Generator Field Monitoring

Comprehensive Clarity in Generator Health

Catch Rotor and Shaft Issues Before They Take Your Generator Offline

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Generator Field Monitoring System

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:

Failure Modes Detected

  • Poor shaft grounding
  • Bearing failure
  • Ground failure
  • Rotor insulation deterioration
  • Rotor imbalance

Customer Testimonials

“The shaft grounding systems are working very well right now. Thanks for the smooth installation and the support. Cutsforth is excellent and you have a very good reputation here.”

J.W.
Senior Engineer
SE Power Plant

“Cutsforth provided the high quality and individual detail that customers have learned to expect from a focused and dedicated subject matter expert. The close attention to detail resulted in our finding and repairing several other problems that could have been the root cause of past collector ring and brush problems.”

T.P.
Principal Engineer
Large East Coast Power Producer

"More informed replacement schedules optimize asset lifetime and performance, thereby reducing operational costs and business risk from unexpected failures."

Ethan Smith
EIT, Capital Planning Engineer
San Jose Water

InsightCM: Keep power flowing smoothly

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:

  • Pole-to-Pole Flux Variations
  • Maximum flux deviation
  • Shorted turns and percent deviation with an FDZC
  • System plots FDZC for each coil over time
  • Shaft voltage and current
  • Ground rope status.
  • Multi-level alarming
  • Voltage and current time-domain waveforms

Measurement Capabilities

Premium Shaft Ground Monitoring

  • Measures shaft voltage/current with waveform capture and advanced alarms
  • Uses patented braided copper ropes for high-quality grounding and data collection
  • Detects issues such as poor shaft contact, bearing and insulation failures, and ground-neutral faults

Rotor Flux Monitoring:

  • Detects early winding-insulation deterioration and rotor imbalances with high-speed sampling
  • Trends generator health over time using real-time and historical measurements
  • Provides early warning of worsening shorts and ground-fault conditions; installs easily without an outage

More information about our generator retrofit hardware

EASYchange Removable Brush Holders
Shaft Grounding Systems

Additional Resources

Tech Brief: Brush Failures and How to Solve Them
Flyer: Quick Guide to Hardware and Services
Webinar: A Conversation about Generator Field Monitoring

Shaft Ground Monitoring FAQs

What voltage and current readings should I expect on my generator?

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.

What should I do if my shaft voltage and/or shaft current exceed my established acceptance criteria?

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.

Do we need Cutsforth Shaft Grounding Assembly to implement Cutsforth Shaft Ground Monitoring systems?

Yes, our shaft ground monitoring systems are compatible with Cutsforth grounding ropes.

What are the differences among the Cutsforth Shaft Ground Monitoring systems?

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.