Machine condition monitoring

Machine condition monitoring (MCM) is a modular solution that integrates key monitoring functions into a single platform defined by the customers’ needs. Thanks to its modularity customers can use the solution for almost any kind of application, values, and in all areas where asset management is a priority.

It can be equally effective when implemented in large power plants with a couple of hundreds of MW installed and when installed in small and medium-sized plants.

Its state-of-the-art tools allow monitoring of all key elements and report crucial information to key stakeholders that can react promptly and protect their equipment. Together with our team the customers can define their own scope of monitoring and decide which features to integrate in order to focus on areas that bring the most significant process improvements.

System description

MCM meets the requirements of ISO 7919-5 and ISO 10816-5 and is applicable to all machine types. The main parts of the MCM monitoring system are:

  • Front edge consisting of measuring sensors and signal conditioners including processing/protection unit
  • Processing/protection unit with associated measurement modules
    • compact DIN rail designed system with the various I/O modules to form a space-saving industrial controller in the control cabinet
    • digital outputs are 2-level (alarm/danger-trip) relays with potential-free contacts available (NO&NC) for all measurements
    • the unit cabinet is delivered fully examined and tested according to the standard procedures and relevant standards
    • the processing unit in addition to measurement and data display through local touch screen enables the analysis of the measured results, diagnostic monitoring, alarm generation,
    • recording/storing measurement data, and communication with other systems
    • standard industrial protocols compatible with the existing power plant systems are used
    • insight into measuring data through local touch display (local HMI) and through the web server (web application)
  • Server computer – robust industrial computer intended to serve one or multiple local processing units of the monitoring system

Measured values

MCM monitoring system measures the following values, according to the Customers’ requirements with the sampling frequency 10 to 30 kHz:

  • Unit Vibration Monitoring System – relative shaft vibrations (relative to the bearing housing) and absolute vibration measurement
  • Process values measurement – process values are imported to the monitoring systems via standard communication protocols such as MODBUS, IEC 104, and others. The most common values to import are active and reactive power, generator currents and voltages, temperatures, and others.
  • Rotating speed – the measurement of one pulse per machine revolution
  • Air gap – monitoring of air gap nominal, max, min, and average values
  • Partial discharge monitoring – consists of 3 couplers per generator installed on the generator end winding and processing unit that analyses data collected from couplers installed outside the generator enclosure. Analyzed data is sent to other systems via standard communication protocol as well as through analog outputs (4-20mA).
  • Hydraulic values, shaft torsion, load angle and any other value that uses standard voltage or current input

Diagnostic system

Signal processing is performed by the processing unit. Standard calculations performed by the MCM system include:

  • Mean values calculations (RMS)
  • Events calculation
  • Alarm calculation (alarm and warning for each measured/processed value)
  • Calculation of max
  • Orbit calculation
  • Signal filtering
  • Spectral analysis
  • Rotating speed calculations

User screens supported

  • Orbit filtration
  • Orbit 2D and 3D (orbits on several planes)
  • Bar display
  • Transients display
  • Timeline (multi-plot)
  • Event (trend) representations (multi-plot)
  • Spectral display(2D and 3D)
  • Polar and linear representation for sensors of the air gap (minimum, maximum, average, rotor shape)
  • Real-time spectrum
  • Position of shaft center (on-line)
  • Position of shaft center in dependency of rotating speed
  • Trends (with restrictive class grouping)
  • Display of the system alarms (active, inactive, confirmed, unconfirmed …)
  • Shaft alignment


  • The complete solution for predictive maintenance and asset management of large machines
  • Flexible and modular integration with applications in the plant
  • Wide range of monitored parameters with fast processing of measured values
  • On-site and on-line access with remote monitoring from any location
  • Advanced elements for maximum protection of the assets
  • Early fault detection – detection of failures at an early stage and focus on critical machine parts with no special diagnostic equipment required
  • Smart trending – the unique feature uses advanced algorithms that predict point when a failure will occur, which makes it ideal for optimized maintenance planning
  • Automated reporting – with automated reports key insight into machine status which significantly saves their time

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