up to $10k
N AVOIDED MOTOR REWINDING, EMERGENCY INTERVENTION, AND UNPLANNED DOWNTIME
Industry
Asset
Problem
Avoided
EARLY DETECTION OF STATOR WINDING INSULATION FAILURE
THE CHALLENGE
A critical submersible pump responsible for water circulation was operating
continuously in a water utility facility.
- Unexpected failure of this asset would have resulted in:
- Unplanned downtime
- Emergency maintenance intervention
- Motor rewinding costs
- Risk to service continuity
WHAT PreditMot DETECTED
PreditMot’s Electrical Signature Analysis (ESA) technology identified a rapid
increase in the motors stator fault indicator, revealing abnormal electrical
behaviour associated with winding insulation degradation.
The anomaly was automatically classified as critical and an alarm was
immediately generated.
- Detected Fault
- Stator winding insulation degradation
- Probable Root Cause
- Insulation breakdown between stator winding and magnetic core
- Detection Lead Time
- Several days to weeks before potential failure
VALIDATION
Following the alarm, the maintenance team performed electrical tests on-site.
The results fully confirmed the diagnosis:
✓ Insulation resistance measured approximately 0 MΩ
✓ Internal inspection revealed severe insulation deterioration
✓ Failure mechanism matched the ESA diagnosis
PreditMot successfully detected the fault before catastrophic motor failure occurred.
BUSINESS IMPACT
UP TO €10,000 AVOIDED COSTS
Avoided:
✓ Motor rewinding costs
✓ Emergency maintenance intervention
✓ Unplanned downtime
✓ Secondary equipment damage
✓ Production and service disruption
CUSTOMER BENEFITS
Improved Reliability
Continuous monitoring provided visibility into the motor's electrical health and enabled informed maintenance decisions.
Safer Maintenance Planning
The pump was removed from service in a controlled manner rather than after a
failure event.
Reduced Operational Risk
Maintenance actions were scheduled proactively, eliminating the uncertainty
associated with unexpected breakdowns.
KEY TECHNICAL TAKEAWAY
Electrical Signature Analysis can identify stator winding insulation degradation at an early stage by detecting subtle changes in the motor’s electrical behaviour.
This case demonstrates how PreditMot enables physics-based fault detection using existing electrical signals, providing actionable insights without requiring intrusive sensors or machine modifications.
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