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Condition monitoring for rotating machinery

Faraday Predictive is a UK condition monitoring equipment supplier specialising in electrical signature analysis (ESA) for motors, pumps, fans, compressors and other motor-driven machinery.

Our systems catch developing faults weeks before they become failures, without fitting sensors to your equipment or stopping production to install. Because we read the motor’s own voltage and current from the switchroom, we can monitor assets other systems can’t reach: submerged pumps, hazardous areas and unmanned sites.

Choose permanent 24/7 monitoring with Inpod, portable spot checks with the P100, or an on-site diagnostic survey from our engineers.

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Quick find:

What our system does | Common faults | Remote condition monitoring | Systems and services | Industries | Why choose | How it works | Case study | FAQs | Speak to us

Developed alongside the UK’s leading mathematicians and engineers

mathematicians and engineers that develop alongside Faraday

What is a condition monitoring system?

A condition monitoring system tracks the health of machinery while it’s running, using measured data rather than fixed service intervals to decide when maintenance is needed. Instead of reacting to breakdowns, or replacing parts that still have life left in them, your team acts on the real condition of each asset.

Faraday Predictive’s systems use electrical signature analysis, also known as motor current signature analysis (MCSA). Our own method, Model-Based Voltage and Current analysis (MBVI), builds a model of how each machine should behave and flags deviations, using the motor itself as the sensor. Because the equipment connects at the switchroom rather than on the machine, installation is straightforward, needs no production stoppage, and works for assets that are submerged, inaccessible or in hazardous areas.

This is what makes condition-based maintenance possible: acting on the real-time state of an asset, not a fixed schedule.

What our condition monitoring system does

Our condition monitoring equipment is built to do more than flag that something is wrong. For each asset, the system:

Identifies and detects potential faults, and the underlying cause, not just the symptom

Tracks the rate at which an issue is developing, so you can see whether a fault is stable or worsening

Provides an estimated rate of deterioration, giving you a realistic timeframe for action

This lets you keep equipment running while planning maintenance properly, rather than reacting to a failure or guessing at a service interval.

The anatomy of a complete condition monitoring system

A complete condition monitoring system is more than a box of electronics. It combines four elements, and Faraday Predictive supplies all of them:

Where conventional systems rely on accelerometers and thermal cameras fitted to each machine, our MBVI technology captures everything from the motor’s voltage and current at the switchgear. The motor is the sensor.

The system builds a model of how each machine should behave and automatically flags deviations, identifying not just that a fault exists but what it is and how fast it is developing.

Dashboards, trends and alerts, accessible remotely by your whole team, on site or off.

Faraday Predictive engineers interpret the data, verify diagnoses and give prioritised, plain-English recommendations, so your team acts on conclusions, not raw signals.

This is why our customers treat condition monitoring as the foundation of their predictive maintenance programme: it converts machine data into maintenance decisions.

Condition monitoring techniques: how faults are found

There are five main condition monitoring techniques: vibration analysis, thermography (thermal imaging), oil analysis, ultrasound and electrical signature analysis (ESA). Most sites use a combination, matched to the asset and the faults that matter most.

Faraday Predictive specialises in ESA. It catches the electrical faults other techniques largely miss, such as winding, rotor and eccentricity faults, and picks up mechanical wear too. Because it works from the switchroom and runs continuously, it suits submerged, hazardous and hard-to-reach assets.

Technique Mechanical faults
imbalance, misalignment, bearing wear		 Electrical faults
winding, rotor, eccentricity		 Heat & thermal issues Lubricant condition No equipment fitted to the machine Continuous monitoring Works without physically reaching the asset
Vibration analysis ✓ ✗ ✗ ✗ ✗ ~ ✗
Thermography ✗ ~ ✓ ✗ ✓ ✗ ✗
Oil analysis ~ ✗ ✗ ✓ ✗ ✗ ✗
Ultrasound ~ ~ ✗ ✗ ✓ ✗ ✗
Electrical signature analysis (ESA)
Faraday Predictive		 ~ ✓ ✗ ✗ ✓ ✓ ✓
✓ Detects well    ~ Partial or indirect    ✗ Not applicable
Why MBVI shows a partial tick for mechanical faults: MBVI picks up mechanical faults such as imbalance, misalignment and bearing wear as they show up in the motor's current and voltage signature. For early-stage or low-severity mechanical wear, dedicated vibration sensors still offer finer resolution. MBVI's advantage is catching electrical and mechanical faults together, continuously, from one point at the switchgear, without needing sensors fitted to the machine itself.

