Early warning.
Planned action.
Operational value.

The motor was running, the risk was growing

The fan motor on the paint shop's ventilation line was still doing its job. But while the other motors in the same group held their normal pattern, this motor's bearing and rotor parameters rose together. Values that quickly reached alarm level drew the maintenance team's attention to this piece of equipment.

A spare motor, and a decision made in time

After the alert, the team planned the intervention around the production flow. The spare motor was brought online and the problem motor was set aside for inspection. The repair could therefore be carried out without interrupting the paint line.

On teardown, bearing wear and rotor damage were confirmed. The bearings were replaced and the rotor was repaired. After maintenance the parameters returned to normal levels, and the alarm did not recur in the following period.

Production and maintenance moved in the same plan

The facility calculated that, without intervention, roughly 189 minutes of production could have been lost. Its assessment — covering production and energy efficiency, equipment life and maintenance costs — stated a total economic contribution of about TRY 95,400.

The first signal came while the motor was still running

The motor of the process fan on the fiber production line was monitored with eMCM. On 5 August, a deviation in the current signature triggered an internal electrical fault warning. Five days later, stator fault and current balance warnings were added to the picture.

The maintenance team chose the timing of the intervention

On 12 August the team reviewed the trends and the warning history and decided to stop the motor for inspection during planned maintenance. The motor was removed on 19 August; visual inspection, insulation resistance and winding resistance measurements confirmed deterioration in the stator windings.

The replacement was completed within planned maintenance

On 26 August the new motor was commissioned. No unplanned production stoppage occurred in the process. The early warning helped the team organise inspection and replacement without having to deal with the motor after an unexpected stop. Monitoring of the new motor through eMCM continued.

From a single reading to a developing trend

When a rotor parameter on the hot water pump's motor exceeded the alarm threshold, eMCM issued an “Inspect 1” warning. While the motor kept running, readings above the threshold became more frequent and the levels reached by the parameter rose.

The maintenance team assessed this trend as it developed over the monitoring period. About two months after the first alarm, the motor was stopped during planned maintenance and taken in for inspection. Rotor unbalance was confirmed on teardown.

The result of the repair was also monitored in operation

The rotor underwent certified balancing to ISO 1940, as stated in the source report. The residual unbalance measured in three planes stayed below the tolerance limits given in the report.

The equipment was recommissioned about one month after balancing. In the monitoring that continued through eMCM, rotor-related alarms ended. The team could therefore assess the result of the maintenance both from the balancing report and from operating data.

A different signal on equipment that kept working

A fabric manufacturer's compressor kept running. The diagnostic headings for bearing, rotor, stator and transmission system were normal. Current and voltage balance, harmonic distortion and power factor were also within the set limits.

Even so, eMCM's electrical fault parameter exceeded the alarm threshold. The other two compressors in the same group staying normal, together with an external electrical fault warning, directed the inspection to the supply circuit of the equipment concerned.

The warning was matched by concrete damage on site

Seven days after the warning, the team opened the panel and inspected the phase connections. Melted insulation on the S-phase cable lug, charring on the cable body and arc marks in the terminal area were found. The connections of the neighbouring phases were sound.

The timing of maintenance was chosen, and the result verified

The damaged connection was repaired in a window planned so as not to disrupt production. The electrical fault parameters fell below the alarm threshold and the warning did not recur in the following days. The compressor had kept running during the week between the warning and the intervention.