Luca Del Nero

Managing Director at DarkWave Thermo - Condition Monitoring Hyperspecialist, International L3 Infrared Trainer.

1 really efficient method for the analysis of Electric Motors -

Motor Testing MCA with AT-PRO
August 24, 2016 • 11 recomendaciones • 1 comentario

I spent many years in manufacturing companies (food, chemical,

mechanical) and one of the most important topic, during our discussions
with the maintenance team, was related to electric motors.

The most applied testing methods were hands ("I feel it warmer than usual")
or big screwdrivers (" I believe that we need to replace the bearings").

From my point of view, as a great supporter of Predictive Maintenance and

instrumental controls, I was not in favour of such type of methods...well,
they were somehow working..."look-listen-hear", always used by paramedics
during first aid, work for electric motors as well...but my feeling has been
always "we need something more".

For bearing inspection I've always been a supporter of Shock Pulse analysis
systems (SPM Instrument) and vibration analysis. The missing part was a

simple, reliable, consistent and "indisputable" method to check the

simple, reliable, consistent and "indisputable" method to check the
electric part of the motors.

Because, despite being extremely "fashion", the Infrared Thermography

doesn't allow an early diagnose, in the majority of situations.

A couple of years ago I've discovered the Motor Testing techniques...in

particular, in this post, we will talk about the MCA technique (Motor
Circuit Analysis), also called "Motor Testing Off Line".

(Another technique is available, the ESA - Electrical Signature Analysis, also

called "Motor Testing On Line", but we will talk about it in more details in a
following post).

Since that moment I've understood the capabilities and the advantages of
this technique in terms of Cost Savings for the maintenance department.

In Italy and Europe this is a technique not so famous and "fashion",

differently from USA and Middle East, therefore I will try to explain briefly
how it works and which are the operating advantages.

Which are the advantages of the MCA technique? 

 

With the intensive use of this testing technique on the electrical motors
installed or stored in the spare part warehouse is possible to: 

find motors with deteriorated performance that will fail in the future;
assess the condition of a backup electrical motor (e.g. for a backup water
pump) before the re-start;
assess the condition of a spare electrical motor before the installation; 
assess the condition of an electric motor before and after the maintenance
(e.g. before and after the stator rewinding by an external supplier);
assess the condition of a brand new motor (that can be out of specs).

 
 

The test is performed with de-energized motor, without removing it from

its location. 

In practice this is a simple, quick and "portable" method that allows to

check, for AC and DC electric motors (but not only) the following aspects:

Electrical connection condition;

Water and/or lubricant contamination in the windings;
Global evaluation of the stator winding condition;
Short circuit evaluation inside the windings; 
Ground insulation; 
Rotor defects assessment; 
Efficiency loss due to impedance unbalance; 
Increased power consumption due to defective connections. 

Above all, very important, the test allows the control when the motors are
still in good condition or begins to have minor problems, therefore a lot
in advance compared to a voltmeter or a Megger...and leaving the motor in
place.
AL-TEST PRO MCA instruments 

 
How does the MCA test work? 

The test is really simple.

Through the injection of high frequency and low voltage current waves,
the system is able to detect the small anomalies in the system and
compare them with the limits defined by the applicable International
Standards.

This means that the test is extremely safe, both for the operator and the
motor.

 
How much time is required to perform an MCA test?
How much time is required to perform an MCA test?

The nice thing about the MCA test is that the test is simple and quick.

It is sufficient to de-energize the motor directly from the electrical

cabinet or from the junction box. Or the motor can be checked directly
in the spare part warehouse.

The technician assess the absence of power supply (to protect himself and
the instrument ) then connects the control cables following the instructions
given by the instrument itself.

The complete test is done in less than 10 minutes and produces an

analysis report that shows the motor conditions with clear
and exhaustive numerical values. 

Example of MCA Motor Testing report (available in English and other

languages)

 
For which electric machines the MCA test is useful?
The MCA test is able to evaluate the operating condition of the following
electric machines: 

AC/DC Motors (LV and MV), installed or stored in the warehouse (brand

new or repaired); 
Generators/Power units;
Servomotors (Brushless);
Instrument transformers;
Power transformers (including MV transformers).

 
Who supplies the Motor Testing service and where the instruments can be
purchased?

DarkWave Thermo, the company that I founded, is able to supply both the
service and the instruments, if the Customer would like to purchase its own
tools.

The ALL-TEST PRO instruments are imported in Italy by Easy Tool, located in

Fabriano (AN). We're proud to be their technical and commercial partners.  

We can supply the testing services worldwide and the instruments in Italy
and other European countries (check with us how and where).

You can find us on:

www.darkwavethermo.com

Escrito por
Luca Del Nero
Managing Director at DarkWave Thermo - Condition Monitoring Hyperspecialist, International L3 Infrared Trainer.

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