Note on thermography and ultrasound: neither technique needs equipment fitted to the machine, both use handheld tools. However, a technician still needs to physically reach the asset to take a reading, with line of sight for a thermal camera or close proximity for an ultrasonic detector. That's why both are marked separately for working without physically reaching the asset, submerged, sealed or hard-to-reach equipment still needs someone there to scan it.

Where condition monitoring fits in a predictive maintenance strategy

Condition monitoring is the data layer. A predictive maintenance strategy is what you build on top of it, the decisions about which assets to monitor, how urgently to act on a warning, and how monitoring changes your wider maintenance plan.

Getting this right usually follows the same sequence:

Identify the assets that matter

Not every machine needs the same level of monitoring. Start with the assets whose failure would stop production, create a safety risk, or cost the most to repair reactively.

Choose the right monitoring approach per asset

Permanently installed systems like Inpod suit critical, always-on assets. Portable tools like the P100 suit periodic checks across a wider fleet. A one-off diagnostic survey suits assets you need answers on quickly.

Set thresholds and ownership

Decide what level of deterioration triggers a work order, and who acts on it. A predictive maintenance strategy only works if the data reaches someone with the authority to schedule the fix.

Feed results back into planning

Every fault caught early, and every false alarm, sharpens the next round of thresholds and asset priorities. A mature strategy improves with every cycle of data.

This is the same structured thinking behind reliability centred maintenance, and it’s why our diagnostic engineers work with you on the plan itself, not just the equipment. Monitoring hundreds of machines produces nothing useful without a strategy for what to do with what it finds.

Watch our condition monitoring system in action

A nice demonstration of how the Faraday Predictive system detects and identifies belt drive signals and responds very clearly to belt wear / loss of tension – and also to re-setting the correct tension. Just one example of how the software responds to each of the many faults it can detect.

Remote condition monitoring, from anywhere

Remote monitoring systems remove the need to be on site to know how your machinery is performing. Faraday Predictive’s remote condition monitoring connects your assets to a secure online platform, so equipment health, alerts and trends are available to your team wherever they are, whether that is the control room, head office or a phone at 2am.

Because our equipment mounts in the switchroom and uses the motor itself as the sensor, remote monitoring can be extended to assets that other systems cannot reach: submerged pumps, machinery in hazardous areas, and equipment on unmanned or difficult-to-access sites.

Our remote condition monitoring solutions are particularly valuable for:

  1. Unmanned and satellite sites. Water utility assets, pumping stations and remote installations can be monitored centrally without routine site visits.
  2. Multi-site operations. One dashboard covering rotating machinery across every plant, with consistent alerting and reporting.
  3. Hazardous and inaccessible equipment. Continuous insight into assets that are dangerous, disruptive or simply impractical to inspect manually.
  4. Stretched maintenance teams. Automatic alerts mean engineers investigate machines that need attention, rather than walking routes past healthy ones.

When a developing fault is detected, the system flags it with a clear diagnosis, giving your team time to plan the repair rather than react to a failure.

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Our condition monitoring systems and services

Our range of condition monitoring equipment covers every level of need, from permanently installed systems to portable instruments and one-off surveys.

Permanent and portable condition monitoring equipment

Permanent switchroom-mounted condition monitoring system – Inpod

The Inpod system provides continuous, online condition monitoring of motor-driven equipment. It detects mechanical, electrical and operational faults in real time and monitors energy consumption alongside asset health, helping you cut both downtime and running costs.

  • Compact design for easy installation
  • 24/7 condition and energy monitoring
  • No sensors required
  • Pricing from £3,250 + VAT
Learn More

Portable condition monitoring device – P100

The P100 is used for spot checks and survey routes. It gives your team a fast, reliable assessment of equipment health without permanent installation, ideal for periodic monitoring of less critical assets or for investigating suspect machines.

(Note: the P100 is for on-the-spot assessment, not continuous monitoring, data is only captured when it’s actively in use.)

  • Quick on-the-spot assessment
  • Portable and easy to use across multiple machines
  • Automated report generation
  • Pricing from £15,000 + VAT
Learn More

On-site diagnostic survey

Our engineers visit your site, assess your rotating machinery and deliver a clear report on the condition of each asset, with prioritised recommendations. A survey is an effective, low-commitment way to establish a baseline and identify problems that are already developing.

