Generator Field Monitoring
Cutsforth has combined Premium Shaft Ground Monitoring and Rotor Flux Monitoring systems into one powerful Generator Field Monitoring system. By combining the functionality into a single platform, customers can achieve the benefits of both systems in one program integrated into InsightCM™ for better trend data and easier system management:
InsightCM captures and trends generator shaft voltage and current, in real time, automatically detecting shorted turns, or abnormal behavior while correlating with vibration and flux data for comprehensive generator health insight. The array of waveform and analysis tools in InsightCM for generator field monitoring includes:
Generator field monitoring is a condition-based monitoring approach focused on the rotor field winding and excitation system of a generator. These components are essential for producing the magnetic field required for power generation, and any degradation can directly impact generator reliability, efficiency, and output stability.
Field monitoring systems continuously measure key electrical and mechanical parameters such as field current, voltage, insulation condition, and ground faults. By analyzing this data in real time, operators can detect early signs of issues like insulation breakdown, winding faults, or intermittent ground conditions before they escalate into critical failures.
Cutsforth enhances this process through advanced sensing technologies and its InsightCM platform, delivering high-resolution data acquisition, continuous diagnostics, and actionable insights. This allows maintenance teams to shift from reactive troubleshooting to predictive maintenance strategies that improve uptime and reduce risk.
Cutsforth’s generator field monitoring solutions are engineered to provide deep visibility into one of the most critical and failure-prone areas of a generator system. Key benefits include:
Industrial operators choose Cutsforth because of its unique combination of domain expertise, advanced technology, and proven results in mission-critical environments.
With more than 30 years of experience in generator maintenance and excitation systems, Cutsforth brings unmatched insight into the challenges associated with rotor field performance. This expertise is embedded into every monitoring solution, ensuring accurate diagnostics and practical, actionable recommendations.
Cutsforth’s integration of high-fidelity sensing with the InsightCM platform creates a full-stack monitoring ecosystem that goes beyond simple data collection. Facilities gain a comprehensive understanding of generator health, enabling smarter maintenance decisions and improved operational resilience.
Additionally, Cutsforth’s commitment to innovation, supported by recent growth funding and strategic acquisitions, ensures that customers benefit from continuously evolving capabilities in predictive maintenance and machine health monitoring.
For industrial facilities where reliability is non-negotiable, Cutsforth provides a trusted, data-driven approach to protecting critical generator assets and maximizing performance.
The OEM usually provides nominal voltage and/or current expectations. “Normal” shaft voltage and current levels vary widely from generator to generator, even two of the same make and model. Establishing a baseline is crucial for proper analysis. We recommend running fresh grounding ropes on a clean shaft surface and monitoring your equipment for a month or so to determine the normal shaft voltage and current ranges for each of your units. From there, focus on the trending of those values. A departure from the normal voltage and current ranges you have established can be a strong indicator that maintenance is warranted.
The leading cause of increases in shaft voltage is a deteriorated shaft-to-rope contact, either by way of contamination or shaft surface deterioration. In cases like this, cleaning the shaft will typically lower the voltages back below the acceptance criteria. If a more aggressive cleaning is required, inquire with Cutsforth about a shaft stoning service. If you have any questions or concerns about the shaft voltage or current levels on your system, create a support request.
Yes, our shaft ground monitoring systems are compatible with Cutsforth grounding ropes.
Assurance Shaft Ground Monitoring: measures and displays in real time voltage, current, and ground rope status. Additionally, the system can pass the real time measurements to a DCS or historian. Premium Shaft Ground Monitoring: continuously measures voltage, current, and ground rope status. The system provides multi-level alarming and time domain waveforms for both voltage and current for analysis. Waveform analysis can detect a wide range of defects, including poor shaft conditions to overheating of the stator core.