Case Study

How VijAI AI is Powering Predictive Maintenance in Solar Plants & Substations

The renewable energy industry is evolving fast — and with that comes a new demand for zero downtime, maximum yield, and top-tier safety.Solar plants and substations operate across vast, remote areas where manual inspection is slow, inconsistent, and reactive.

PPEAI

Ensures all solar technicians and substation engineers wear the required safety gear before entering high-voltage or rooftop areas.

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FIREAI

Solar inverter rooms, transformer bays, and battery banks are fire-sensitive zones.FIRE AI identifies smoke, spark, or temperature changes instantly through visual sensors

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GESTEAI

Prevents distractions inside substations by detecting unsafe gestures like mobile phone use, inattentive movement, or careless walking near live equipment, busbars, breaker panels, or energized conductors.

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DRIVEAI

Monitors vehicle motion, reversing, speeding or rash driving in factory/logistics zones.

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ZONEAI

Monitors restricted areas such as high-voltage switchyards, transformer zones, or control rooms.

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PULSEAI

PULSEAI is a breakthrough module designed specifically for solar plant optimization.

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SAFEAI

Every violation is logged and visual evidence is stored for safety reviews and training.

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SECUREAI

Uses facial recognition and motion detection to prevent unauthorized access to control rooms, SCADA units, relay panels, high-voltage yards, and critical infrastructure areas—significantly reducing security and tampering risks.

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GUARDAI

Continuously checks substation equipment—like transformers, breakers, isolators, switchgear, and relay panels—to ensure all protective guards, covers, and interlocks are restored after maintenance. Prevents unsafe energization and operational hazards.

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VijAI AI uses advanced computer vision and deep learning to transform standard cameras into powerful maintenance and safety tools.It continuously observes panels, equipment, and people — interpreting visual data to raise smart, actionable alerts for every risk or anomaly

VijAI Impact Statistics

60%

fewer manual inspection hours

35%

increase in early fault detection accuracy

45%

reduction in maintenance-related safety incidents

50%

faster fault identification in solar panels

The Challenge

Arc Flash Risk in Electrical Environments

Workers entering high-voltage areas without correct Arc-Rated PPE

Difficulty in manually verifying compliance across multiple access gates.

Over-reliance on human supervision for PPE checks.

Limited visibility into real-time PPE compliance records

How It Works
*Visual Identification at Entry Points: CCTV or access cameras scan personnel approaching controlled areas.PPE AI identifies their clothing and gear in real time.
* AI Verification of Arc Flash PPE: The algorithm checks for the presence and color/type of arc-rated PPE (AR suit, gloves, face shield)
* Integration with Access Control Systems: PPE AI can interface with gate barriers, RFID badges, or smart gates, ensuring physical entry is permitted only when PPE verification is successful.

Why Substations Choose VijAI PPEAI
*AI-powered Arc Flash PPE Detection
* Instant Alerts for Unsafe Entries
* Zero Human Dependency for PPE Verification
* Seamless CCTV + Access Control Integration
* Global Compliance with NFPA, OSHA, IEC Standards
* Cloud Dashboard for EHS Audit Reporting

Conclusion
In high-voltage environments, seconds can mean survival. With PPE AI, substations and electrical utilities gain an intelligent guardian that never blinks — verifying every worker, every shift, every time.