In one of Brazil’s largest cement plants, an advanced 2350 kW induction motor driving a vertical roller mill was closely monitored by our continuous online motor condition monitoring (MCM) technology, which identified a critical rotor insulation problem at an early stage—before serious failures or costly downtime occurred.

Challenge:

Motors in such industrial applications experience severe and frequent load changes, complicating traditional condition monitoring and timely fault detection. How to prevent catastrophic failure that could lead to multi-million damage?

Solution:

The continuous online monitoring system utilizes non-invasive sensors measuring motor electrical signals in real time. The quick installation requires no production stoppage — a key factor in demanding industrial environments.

Detailed Diagnostics:

The system detected unusual frequency components in the reactive power spectrum, indicating degradation of the rotor insulation. Following platform alerts, the maintenance team promptly inspected and cleaned the brush system contaminated by cement dust.

Results:

  • Significant improvement in rotor insulation confirmed by measurements before and after intervention.
  • Motor returned to normal operating conditions with reduced failure risk.
  • Prevention of a potential failure estimated to cost between €330,000 and €440,000.
  • Continuous monitoring enables ongoing safety and optimized maintenance planning.

Conclusion:

This case demonstrates how cutting-edge online monitoring and precise diagnostics significantly reduce risk and cost while ensuring maximum safety and reliability in challenging industrial conditions. Our team of experienced professionals supports technology implementation that empowers clients to shift from reactive to proactive maintenance strategies for sustainable long-term operations.