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On-site motor diagnostic survey

Same-day motor condition testing for pumps, fans, compressors and other rotating machinery

An on-site diagnostic survey is a one-day visit in which Faraday Predictive tests your electric motors and the machines they drive while they keep running. Using motor current signature analysis (MCSA), we assess the mechanical, electrical and operational health of 4 to 12 machines and give you a written report the same day. There is no hardware to buy and minimal shutdown.

It is the quickest way to find developing faults before they force an unplanned stop, and to see how the P100 portable equipment health assessor performs on your own plant before you invest.

Book a survey

From £1045

Engineer performing an on-site diagnostic survey with portable condition monitoring equipment

What is included in a one-day motor condition survey

  • A Faraday Predictive engineer on site for one full day
  • Electric motor testing on as many machines as you can make available, typically 4 to 12
  • Motor current signature analysis of each motor and its driven load
  • A written equipment health report for every machine, issued on the day
  • Clear advice on any faults found and what action to take
  • Hands-on P100 training for your technicians, so they can see how easy the kit is to use
  • A survey fee that is refundable against a P100 purchase within 30 days

How the survey works

1

Discovery call and quote

We discuss your plant, which machines matter most and your electrical operating procedures, then confirm the quote and date.

2

Plan the day

You choose the motors to test, prioritising critical assets and any machine you already have concerns about. We send our method statement and risk assessment in advance.

3

On-site testing

Measurements are taken at the motor starter or motor control centre (MCC) while each machine runs normally. Nothing is fitted to the machine itself.

4

Same-day report

Before we leave, you receive a report on the condition of each machine, the faults identified and the recommended next steps.

5

Follow-up

Where equipment needs deeper analysis, we provide a detailed written report a few days later and talk it through with your team.

What faults can motor current signature analysis detect?

An electric motor acts as a sensor for everything connected to it. Mechanical and electrical problems change the current it draws in small but measurable ways, and MCSA reads those changes to identify faults early. A survey typically covers:

  • Mechanical faults: bearing wear, misalignment, imbalance, looseness, belt and coupling problems
  • Electrical faults: broken or cracked rotor bars, stator winding issues, air gap eccentricity, supply voltage imbalance
  • Driven equipment problems: issues in pumps, fans, compressors and gearboxes driven by the motor
  • Operational issues: machines running away from their best efficiency point, wasting energy or wearing faster than they should

Finding these faults at an early stage means repairs can be planned into a scheduled shutdown, rather than forced on you by an unexpected breakdown.

Why test from the motor starter panel?

Traditional condition monitoring often relies on vibration sensors mounted on each machine. Our on-site electric motor testing takes its measurements from the electrical supply instead, which brings practical advantages:

Non-invasive:

no sensors on the machine and no need to stop it

Safer access:

motors in hard-to-reach, hot or hazardous locations are tested from the switch room

Faster testing:

if test plugs are already fitted to your motor starter panels, measurements are taken without opening the starter door, so more machines are covered in a day

Wider view:

one measurement assesses the motor, the driven equipment and the electrical supply together

You will need to provide an electrically authorised person to give access to the inside of electrical cabinets where test plugs are not fitted.

Your equipment health report

For straightforward equipment, our automatically generated reports, supplied in Word format, give a clear guide to the health of each machine: the nature of any faults found, the evidence behind each diagnosis and the action we recommend.

For complex equipment, or equipment in complex situations, we provide further manual analysis and interpretation. A detailed written report follows a few days after the visit, and we present the results by phone, video call or face-to-face, as suits you.

Example images of Condition Monitoring Reports from Faraday Predictive Software

On-site diagnostic survey cost

Refundable against a P100: the survey fee is refunded against the purchase price of a P100 unit if we receive your purchase order within 30 days of the visit.

Standard onshore UK test day

£1045 plus travel and subsistence

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Offshore test day (North Sea)

£1350 plus travel and subsistence

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Who uses an on-site diagnostic survey?

Our motor condition surveys are used across industries where unplanned downtime is expensive, including oil and gas, water utilities, manufacturing, chemicals and process, pharmaceuticals, and power generation.

It suits you if you:

  • Want an independent health check on critical rotating machinery
  • Are evaluating predictive maintenance and want results before buying equipment
  • Have a machine that is noisy, hot or tripping and need a diagnosis quickly
  • Need a baseline of asset condition before a planned shutdown

From a one-day survey to ongoing condition monitoring

A survey gives you a snapshot of asset health and a practical first step into predictive maintenance. Most faults develop over weeks or months, so regular measurement gives the earliest warning.

After your survey, you can:

Book your on-site diagnostic survey

Find out what condition your motors and machines are really in, with results the same day, and cut the risk of unplanned downtime.

To arrange a visit, or to find out more about what is involved, call us on 0333 772 0748 or send an enquiry.

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Frequently Asked Questions

An on-site diagnostic survey is a one-day visit where Faraday Predictive tests your motors and rotating machinery while they run. We use motor current signature analysis to assess mechanical, electrical and operational condition, and give you a written report on the same day.

A standard onshore UK survey day costs £1045 plus travel and subsistence. An offshore day in the North Sea costs £1350 plus travel and subsistence. The fee is refundable against a P100 purchase if we receive your purchase order within 30 days of the visit.

Most survey days cover between 4 and 12 machines. The number depends on your operation, your electrical operating procedures and the connections available. If test plugs are already fitted to your motor starter panels, testing is quicker and more machines can be covered.

No. Motor current signature analysis is carried out while the motor runs under normal load, so production continues. Depending on your site’s electrical safety procedures, access to the starter cabinet may be needed; with test plugs fitted, the cabinet door stays closed.

Motor current signature analysis is a condition monitoring technique that analyses the electrical current a motor draws. Faults in the motor or the machine it drives create small, characteristic changes in that current, which reveal problems such as bearing wear, misalignment and rotor bar damage, without fitting sensors to the machine.

A survey can detect mechanical faults such as bearing wear, misalignment, imbalance and looseness, and electrical faults such as broken rotor bars, stator winding problems and supply imbalance. It also highlights problems in driven equipment like pumps and fans, and machines running inefficiently.

Vibration analysis uses sensors mounted on each machine, while MCSA measures from the motor’s electrical supply, usually at the starter panel. MCSA can be used on machines that are hard or unsafe to reach and also detects electrical faults. The two techniques complement each other.

You need to provide an electrically authorised person who can give access to the inside of electrical cabinets, plus access to the machines on your test list. It helps to share a list of priority motors and any known concerns before the visit.

You receive a written report for each machine on the day of the survey. For complex equipment, we can provide a more detailed report with manual analysis a few days later, followed by a presentation of the results by phone, video call or in person.

Yes. We carry out offshore diagnostic surveys in the North Sea, priced at £1350 per test day plus travel and subsistence.

You can act on the report’s recommendations straight away. Many clients then continue monitoring with a P100 portable kit, using their refunded survey fee, or fit Inpod for continuous monitoring of critical machines. We also offer ongoing condition monitoring services.