Artesis e-PCM — Generator and Wind Turbine Monitoring

Description

Artesis e-PCM (Electronic Plant Condition Monitoring) is a specialised system for monitoring generators and their prime movers. It uses patented sensorless technology — the generator itself becomes a complex sensor for faults in the turbine, engine or driven train.

Key features

Sensorless generator monitoring

• Generator as sensor — analyses generator output signals
• No extra sensors on the prime mover
• Real-time online monitoring 24/7
• AI algorithms — automatic fault classification

Applications

Wind turbines

• Main shaft bearings
• Generator bearings
• Gearbox (where fitted)
• Rotor imbalance
• Blade-related effects (indirect)

Diesel generators

• Engine mechanical faults
• Generator electrical issues
• Fuel system problems
• Cooling fan condition

Gas and steam turbines

• Rotor imbalance and misalignment
• Bearing wear and lubrication
• Coupling to generator
• Overall vibration-related stress

Detectable faults

Prime-mover mechanical faults

Fault	Early warning
Rotor imbalance	2–4 weeks
Misalignment	1–3 weeks
Bearing wear	4–8 weeks
Mechanical looseness	1–2 weeks
Gearbox defects	2–6 weeks

Generator electrical faults

• Stator winding looseness or shorts
• Rotor winding defects
• Load asymmetry
• Power-quality harmonics

Technical specifications

Measurement

Parameter	Value
Monitoring	Online 24/7
Inputs	3-phase generator voltage and current
Sampling	High rate (up to 10 kHz)
Frequency	50/60 Hz (application-dependent)
Rating	kVA to MVA

Communications

Interface	Description
Ethernet	TCP/IP
Modbus TCP	SCADA / PLC
Analog outputs	4–20 mA (optional)
Relay outputs	Alarm contacts (optional)
OPC UA	Optional

Installation

• DIN rail or panel mount
• 100–240 V AC/DC supply
• IP20 in cabinet; IP54 optional

Wind energy detail

Monitored components

1. Main shaft — bearings, rotor balance, coupling
2. Generator — bearings, windings, air gap
3. Auxiliary systems — pitch hydraulics pumps

Benefits for wind farms

• No sensors in the nacelle for prime-mover faults
• Fewer climbs and maintenance visits
• Early warning → planned instead of emergency stops
• Remote monitoring from control centre

Backup power (diesel gensets)

Monitored components

1. Engine — bearings, fuel, cooling fan
2. Generator — rotor, stator, excitation, AVR

Benefits

• Assured readiness when grid fails
• Automatic health checks during test runs
• Prevents costly critical-backup failures

Software

Artesis Cloud

• Fleet dashboard for all generators
• Trend analysis and alarms
• Email / SMS notifications
• Remote access and management reports

Control-system integration

• SCADA alarm levels
• PLC trip signals on critical faults
• DCS for large power plants

Advantages vs traditional vibration

Feature	Traditional vibration	e-PCM
Rotor sensors	Required	Not required
Nacelle access	Frequent	Reduced
Analog wiring	Long runs	Digital only
Installation cost	High	Lower
Generator electrical faults	Partial	Full coverage

Wind-farm ROI

• Lower OPEX — fewer technician visits
• Higher availability — less unplanned downtime
• Condition-based maintenance scheduling
• Extended asset life
• Improved safety — less work at height

Case example — wind farm

Site: 20 × 2.5 MW turbines

Challenge: High maintenance cost, bearing-related trips, expensive nacelle access

Solution: e-PCM on all turbines + central SCADA + cloud monitoring

Results:

Metric	Before	After
Unplanned stops	8/year	1/year
Maintenance visits	40/year	20/year
Failure cost	$200K/year	$25K/year
Availability	94%	98.5%
ROI	—	14 months

Package contents

Standard kit

• e-PCM monitoring unit
• Current transformers (3)
• Voltage measurement leads
• Mounting accessories
• Base software licence

Options

• DIN rail kit
• Outdoor IP54 enclosure
• Analog / relay output modules
• Extended cloud subscription
• SCADA integration kit