Phosphate Mining Operation Enhances Electrical Safety and Reliability with IRISS Infrared Windows

Executive Summary

A major phosphate mining operation in the U.S. faced challenges maintaining its 4,160V high-power electrical equipment, including sled-mounted motor/pump systems and motor controller speed drives. Traditional inspection methods posed safety risks and were not sustainable for condition-based maintenance (CBM).

Partnering with Connected Power Phosphate Services, the mine deployed CAP-ENV Series infrared windows from IRISS to enable safe, closed-panel thermal inspections. These rugged, large-format IR windows allowed for real-time monitoring of cable terminations, starter capacitor terminals, and motor brushes, improving safety and reliability. Following a successful pilot, the mine expanded installations across fourteen sled systems, eliminating previous failures associated with round crystal IR windows.

Challenge: Harsh Conditions and MSHA Compliance Needs

Phosphate mining operations rely on high-voltage (4,160V) electrical systems to pump slurry from excavation sites to processing plants. Maintaining these systems presented several challenges:

• Operational Risks: The mine’s 1,500 HP motor/pump systems operate at dangerously high voltages, requiring safer inspection methods.
• Safety & Compliance: Mining regulations (MSHA) require visual confirmation of disconnection from short-circuit protection devices.
• Equipment Vulnerability: Previous round crystal IR windows failed under harsh conditions, suffering vibration damage and early degradation.
• Inspection Limitations: Performing thermal scans under load required opening panels, exposing personnel to arc flash hazards.

The mine needed a durable, long-term solution to enable safer, more efficient thermal inspections without compromising system integrity.

Solution: CAP-ENV IR Windows for Safer Mining Inspections

Connected Power Phosphate Services, an IRISS channel partner, recommended the installation of CAP-ENV Series IR windows to enable closed-panel infrared inspections across the mine’s electrical systems.

Key Features of the IRISS Solution:

• Large-Format Inspection Access – CAP-ENV-12 windows were installed on the motor starter housing, allowing infrared inspection of main cable leads and motor brushes.
• Expanded Coverage – CAP-ENV-24 windows were mounted on incoming cable termination chambers, providing visibility into main cable terminations and starter capacitor terminals.
• Compliance with Mining Regulations – IR windows enabled visual confirmation of disconnection, satisfying MSHA requirements.
• Engineered for Harsh Environments – NEMA 6 / IP67-rated stainless steel construction resists moisture, shock, and vibration.

Lifetime Reliability – Unlike competitor products, IRISS’s patented polymer optics maintain fixed and stable infrared transmission (FAST), ensuring consistent performance over time.

The initial installation covered six IR windows per motor/pump skid and an additional five IR windows on motor controller skids. IRISS worked closely with the installation team to modify designs for mounting on ¼-inch steel motor housings, ensuring a seamless fit.

Outcome: Improved Reliability and Regulatory Compliance

The IRISS CAP-ENV Series provided an immediate improvement in inspection efficiency, equipment reliability, and safety.

Key Results:

• Enhanced Safety – Infrared inspections are now conducted with panels closed, reducing arc flash risks.
• Improved Equipment Reliability – The 14 installed sled systems now undergo regular condition-based maintenance, preventing unexpected failures.
• Long-Term Durability – Unlike previous round crystal IR windows, which failed within months, IRISS polymer-based windows have had zero issues over two years.
• Regulatory Compliance – The solution fully meets MSHA safety requirements for visual electrical inspections.

Ralph Durance, President of Connected Power Phosphate Services, emphasized the project’s success: “The mine was so happy with the first sleds that they quickly agreed to roll this out on a wider basis. IRISS has been great to work with, making design modifications to install these units—especially when mounting to a ¼-inch steel plate. We have had zero issues with the IRISS products since we started this program two years ago.”

Key Takeaways

Phosphate mining operations require rugged, reliable inspection solutions for high-voltage equipment.

IRISS CAP-ENV Series infrared windows provide safer, more efficient thermal monitoring while eliminating maintenance risks.

Harsh mining environments demand durable, long-lasting solutions—IRISS polymer optics outperform traditional round crystal IR windows.

Following a successful rollout, the mine continues to expand IRISS solutions across its fleet.

Looking for a safer, more reliable way to inspect electrical assets? Contact IRISS today to learn more about our customized industrial inspection solutions.