EASYchange® Brush Condition Monitoring

Never before possible Brush health analytics can now be delivered to the control room system and maintenance can be performed based on brush condition, rather than a calendar.

BRUSH MAINTENANCE, FOR THE DATA-DRIVEN WORLD.

Since 2001, Cutsforth™ has installed over 40,000 of the best-in-class EASYchange® brush holders on turbine generators worldwide.  Now, with our exclusive EASYchange® Brush Condition Monitoring, Cutsforth™ offers an even better way to operate your generator’s brush-type excitation. Brush health can now be delivered to the control room system and maintenance can be performed based on brush condition, rather than a calendar.

Automated measurements and brush health analytics allow plant operators to improve the efficiency of technicians’ daily and weekly tasks by dispatching them to the collector when maintenance is actually needed.

The Brush Condition Monitoring System is composed of a Cutsforth™ developed industrial data logger product known as the Brush Health Sensor (BHS), shown here installed on the EASYchange® brush holder, and a System Controller equipped with a touch-screen interface that compiles the data collected from several BHS units installed with the EASYchange® brush holders.

The patented hardware & technology processes and transmits the following data points over a 2.4 GHz wireless link to local displays as well as via MODBUS protocol into a plant’s DCS, Historian or National Instruments’ InsightCMTM system:

Most Recent Recorded Values:

  • Usable Brush Length (%)
  • Brush Vibration (Mils Displacement, Pk-to-Pk)
  • Relative Temperature (F or C)

Configurable Brush Health Alerts:

  • Brush Length Warnings
  • High Vibration

 

Historical Data Trending:

  • Wear Rate
  • Usable Length
  • Vibration
  • Peak Temperature

At the generator, the System Controller’s touchscreen user interface visually alerts users of short brushes and high vibrations, both based on plant defined thresholds.

This same critical data can also be relayed to the control room or historian reducing the number of unnecessary physical inspections.

For quick reference, brush health historical analytics are logged  by the system and available on the Brush Detail screen for each brush holder location.

Ultimately, the combination of recent and historical brush health analytics will improve operator efficiencies and optimize a plant’s staff utilization reducing operating expenses.

The data squares represent each individual brush of the system, providing relevant data and critical threshold warnings as shown.