Condition-based inspection also supports your legal duties. Regular monitoring of work equipment helps demonstrate compliance with the Provision and Use of Work Equipment Regulations (PUWER) and the Health and Safety at Work Act, providing a documented record that machinery is maintained in a safe condition.

Learn More

Talk to us about your condition monitoring requirements.

Request a site survey

Condition monitoring services across a range of sectors

Faraday Predictive systems are monitoring rotating machinery across the UK’s most demanding sectors, from offshore platforms to pharmaceutical cleanrooms. Because our equipment installs at the switchgear rather than on the machine, it suits environments where fitting sensors is difficult, disruptive or dangerous.

Explore how condition monitoring works in your sector:

Companies we work with

companies that use Faraday Predictive

Why choose Faraday Predictive as your condition monitoring equipment supplier

Unplanned breakdowns cost UK manufacturers an average of 49 lost hours every year, time that directly hits production output, delivery commitments, and client relationships. Monitoring is only as good as the people reading the data.

1

A small, senior team

Spanning reliability engineering, maintenance engineering, mechanical, aerospace, electrical and software engineering, working closely with leading mathematicians in academia.

2

40 years of combined experience

Using motor current to assess the condition of rotating machinery, 20 years developing model-based analysis linked to that motor current data, and 10 years building what is now the Faraday system.

3

UK-based engineering support

No offshore call centres or long response delays

4

Selected by industry leaders worldwide

Our systems are in use across oil and gas, power generation, water, pharmaceuticals, manufacturing, marine and more.

5

ISO 9001 certified quality management

6

2026 ABB Startup Challenge Winner

Case study

Offshore platform saved £1M+ with early fault detection

Unexpected vibration issues threatened power generation on a critical North Sea platform. Vibration monitoring, Partial Discharge testing, and the manufacturers, has assessed the machine but not been able to pinpoint a diagnosis. The client turned to Faraday Predictive for a fast, date-drive diagnosis – and avoided costly downtime.

✔️ Identified rotor asymmetry using portable MBVI testing

✔️ Diagnosed turn-to-turn insulation failure without invasive inspection

✔️ Confirmed fault post-overhaul – saving >£0.5M in generator failure costs

✔️ Proved second unit was healthy – avoiding unnecessary £1M+ overhaul

See how smart diagnostics can save you millions…

Motor condition monitoring with MBVI technology

Most condition monitoring equipment relies on sensors mounted on the machine, which makes coverage expensive and leaves gaps between inspection routes. Our approach to motor condition monitoring is different. MBVI analyses the voltage and current signals already flowing to the motor, building a model of how the machine should behave and flagging deviations that indicate faults such as:

  • Bearing wear and lubrication problems
  • Misalignment and imbalance
  • Cavitation in pumps
  • Rotor and stator faults
  • Load and process-related issues in the driven equipment

Because the motor acts as the sensor, one system can cover large fleets of motor-driven assets at a practical cost, and monitoring continues 24/7 rather than only when a technician walks the route.

Condition monitoring as part of your maintenance strategy

Condition monitoring maintenance replaces guesswork with evidence. Rather than servicing equipment on a fixed calendar, or worse, waiting for it to fail, maintenance is triggered by the measured condition of the asset. The results our customers see include:

  1. Fewer unplanned stoppages and emergency repairs
  2. Lower maintenance spend, with work done only when it is needed
  3. Longer asset life
  4. Safer operations, with fewer interventions on live equipment
  5. Reduced energy waste from machines running in poor condition

Energy optimisation of rotating machinery

Our condition monitoring services extend beyond fault detection into energy performance. Developing faults, such as bearing wear, misalignment, or current imbalance, typically increase the electrical energy a motor draws to do the same mechanical work. Because our systems already measure the motor’s electrical signature, they can quantify this wasted energy directly, giving you a measurable, cost-justified case for action before the fault progresses further.

Our end-to-end energy optimisation service includes installation, training, data analysis, and ongoing support. Whether you’re in manufacturing, energy, or marine, we tailor the service to your specific maintenance goals.

