New condition-monitoring service from ABB

Service for large induction motors offers early warning against motor failure

A new condition-monitoring service for large induction motors, which can detect potential motor failure well in advance, has been introduced by ABB.

Called ABB MACHsense-P, the service can spot trouble with bearings, rotor winding defects, imbalances, internal misalignments and voltage abnormalities, providing an early-warning to plant engineers, thereby saving costly downtime.

The service provides: accurate diagnosis; reports quickly, with a summary delivered on-site; includes integrated analysis for current, voltage and vibration; rates defects clearly, by severity; recommends specific repairs; considers machine design in judging defect severity; reduces unplanned downtime; and issues early warnings, allowing time for planning maintenance.

The key to this is ABB's software, which accurately analyses vibrations and other data collected from the motor. ABB's analysis system uses algorithms that pick out specific signals. If users are concerned about bearings, the system can isolate the signals coming from the bearings.

Technicians at ABB service centres in 35 countries, including the UK, are now trained to use ABB MACHsense-P. The technician attaches sensors to the motor being tested at the customer’s site. Certain sensors, using accelerometers, convert vibrations into electrical signals. Others measure electrical data. The signals are picked up by a data collector, which is in turn connected to a laptop. In one day, a technician can usually test between four and six motors.   

The customer immediately receives an on-site summary of the motor’s performance, which is presented as a colour-coded report rating four key areas: anti-friction bearings, cage rotor, installation and power supply. Later, following extensive analysis by experts, the customer receives a more detailed report for those motors highlighted in the initial site summary as being of concern. 


MACHsense-P service is available in one of two ways. A ‘standard’ service comes as part of a regular six-month maintenance plan, while ‘advanced’ service refers to a one-time intervention to troubleshoot a specific problem.

Next year ABB plan to expand the service from large induction motors to synchronous motors and wind generators.

For further information on this service in the UK please contact 01480 488080 or e-mail [email protected]