Oil and gas
Gas processing, oil sands and pipeline pump stations.
Drive-agnostic diagnostics for medium-voltage drives
Know before
it trips.
FaultAware connects to any brand of medium-voltage drive, reads the data the drive already holds, and shows live condition, active warnings and fault history for your whole fleet in one place. Read-only. On site. No internet connection.
- Drive makes
- Rockwell · ABB · Siemens · TMEIC · and more
- Connects by
- Modbus RTU · Modbus TCP · EtherNet/IP
- Access to the drive
- Read-only · no control-network path
- Cloud
- None. The module has no internet connection.
The problem
The most expensive hour in the plant starts with a drive.
Medium-voltage drives sit upstream of the crushers, pumps and compressors that run a continuous-process plant. When one trips, production stops, and diagnosis waits on the OEM.
The warning was usually already there.
Before most drive failures the drive had already said something: a ground-fault warning acknowledged by an operator, a trip reset from the control room, a temperature creeping up for a week. Nobody's job was to watch it.
Failures surface only at the trip.
The drive holds the warning signs, but nobody reads them between outages. The first signal the operator gets is the process stopping.
Every brand has its own tool.
Rockwell, ABB, Siemens and TMEIC each need their own software, training and vendor. Most sites run a mix, and nobody sees the whole fleet at once.
Cloud monitoring can't get in.
The sites with the highest downtime cost block anything that touches the control network or sends data off site. Most connected products fail the OT review before a pilot starts.
How it works
One module per drive. One view for every drive on site.
-
01 · Connect
To the drive's own communication port.
The module reads the data points every MV drive already produces. It works across makes and models, suits brownfield sites, and installs in hours during a normal maintenance window.
-
02 · Diagnose
Root cause in minutes, not days.
Live telemetry, active warnings with alarm help, and the full fault history, in plain language. During an outage your technicians start from the evidence instead of trial and error.
-
03 · Act
Decisions on data, not on the OEM's schedule.
The condition of every drive, compared with how the same drive behaves at the same load, in front of the people who plan the work. Fix it in a planned window, before it becomes a trip.
Diagnostics shortens the outage. Prediction prevents it.
Diagnostics is available today. Predictive fault detection is next: as the fault library grows, early warnings turn emergency trips into planned work orders, with remaining-life estimates and guidance on what to do.
Why FaultAware
Nobody else is watching the drive itself.
FaultAware watches the power stack, the DC-bus capacitors, the cooling and the control health of the drive, on every make in your fleet, without leaving the site.
| Approach | Watches the drive | Any make | Runs on site, no cloud |
|---|---|---|---|
| FaultAware | Yes | Yes | Yes |
| Drive OEM platforms | Yes | Their own drives only | Usually a cloud or managed service |
| Motor signature analysis at the MCC | No, the motor and its load | Yes | Usually a cloud or managed service |
| Partial discharge monitors | No, switchgear and windings | Yes | Yes |
Brownfield sites run mixed fleets. A single system of record across ABB, Siemens, Rockwell and TMEIC is the one thing no drive maker has a reason to build.
Security
Built to pass the OT review that stops most tools.
Designed from day one for air-gapped, OT-controlled sites. We will walk your security team through every connection before anything is installed.
- Read-only
- The module can only read the drive's data. It has no capability to write to the drive or change a setting.
- No control-network path
- Galvanically separate from plant networks. Nothing on the control network can reach it.
- No internet connection
- The module is not connected to the internet and needs no cloud. Analysis runs on site.
- Encrypted at the panel
- The technician's mobile app connects to the module over a short-range encrypted link, within reach of the drive only.
Why it matters now
Older drives, fewer experts, stricter networks.
The fleet is ageing
Drives installed in the 1990s and 2000s are deep into their service life. Failure rates climb just as replacement lead times stretch.
The experts are retiring
Skilled drive technicians are scarce. What they know about faults has to live somewhere the next crew can reach it.
Reliability budgets exist
Predictive maintenance is a standard line in heavy-industry operating budgets. MV drives are the asset it has not reached.
OT security is policy
Regulation and internal OT rules push sites toward air-gapped networks, which rules out cloud-only monitoring.
Industries
Where MV drives concentrate and downtime hurts most.
Mining
Mills, crushers, slurry pumps, fans and conveyors.
Water and wastewater
Aeration blowers, high-lift and influent pumps.
Also cement, pulp and paper, and marine.
Pricing
Quoted for your site.
For a pricing quote, contact us at [email protected]. Tell us how many drives you run, which makes, and where, and we will reply with a written quote.
See what your drives already know.
Send us your drive list, makes and models included. We will tell you what FaultAware reads from each one and how it fits your OT review.
- [email protected]
- Serving
- Canada and the United States
- Company
- FaultAware Inc., Hamilton, Ontario