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Motor Current Signature Analysis (MCSA)

One of several techniques for collecting data on the condition of an asset.



Purpose
The objective is:


Process
Listed below are the key steps in the MCSA process

      A. Before Analysis

  • Purchase equipment or engage contractors
  • Staff training on how to use the equipment
      B. During Analysis
  • motor current readings are recorded and analyzed in the frequency domain
  • In order to analyze the data, a Fast Fourier Transform (FFT) is performed
  • Test readings are compared with past levels, with significant change as an indicator of developing machinery faults.
  • Identify signals
  • Grade the results
      C. After Analysis
  • Report to stakeholders
  • Make decisions
  • Determine CAPA's, if any
  • Determine next assessment interval

Conditions & Condition Grades
Listed below are the condition grades for this technology

      A. Mechanical
  • Bearing fault detection
  • Belt problems
  • Coupler problems
  • Mechanical faults related to belts, couplers, alignment and more are easily found through the use of a demodulated current spectrum.
  • locating rotor faults in motors
  • Locating air gap problems in motors.
      B. Other





Attributes
Listed below are some of the key attributes of motor current signature analysis:

Evaluation
Listed belows are some of the pros:
  • A comprehensive monitoring program usually includes MCSA
  • Early detection can result in risk mitigation and cost savings
  • A relatively young technology that is not yet widely used
  • when it comes to belt and coupler problems, demodulation will give an earlier and often more accurate fault indication than vibration analysis. 
When belts or couplers begin to wear, it is often not noticed in a vibration spectrum until the fault is nearing catastrophic failure
Listed below are some of the cons:
  • Requires a capital investment in diagnostic eqiupment
  • Requires staff training


Candidate Assets
Listed below are some of the candidate assets for motor current signature analysis:
  • Induction motors
Ferrography as one of the predictive maintenance (pdM) technologies along the P-F Curve in relation to Potential Failure (P) and Functional Failure (F)
Fig. Motor current signature analysis as one of the predictive maintenance (PdM) technologies along the P-F Curve in relation to Potential Failure (P) and Functional Failure (F).



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