Condition monitoring for power generation industry

Power generation downtime prevention & predictive maintenance

The power generation industry relies on dependable, predictable operation. Any unexpected downtime can result in lost revenue, penalties for contract non-compliance, and operational disruption. Efficient maintenance and operation are critical, especially as margins are tighter than in other industries.

Condition monitoring systems for power generation allow early fault detection, enabling operators to move from reactive maintenance to predictive maintenance, reducing downtime and protecting both revenue and asset life.

Particularly valuable applications include monitoring “balance of plant” equipment that is often inaccessible or difficult to measure, such as:

1. Forced draft fans, induced draft fans, cooling fans
2. Combustion air fans
3. Vertical-axis cooling water pumps
4. Lubricating oil pumps and fuel pumps

By monitoring these assets with Faraday Predictive MBVI systems, operators can detect developing faults before they impact output, reducing operational risk.

Why condition monitoring matters in power generation

Condition monitoring for power generation assets is about more than avoiding failures. It improves operational resilience and decision-making, supporting:

1. Downtime reduction – early detection prevents unplanned shutdowns
2. Maintenance optimisation – transition from time-based to predictive maintenance
3. Cost control – reduce emergency maintenance, fines, and lost production
4. Extended asset life – prevent hidden faults from escalating

Even where main generators and turbines are already well-monitored (e.g., proximity probes on main bearings, Bently Nevada systems), Faraday MBVI systems provide an additional perspective, monitoring electrical and mechanical phenomena in ways vibration sensors cannot.

Extending coverage to hard-to-monitor assets

Modern MBVI systems can be deployed across assets that are difficult, hazardous, or expensive to monitor:

• Generators in switchgear-equipped areas
• Pumps and fans located in restricted or wet environments
• Wind turbine generators and associated gearbox output

Installation is simple and safe:

• Connection using split-core CTs from secondary circuits of existing CTs/VTs
• Can often be done at ground level, avoiding work at height
• Fully switchroom-mounted, avoiding ATEX and hazardous area complications

Overcoming traditional challenges in power generation monitoring

ATEX & hazardous areas
Switchroom-mounted systems avoid the complexity and compliance costs associated with hazardous-area installations.

Cabling and installation costs
Large power stations often require long sensor cable runs. Installing monitoring hardware within the switchgear dramatically reduces cable lengths, labour, and costs.

Wireless limitations
Battery-powered wireless sensors often have short lifespans, signal attenuation, and low data capture rates. Faraday systems are permanently powered, enabling continuous 24/7 monitoring without compromise.

Typical power generation assets benefiting from MBVI condition monitoring

1. Steam turbines and gas turbines
2. Main generators
3. Cooling water pumps (vertical-axis, submerged)
4. Lubricating oil pumps, fuel pumps
5. Forced draft fans, induced draft fans, combustion air fans
6. Wind turbine generators and gearboxes

Early detection of developing faults on these assets can significantly reduce downtime and operational risk.