A power plant uses electrical signature analysis for performance assessment.
In this All Test-Pro case study, a power plant used Electrical Signature Analysis (ESA) to investigate performance issues in aging water pump motors by measuring voltage and current signals to assess both electrical and mechanical conditions of the entire system.
The analysis revealed that the motors themselves were functioning properly, but identified turbulence in the water flow as the root cause of poor pump performance—something other diagnostic methods had missed.
Pump performance issues identified in aging system
ESA used to assess full motor and pump condition
Motors found electrically and mechanically sound
Turbulence detected as root cause of poor performance
Issue was missed by other diagnostic methods
ESA enabled targeted corrective action
Highlights value of predictive maintenance and combined diagnostics
Key Takeaway:
Electrical Signature Analysis (ESA) can detect hidden performance issues across the entire motor-driven system—even when both electrical and mechanical components appear healthy—making it a powerful tool for identifying root causes like flow turbulence and improving predictive maintenance.
Quick Diagnostics That Save Time and Money: The Value of 3 Minutes of Motor Failure Testing
This All-Test Pro article highlights a hospital motor failure where initial basic testing pointed to the drive as the issue.
After replacing the drive without resolving the problem, a motor circuit analysis test quickly identified an internal motor fault, demonstrating how proper, fast diagnostics can prevent unnecessary costs, downtime, and repairs.
In just 3 minutes, testing revealed an internal phase fault that standard tests missed.
The hospital incurred unnecessary costs (VFD replacement, crane rental, downtime).
Proper motor circuit testing can quickly identify real faults and prevent costly misdiagnosis.
Key message: A few minutes of advanced testing can save significant time, money, and downtime.
Key Takeaway:
Spending just about 3 minutes using a proper motor diagnostic tool like Motor Circuit Analysis (MCA) can identify the real cause of a motor failure—saving significant time, money, and unnecessary equipment replacements. In the case study, basic tests misled technicians and led to a faulty VFD replacement and costly motor removal, whereas a quick MCA test pinpointed the actual motor fault right away.
Yellotec offers advanced services in Motor Circuit Analysis (MCA) and Electrical Signature Analysis (ESA) to ensure the reliability of your electric motors, transformers, and generators.
Electric motor testing services are essential for maintaining the success and efficiency of your equipment. Utilizing innovative cutting-edge technology, Yellotec’s expert team conducts measurements from Motor Control Centers (MCCs), isolators, and Variable Frequency Drives (VFDs).
Yellotec recommends Regular Motor Circuit Analysis (MCA) and Electrical Signature Analysis (ESA) for critical motors in use; spare motors in storage; electrical motors that frequently stop/start, electrical motors in harsh environments; and electrical motors with known issues.
Proudly partnered with ALL-TEST Pro’s electric motor testing equipment, Yellotec delivers comprehensive motor health analyses that surpass standard testing methods, ensuring long-term dependability.
Contact Yellotec today for advanced motor testing solutions to keep your equipment reliable and efficient.
Detected Failure Modes:
Turn-to-Turn Faults
Coil-to-Coil Faults
Phase-to-Phase Faults
Insulation Failures
Open Phases
Contamination
Faulty Connections
Broken or Cracked Rotor Bars
Casting Voids
Rotor Eccentricity
Ground Faults
Cable Faults
Service Recommendations:
Regular Motor Circuit Analysis (MCA) and Electrical Signature Analysis (ESA) are recommended for:
Critical motors in use.
Spare motors in storage.
Electrical Motors that frequently stop/start.
Electrical Motors in harsh environments.
Electrical Motors with known issues.
Contact Yellotec today for advanced motor testing solutions to keep your equipment reliable and efficient. Book your service today by filling in the form below:
Visit our stand at Electra Mining 2024: Showcasing Yellotec’s Machine Health and Reliability Solutions.
Yellotec strives to offer the most effective and efficient technology in all machine health and reliability monitoring equipment. We are excited to announce our participation in the Electra Mining 2024 event, taking place from 2 – 6 September 2024 at the Johannesburg Expo Centre. This premier mining, industrial, construction, and electrical trade show provides a unique platform for industry leaders to showcase cutting-edge technologies, solutions, and services.
At Electra Mining, Yellotec will present its latest innovations and demonstrate how our solutions can help clients improve efficiency, safety, and sustainability in their operations. We invite all attendees to visit our booth and learn more about how our solutions can meet the evolving needs of the mining and industrial sectors. For more information or to schedule a meeting with our team at the event, please contact info@yellotec.com.
Ranked as one of the world’s largest mining shows and the biggest mining, manufacturing, automation, electrical, and power trade show in Southern Africa, Electra Mining Africa has a proven track record of driving sales, generating leads, and building brand awareness. They say the trick to seeing the future is knowing where to look. With nearly five decades of accumulated experience since its inaugural show, Electra Mining Africa has built a reputation for being a trade show that adapts to changing times and consistently delivers a strong return on investment for exhibitors, even during challenging economic conditions.
Join the Yellotec Webinar and learn how advanced Electrical Motor Testing and Analysis helped a Petrochemical Plant identify potential failures caused by stator looseness.
Motor Circuit Analysis enables easy detection of pending equipment failure and root causes. Unplanned downtime can be extremely costly, with potential losses reaching up to $22,000 per minute.
Date and Time:
Thursday, 15 August 2024
14h00 SAST
Recording and Presentation will only be available for Registered Participants
Agenda:
What is Motor Circuit Analysis
Why do Motor Circuit Analysis
New Technologies for Motor Circuit Analysis
Case Study: Detecting Stator Looseness
Q&A Session
Join industry-leading speakers from Yellotec and ALL-Test Pro to gain expert insights into the latest advancements and practical applications in motor diagnostics. This session is designed for professionals seeking to enhance their understanding and skills in Motor Circuit Analysis (MCA) and Electrical Signature Analysis (ESA) to improve reliability.
