangered personnel and violated safety regulations.

The Rugged Monitoring Solution

Rugged Monitoring implemented a non-intrusive, scalable monitoring architecture combining 3rd party system integration of an IR camera with our enterprise-level APM, RM EYE.

Multi-Hotspot Temperature Monitoring

Avoided the need to deploy multiple sensors for every hotspot, minimizing CapEx and OpEx.
RM EYE, Enterprise APM Suite

Actionable insights enabled predictive rather than reactive decision-making.
Dynamic Alarm Limits

Delivered context-aware alerts that improved operator trust and response times.
Low-Bandwidth Compatibility

Optimized communication across six sites without investing in new communications hardware.

The Outcome

Our integrated condition monitoring solution delivered measurable improvements in operational efficiency, asset reliability, and safety:

First-of-its-kind digital transformation project for switchyards in India.
35% reduction in maintenance costs
Improved data accuracy and decision-making
Centralized monitoring for optimized O&M strategies.

The project set a new standard for digital transformation in the power sector, demonstrating how scalable Industry 4.0 solutions can deliver cost savings, enhanced reliability, and improved safety in mission-critical infrastructure.

With RM EYE, the future of switchyard monitoring is no longer reactive; it is predictive, centralized, and efficient.

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