This case study is from a food & beverage plant located in Ireland where electrical issues in homogenizer motor were detected through the Eastway Safeguard® system.

The Eastway Safeguard® online monitoring system was installed in 2018 on the critical production equipment in the plant, including Liquid Homogenizers, Air Compressors and Production Fillers. Additionally, Eastway provide bi-monthly on-site vibration analysis surveys and annual surveys for ultrasonic leakage, steam traps and thermography to this plant.

The Eastway Safeguard® continuous vibration system on this Homogeniser replaced the pre-existing manual vibration data collection programme on this critical asset. The plant adopted the 24/7 Eastway Safeguard® system to support the increased production output demands by reducing their risk of unplanned machine downtime in addition to utilising technology for greater visibility on asset condition and performance

Case Description

In October 2021, high vibration values, acceleration (g RMS), were detected on the homogenizer motor non-drive end and motor drive end through the Eastway Safeguard® online vibration system. Automatic alerts were sent to key personnel and the Eastway team. See Figure 1. which display the motor drive end acceleration trend from August to October showing this increase in vibration values.

Figure 1. Acceleration trend – Motor drive end from August 2021 to October 2021

Recommended Action

Further analysis of the vibration from the motor non-drive end and motor drive end data was completed by the Eastway remote monitoring team. On the analysis, the vibration FFT spectra (Fast Fourier Transform), enveloped spectra and time waveform signatures were examined. This analysis indicated the presence of an electrical related issue at the motor (non-uniform magnetic field), see Figure .2 from the motor non-drive end test point an acceleration FFT sample showing electrical frequencies and Figure 3. a time-waveform sample which indicated impacting in the motor. In addition, Eastway reliability team confirmed with the site maintenance team that the winding temperature was increasing in the motor.

Based on the previous analysis it was recommended to overhaul the motor and check condition of the windings, rotor, and stator at next downtime to prevent further damage.

Figure 2. Acceleration FFT spectra from motor non-drive end on 05 Oct 2021 displaying electrical frequencies

Figure 3. Acceleration waveform from motor non-drive end indicating impacts in the motor

Action Taken

As recommended by Eastway, the motor was overhauled between October and November 2021 and the windings were found to have significant damage and debris built-up over time. As a result of the maintenance works, values dropped significantly and have remained below warning levels ever since. See Figure 4. for acceleration (g RMS) trend showing this decrease in vibration values.

Figure 4. Acceleration trend – Motor non-drive end after motor overhaul


Detecting the electrical issues in homogenizer motor in advance, enabled timely planning and sufficient lead time to order components and have the correct tools in place. In addition to identifying potential faults leading to reduction in downtime, this also significantly reduced the man hours to repair the equipment and carry out maintenance work in an efficient way. Planned downtime avoids the loss in production and increases overall equipment efficiency.

Table 1. illustrates the importance of having a 24/7 monitoring service in place to detect failures, in this case electrical issues in homogenizer motor were detected, allowing corrections to be carried out before costly system failures occur.

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