Smarter Machines, Lower Costs
How Electrical Signature Analysis detects faults, prevents failures, and quantifies energy savings across 10 industries — without a single shutdown.
Unplanned Equipment Failure Is More Expensive Than You Think
Traditional vibration monitoring misses electrical root causes and cannot quantify energy waste. There is a better way.
The Motor Tells Its Own Story
ESA captures voltage and current waveforms at the motor control panel using clamp-on current transformers. The magnetic air gap between rotor and stator acts as a non-contact transducer — every bearing defect, gear fault, and belt slip creates a unique signature in the current spectrum.
No shutdown. No disassembly. No physical contact with rotating parts. One 30-minute measurement gives a full health picture of the motor and everything connected to its shaft.
12 Fault Classes. One Measurement.
| Fault Type | Detection Signal | Risk |
|---|---|---|
| Broken / Cracked Rotor Bars | MCSA sideband dB vs. line frequency (f ± PPF) | HIGH |
| Stator Winding Short Circuit | VSA + CSA three-phase imbalance + 3rd harmonic | HIGH |
| Static Eccentricity | Rotor bar harmonics ± LF and 2LF sidebands | MEDIUM |
| Dynamic Eccentricity | Rotor bar harmonics ± LF, 2LF + running speed sidebands | MEDIUM |
| Bearing Defect – Outer Race (BPFO) | Current modulation at outer race defect frequency | HIGH |
| Bearing Defect – Inner Race (BPFI) | Current modulation at inner race defect frequency | HIGH |
| Gear Mesh Anomaly | GMF = Gear Teeth × Shaft Speed (Hz) ± sidebands | MEDIUM |
| Belt Slip / Misalignment | f_belt = Belt Speed ÷ Belt Length | MEDIUM |
| Impeller / Blade Pass Fault | BPF = No. of Blades × Shaft Speed | MEDIUM |
| Phase Unbalance | PQA negative sequence component | LOW |
| Harmonic Distortion (THD) | FFT spectrum to 5th harmonic | LOW |
| Power Factor Degradation | Reactive power ratio vs. nameplate PF | LOW |
Rotor Health — 7-Level Severity Scale
Every Solar Warehouse report includes a rotor dB score, severity rating, and plain-English recommended action — no jargon.
| –dB Level | Rotor Condition | Recommended Action |
|---|---|---|
| > 60 dB | EXCELLENT | No action required |
| 54 – 60 dB | GOOD | Continue scheduled monitoring |
| 48 – 54 dB | MODERATE | Increase monitoring frequency |
| 42 – 48 dB | DEVELOPING | Trend and test frequency |
| 36 – 42 dB | BROKEN BARS | Confirm with vibration; plan repair |
| 30 – 36 dB | MULTIPLE BREAKS | Repair or replace ASAP |
| < 30 dB | SEVERE | Immediate repair — do not run |
We Don’t Just Find Faults — We Price Them
Every fault is translated to kilowatts lost and dollars wasted per year. Clients see the ROI on the first report.
4 Steps. Zero Downtime.
10 Industries. One Platform. No Shutdown Required.
From a 1 kW lift motor to a 1.6 MW wind turbine generator — the physics of ESA scale with the machine.
The Numbers Speak for Themselves
| Scenario | Fault Detected | Annual Saving | Survey ROI |
|---|---|---|---|
| 181 kW Belt Drive Motor | Belt slip + misalignment (7.7 kW) | $5,544 / yr | < 1 month |
| Pump Motor | Bearing + impeller losses (5.49 kW) | $5,469 / yr + 38.5t CO₂ | < 1 month |
| 1.6 MW Wind Generator | 3 bearing defect types (2.43 kW) | $15,000+ avoided replacement | Immediate |
| Elevator Drive (VFD, 0.406 Hz) | Outer race + cage fault | Full motor/gear replacement avoided | Immediate |
Condition Monitoring Is Your Carbon Reduction Strategy
Motor inefficiency is a direct source of scope 2 emissions. Fixing bearing and impeller faults in a single pump motor saves 38.5 tonnes of CO₂ per year — equivalent to removing 8 passenger cars from the road.
Every Solar Warehouse ESA report includes CO₂ equivalent calculations, giving your sustainability team data-ready inputs for ESG disclosure — directly from the maintenance workflow.
Why Solar Warehouse PTE Ltd?
Ready to Find Out What Your Machines Are Telling You?
A Solar Warehouse ESA survey takes 30 minutes per motor. The insights last a lifetime.
Solar Warehouse PTE Ltd · www.solarwarehouse.sg · contact@solarwarehouse.info · Singapore