STERLING DamShield AI™
Dam safety instrumentation and analytics in one dashboard: deformation, seepage, pore pressure, settlement and reservoir levels. Early abnormality alerts help dam owners act before a structural or flood event.
AI Based Solutions · Designed and made in Nagpur, India
AI Based Solutions for predictive maintenance
Wireless sensing, machine analytics and early-warning software for power plants, substations, dams and process plants. Our flagship STERLING BusbarGuard AI™ watches electric busbars continuously, backed by more than 200 completed electrical and automation projects across India.
AI Based Solution · Flagship product
STERLING BusbarGuard AI™
Wireless Temperature Monitoring System for Electric Busbars — Predictive Maintenance
Predictive maintenance for electric busbars, joints, cable terminations and switchgear. Clip-on wireless temperature sensors, STERLING gateways and analytics turn a rising busbar temperature into a planned maintenance job — long before a flashover.
Wireless temperature sensor — STERLING SET-WTS-01
See the hot joint weeks before it fails
Loose connections, ageing contacts and overload raise busbar temperature long before a flashover. STERLING clip-on sensors sit directly on the live busbar, report every few minutes and turn a rising trend into a planned maintenance job — not an outage. One system, from sensor to alarm: STERLING BusbarGuard AI™.
- Clip-on sensor for LT and HT joints — no wiring, no external supply
- 10-year battery, IP67 sealed, 2.4 GHz self-healing mesh
- One gateway collects up to 500 sensors over 500 m
- Trend, rate-of-rise and phase-difference alerts
- SCADA (Modbus TCP, IEC 61850, OPC UA) and cloud dashboard
- Every sensor and gateway carries the STERLING nameplate
Range−40 to 150 °C
Accuracy± 1 °C
Radio2.4 GHz mesh
Battery10 years
ProtectionIP67
Per gateway500 sensors
200+government & private projects completed
100 mlocal wireless sensor range
Electric busbarjoints, terminations and switchgear
24 × 7continuous predictive monitoring
More AI based solutions
Other AI based solutions from STERLING
Each solution combines the sensors, gateways, PLC/SCADA integration and analytics we supply ourselves — so one team owns the instrument, the data and the alarm.
STERLING StructureShield AI™
Structural health for dams, bridges and buildings using GNSS, inclinometers, crack gauges and vibration sensors. Asset owners get a live health index and a clear inspection priority instead of periodic manual surveys.
STERLING GridSentinel AI™
Transmission tower tilt, displacement and vibration monitoring for lines in mining, flood and landslide zones. Maintenance teams receive condition-based alerts before a tower leans, settles or fails.
STERLING AshShield AI™
Ash bund and embankment safety: settlement, slope movement, seepage and ground deformation. Built for thermal plants that must keep ash dykes stable through monsoon loading and continuous ash deposition.
STERLING MotorShield AI™
Motor current signature analysis combined with vibration and temperature analytics. Bearing, rotor and misalignment faults are flagged weeks before a forced outage, so the motor is repaired on a planned stop.
STERLING VibraShield AI™
Turbine and rotating-machinery vibration surveillance with AI anomaly detection for turbines, pumps, fans and blowers. Protects critical machines and reduces unplanned trips with early warning of changing vibration signatures.
STERLING LifeShield AI™
Gas detection and personnel safety for H₂S, NH₃, CO, Cl₂, CH₄ and oxygen deficiency, integrated with PLC/SCADA alarms. Protects confined spaces in water, sewage, chemical and process plants with live readings and escalation.
STERLING PumpShield AI™
Pump and utility monitoring in one view: flow, pressure, power, runtime and equipment condition. Identifies inefficient pumping and failing bearings before they stop supply, and shows the energy cost of every duty point.
STERLING AquaShield AI™
Water and wastewater process analytics integrated with quality and process instruments. Tracks loss, dosing, energy per kilolitre and early process drift across WTP, RO and STP plants.
STERLING HeatWise AI™
Power-plant performance and heat-rate analytics for boiler, turbine and efficiency improvement. Shows where each unit loses heat, which parameter moved first, and what to correct for the next operating cycle.
STERLING AssetShield AI™
Transformer, switchgear and substation monitoring: temperature, load, alarms and a health index for every asset. Prioritises maintenance across the whole substation instead of reacting to the loudest alarm.
STERLING BusbarGuard AI™
Our wireless busbar thermal-monitoring product: clip-on sensors, STERLING gateways and predictive alerts before a joint fails. Part of 200+ government and private electrical & automation projects completed.
GridSentinel AI · product tour
See tower intelligence in action.
A 96-second walkthrough of the STERLING GridSentinel AI dashboard: tower tilt and vibration, sensor and gateway health, live event timeline and early-warning alerts. The same interface runs on the hardware we install in the field.
- Tower tilt, vibration and wind in one view
- Sensor, gateway and battery health
- Event timeline with alert escalation
STERLING
GridSentinel AI product tour · 1 min 36 s · 1080p · simulated data
Want this running in your plant?
Send us your single-line diagram, dam or plant equipment list - we will propose the sensors, gateways and dashboards.