Safeguarding Assets from Single Phasing Events

Single phasing a 3-phase motor is a critical issue. This occurs when one phase is no longer powered, leaving the two remaining motor leads left to attempt to carry the load. This results in increased current on the two remaining motor leads, which in turn causes increased heating in the motor stator. If the motor is operated in this manner for too long the motor winding insulation will break down and ground fault. InsiteAI's Real-Time Alerts and Notifications play a vital role in identifying and mitigating such issues before they escalate, thereby protecting valuable assets and preventing costly downtime.

How Single Phasing Can Damage 3-Phase Motors

A recent incident highlights the effectiveness of InsiteAI's alert system. A customer experienced critical single phasing alerts at their facility, which were not directly related to the motor itself. Instead, a control issue was causing the power drops by opening and rapidly reclosing the motor starter. The InsiteAI's Real-Time Alerts were promptly reported to the customer and further discussed during monthly review calls, ensuring they were aware of the emerging issue.

InsiteAI’s Role in Detecting and Mitigating Control Issues Leading to Single Phasing

As the situation progressed, the frequency of power drops increased, signaling a worsening problem. Despite continued notifications, the issue escalated until the contactor failed, resulting in two phases of the motor starter contactor welding shut. This failure led to a single phasing experience for the motor. Thanks to InsiteAI's real-time alerts, the customer was immediately informed of the event, enabling them to address the issue before any significant load was placed on the motor. This timely notification was crucial in preventing catastrophic failure and protecting the motor from damage.

What made this incident particularly interesting was that the motor itself was not the primary culprit; the control issue caused the contactor failure which resulted in the motor single phasing. The alert not only identified the issue but also prompted additional investigations. These investigations uncovered an error within the control logic of the PLC. This control logic error was present on similar assets within the facility, and by addressing it promptly, the customer was able to prevent similar single phasing events and contactor failures on other equipment.

Protect Your Assets with InsiteAI’s Proactive Monitoring

InsiteAI's Real-Time Alerts and Notifications provided the customer with the foresight and actionable insights needed to protect their assets, ensuring operational continuity and avoiding costly repairs. This proactive approach is a testament to the value of advanced monitoring systems in modern industrial environments.