Want to put a figure on what this could be worth to your site? Try our cost of downtime calculator →

Installing our condition monitoring system is simple

✔️ No hefty installation costs

✔️ Non-invasive – no sensors on machinery

✔️ Installed in switchgear, not on the machine

condition monitoring equipment

Results you can measure

Many of our customers experience improved reliability and energy savings within weeks. Whether you need a rapid solution or a long-term strategy, we deliver measurable results fast.

Still unsure? 

We believe in our system so much that we offer a FREE demo so you can see the value before you commit. There is no risk, just real, proven results.

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Book a free 10 minute chat

Here’s how it works

  • Step 1: Discovery Call & Quote
    Schedule a call to discuss your challenges, explore how the system will benefit you and receive your quote.
  • Step 2: Simple Installation
    By your own in-house electrical staff or your preferred electrical contractors
  • Step 3: Training & Onboarding
    We train your team so you can get the most from the system from day one.

You’ll start receiving actionable insights as soon as the day of installation, helping you identify inefficiencies and optimise operations from week one.

Non-invasive installation | Minimal shutdown requirement  | Actionable reports rapid impact

Case study

Long standing mystery in oil & gas solved with our portable condition monitoring system – P100

An operator of an offshore oil production platform had a problem with an emergency firewater pump failing to start properly. The issue had persisted for nearly a year and a team of experts had failed to diagnose the cause. With our help, and use of the P100, we were able to identify a mechanical problem allowing for them to plan a way forward.

✔️ Diagnosed in days – Quickly identified a fault where experts had failed for nearly a year.
✔️ Minimal intrusion, maximum insight – Used only voltage and current data. This makes our approach a cost-effective alternative to vibration condition monitoring, delivering results without complex hardware.
✔️ Portable & powerful – Utilised the compact P100 to assess complex offshore machinery.

Client Testimonial:
“We presented the findings to the asset leadership, and they agreed, with no further challenge. For me personally, the findings made perfect sense – it felt like all the various pieces of the puzzle suddenly fell into place.”

Frequently asked questions

Most condition monitoring suppliers, including SKF and Fluke, focus on vibration sensors fitted to each machine. Faraday Predictive uses electrical signature analysis instead, reading the motor’s voltage and current from the switchgear.

That means no sensors on the machine, continuous monitoring of assets that are submerged or in hazardous areas, and detection of electrical faults that vibration largely misses. Many sites use both: vibration for the finest resolution on critical bearings, and ESA for broad, continuous fleet coverage.

Electrical signature analysis, also called motor current signature analysis (MCSA), is a condition monitoring technique that diagnoses faults by analysing the voltage and current supplied to an electric motor.

Changes in these signals reveal electrical faults such as winding and rotor problems, and mechanical faults such as bearing wear, misalignment, imbalance and pump cavitation. Faraday Predictive’s MBVI method applies ESA continuously from the switchroom, using the motor itself as the sensor.

No. Our MBVI technology reads the motor’s existing voltage and current signals from the switchgear, so nothing is fitted to the machine itself.

A system is the equipment and software that collects and analyses the data. A service adds our engineers interpreting that data, verifying diagnoses, and giving you plain-English recommendations. Faraday Predictive supplies both together.

Pricing depends on the number of assets and the mix of permanent and portable monitoring you need. Inpod starts from £3,250 + VAT per unit; a full quote follows a short discovery call.

Installation is non-invasive and can typically be carried out by your own electrical team or contractors, with minimal shutdown required. Most sites start receiving insights from the day of installation.

Yes. Our platform gives your team access to equipment health, alerts and trends from anywhere, on site, at head office, or from a phone at 2am.

Critical rotating machinery where failure would stop production, create a safety risk, or cost the most to repair reactively, typically pumps, motors, fans and compressors.

Speak to an engineer

No two plants have the same critical assets, failure history or maintenance resources, so we do not sell a one-size-fits-all package. Every engagement starts by understanding which machines keep you awake at night, how they fail and what a failure costs you.

From there we recommend the right mix: permanent Inpod monitoring for critical assets, P100 spot checks for the balance of plant, and diagnostic surveys where you need answers quickly.

Hundreds of UK businesses trust Faraday Predictive to reduce downtime, cut costs, and optimise energy. See the results before you commit, free demo, no risk, real data. Tell us about your plant and the assets that keep you awake at night. We will recommend the right combination of condition monitoring systems and services for your operation.

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Book a free 10 minute chat