Featuring Panel of Speakers:
Reynhard Heymans // Yellotec
Reynhard Heymans, as a young electrical engineer, was introduced to Thermal Imaging Cameras in 1997 by the legendary Tjaart Broodryk.
Over the subsequent 18 years, his ardor for Condition Based Maintenance became evident through its diverse applications, encompassing electrical, mechanical, refractory, enterprise risk management, and more. In 2016, he earned a Masters Degree in Business Administration, strategically positioning himself for a transition into New Business Development. Throughout his career evolution, he has maintained valuable partnerships with prominent Global OEM companies like Atten2, Teledyne FLIR, FLUKE Reliability, and other. Even after more than 25 years, Reynhard Heymans continues to be driven by a passion for pioneering tools and methodologies aimed at enhancing overall equipment effectiveness and reducing operational costs for his clients.
Riaan Greeff // Vaal University of Technology
Mr. Riaan Greeff – Vaal University of Technology, Consultant to Specialised Equipment and Technology Solutions (Pty) Ltd. (SETS)
Born in Umtata, Transkei, in 1973, Riaan Greeff has been passionate about electrical and electronic technology since childhood. He excelled in Technical Electronics in high school and earned his B.Tech in Engineering with honors from Vaal Triangle Technikon in 1995.
Mr. Greeff has worked at the Vaal University of Technology since 1996, supporting research and innovation in electronic engineering. Over his 27-year career, he has held roles as a technician, lecturer, consultant, and examiner, and served as Coordinator for the French South African Schneider Electric Education Centre (F’SASEC).
Currently, Mr. Greeff is a Master of Engineering candidate at the University of Johannesburg, focusing on the statistical analysis of circuit breakers.
In the realm of motor diagnostics, two standout tools are revolutionizing the industry: the ATPOL III™ Power Quality and Motor Analyzer and the ALL-TEST PRO 7™ Professional.
These devices offer unparalleled capabilities for ensuring the health and efficiency of motors, transformers, and generators, making them indispensable for industrial maintenance and reliability professionals.
ATPOL III™ Power Quality and Motor Analyzer
Dual Functionality: Acts as both a Power Quality Analyzer (PQA) and Electrical Signature Analyzer (ESA).
Rapid Testing: Delivers comprehensive assessments in just 60 seconds.
Data Logging: Extensive data tracking, including energy usage, harmonic analysis, and voltage/current charting
Early Fault Detection: Identifies issues early to prevent motor failure.
Versatile Analysis: Evaluates incoming power, control circuits, and driven loads.
Robust Software: ESA software for tracking, trending, and reporting motor conditions.
High Compliance: Meets CAT III 1000V and CAT IV 600V safety ratings.
Comprehensive Testing: Assesses both electrical and mechanical efficiencies of AC/DC motors, generators, and transformers.
ALL-TEST PRO 7™ Professional
Comprehensive Testing: Suitable for AC and DC motors, generators, and transformers.
Quick and Efficient: Conducts tests in less than 3 minutes.
Advanced Troubleshooting: Features like the Z/θ Test for identifying specific motor issues.
Condition Monitoring: Allows continuous monitoring and trending of motor health.
Patented Technologies: Uses TVS™ and Stator and Rotor Signatures™ for precise diagnostics.
Multi-functional Analysis: Detects a variety of faults, including stator, rotor, ground, winding faults, and open connections.
Why These are Essential:
Both ATPOL III™ and ALL-TEST PRO 7™ Professional are designed to enhance productivity, ensure safety, and provide accurate diagnostics. They are built to withstand industrial environments, making them ideal for field and on-site applications.
By incorporating the ATPOL III™ and ALL-TEST PRO 7™ Professional into your maintenance toolkit, you ensure that your motors and electrical equipment are in optimal condition, reducing downtime and improving overall efficiency.
Yellotec offer a comprehensive range of products and services for Motor Circuit Analysis, Electric Motor Testing, Electrical Signature Analysis, and other.
The Rotor Fault Zone is part of the Six Fault Zones approach to access your motor’s condition.
The Rotor Fault Zone refers to the condition of the rotor bars, rotor laminations, and end rings. Although only a small percentage of the motor problems, rotor faults can influence other fault zones to fail.
This article from PdMA covers the Rotor Fault Zone in better detail.
Listen to Todd Gunderson the Vice President of Sales and Marketing for PdMA Corporation as describes how the MCEMax is an essential technology to help in the detection of Rotor anomalies
Listen to Noah Bethel and Todd Gunderson as they walk you through their latest case study showing the MCEMax finding a Wound Rotor Motor fault
Need a recap on all six fault zones?
Read our previous article with PdMA’s David L. McKinnon white paper that provides a brief introduction to a Six Fault Zone approach for predictive maintenance on motors.
To confidently report the electrical condition of a motor, there are six areas of interest known as Fault Zones that must be looked at during the troubleshooting effort.
These Fault Zones are Power Quality, Power Circuit, Stator, Insulation, Rotor, and Air Gap.
Power Quality: Quality of the voltage and current
Stator: Turn-to-turn insulation and internal coil connections
Air Gap: Quality of the air gap between the rotor and the stator
Insulation: Winding to ground insulation
Rotor: Health of the rotor cage and laminations
Power Circuit: Circuit supplying power to the motor
This insightful white paper by PdMA’s David L. McKinnon will provide a brief introduction to a Six Fault Zone approach for predictive maintenance on motors.
