Posted by Understanding the Difference Between Electric Motor Repair vs. Motor Replacement
What is the Difference Between Replacing and Repairing a Motor?
Replacing a motor is the process of removing the old motor and installing a new one in its place. Repairing a motor is the process of repairing an old motor to make it work like new again.
When you replace a motor, you are throwing away the old one and replacing it with a new one. When you repair a motor, you are fixing it so that it can work like new again.
When Should You Choose to Replace or Repair a Motor?
Many people are not sure when they should replace or repair a motor. There are many factors that go into the decision, such as cost and how often the motor is being used.
If you have a motor that is not being used too often, then it might be worth repairing it instead of replacing it. However, if the motor is being used all day every day, then you should probably replace it instead of repairing it.
Electric Motors — Repair Vs Replace
The high expense of plant downtime, along with varied motor prices and a slew of new problem detection and repair methods, has made deciding whether to repair or replace an electric motor significantly more difficult. Mike Brook, WYKO Industrial Services’ business development director, offers a simple guidance for plant and maintenance engineers, describing how to keep shutdowns to a minimum and cut expenses over a longer period of time by making the right decision.
Prevention is always preferable to cure, and many plants currently conduct frequent condition-monitoring studies to predict when and how a motor unit might fail. This not only allows plant managers to schedule repairs, but it also prevents them from being obliged to take the quickest and most expensive option when a problem is detected.
As many plant/maintenance engineers are well aware, if a motor fails unexpectedly, production losses, delivery issues, and revenue losses can quickly spiral out of hand. The most effective way to deal with such situations is to have as much information as possible about the plant and the many options available ahead of time, so that the quickest and most cost-effective answer is obvious right away.
Spare units can be purchased, quickest/cheapest suppliers can be noted, and all the information needed to ensure a reliable repair will be immediately available by conducting a survey of all the motors used in a plant, noting their nameplate information, details of the application requirements, and how important they are to production.
Why do motors fail?
Condition monitoring and plant surveys should both provide insight into why a unit has failed or is failing. Electrical, thermal, noise, vibration, and oil analysis can identify polluted windings and failing insulation, bearings, and lubrication, providing engineers with crucial information about the unit’s efficiency, as well as the cost and timeframe of repairs. The plant/equipment survey, on the other hand, gives data that allows engineers to evaluate the motor’s suitability for its intended use. For example, a motor may burn out due to insufficient power rating or changes in the driven load or gearing, which necessitates more power or torque output.
Environmental considerations, such as increased moisture levels or ambient operating temperatures, should also be considered. The motor’s repair history can be utilized to estimate the unit’s life expectancy following repair. Overloading, using improper or excessive amounts of grease for the application, or a lack of cleaning are all factors that contribute to bearing failures, which account for more than half of all motor failures.
Replacement options?
Standard 415V motors should ideally be kept in stock on site to minimize downtime, but larger organizations are increasingly having consignment inventories left on site by a contracted supplier to reduce the investment expenses associated. Making an assessment of potential suppliers with cost comparisons will help save time and money when the requirement arises if keeping stock is uneconomic for the provider or motor functions are more specialized at a site.
When repairing a motor, knowing what repair services a company offers and the costs associated with each level of repair can help you avoid unexpected costs, such as the difference between basic reconditioning, re-insulating, stator rewinding, stator repair, major lamination repair, or a new shaft.
What to repair or replace?
Standard motors of 11kW or less should be replaced as a general rule, as they are typically stock goods available on short notice and are uneconomic to repair. Testing/dismantling to determine the reason of failure is, nevertheless, suggested. Motors of 11kW and above may be worth fixing, depending on the severity of the failure mode. If repairing the unit is cost-effective, it can be done swiftly to take advantage of a shutdown time or returned to the site as replacement stock.
However, in an emergency breakdown situation, the expense of waiting for an analysis virtually always outweighs the money saved by repairing. Replacement units in the 11–250kW range are frequently available in less than 48 hours, making them a viable option.
Servomotors used in high-precision automated positioning systems and motors designed for specialist power-transmission applications are examples of exceptions in the 11–250kW range. Eff1 high-efficiency and ATEX explosive atmosphere motors can also be exceptions, due to their complex designs, which necessitate costly replacement and repairs. Furthermore, typical motors that merely require an electrical or mechanical refurbishment can be repaired rather than replaced, saving time and money.
Motors with a power rating of 250 kW or more are frequently repaired. Large medium-voltage motors may be removed from premises, shafts re-machined, stators rewound, insulation restored, and the motor re-installed within weeks, if not days, whereas new replacements have months-long lead periods.
The only exception to this rule is when the failure is severe, such as when bearing mounts, frames, stator cores, or shafts need to be replaced; nevertheless, even in this instance, it is generally worth repairing the unit and maintaining it as a backup in the long run. Depending on the urgency of the task and the form of the breakdown, some businesses can repair motors more rapidly; however, more costs may be paid, emphasizing the importance of planning ahead.
A survey should take into consideration past repairs, allowing engineers to determine whether the damage is isolated to the same location, whether the repair was completed to the correct standard, or if the unit is inappropriate for the application once again. It is normally worth repairing the unit a second time if the damage is restricted to these regions and the previous work was profitable, but repairing more damage may result in declining returns.
What are the benefits of a repair?
If a motor fails because it was designed incorrectly for the purpose (for example, if more output is required or it is exposed to dust, moisture, or explosive gases), an upgrade repair can adapt the previous motor to the new conditions. Replacement of the insulation, for example, can allow the motor to function at greater temperatures, whilst high-speed bearings, lubricants, and balancing can increase rev/min performance or even prolong the motor’s operational life beyond that of a new motor.
It’s also worth noting that the cause of motor failure can be determined during the repair process and that information can be passed on to the client to help avoid the problem from happening again.
When deciding whether to repair or replace a motor, keep in mind that service centers like Wyko EMS can improve the efficiency of motors by replacing windings and other components, lowering the ‘whole-life costs’ of larger motors. Plant managers can ensure that the most realistic payback period is always available by keeping the survey up to date when cheaper/more efficient substitutes become available.
How to choose a supplier
Choosing the correct firm to deal with can be a difficult undertaking unless a plant already has an established survey of all its motors and a solid working relationship with both motor suppliers and repairers. Smaller facilities may have all of the necessary expertise in the hands of a few knowledgeable people, but larger plants may rely on consignment stocks and a complicated repair schedule, with all duties assigned to a few key suppliers.
The bulk of sites are somewhere in the middle, with engineers constantly juggling a number of suppliers that provide the greatest option for one service but not for another. For example, a low-cost motor provider may not be able to provide the necessary support in terms of application problem-solving, manufacturers may supply custom units but not repair them, and major suppliers who leave consignment stocks may not be able to fix them.
Each year, Wyko repairs or replaces over 10,000 motors, specializing in all aspects of motor replacement, from condition monitoring to conducting motor-usage surveys, supplying motors off the shelf to leaving consignment stocks, repairing motors of any type or size to installing and maintaining the units, and providing impartial advice in all of these areas.
How to Know Whether to Repair or Replace your Electric Motor?
The repair/rewinding of electric motors is widely discussed in this EASA document. We find that the problem has a section titled which discusses the advantages and disadvantages of either repairing or replacing your electric motor.
With all the options out there to choose from, it can be hard to make a decision. But with some help from these questions, you can arrive at a decision in no time.
The “Repair-replace” Business Model
The process kicks-off the moment a motor fails.
Question #1 – Is the motor suitable for the application in which it failed? If the answer is no then investigate replacing it with a suitable motor and you are done. But if the answer is yes, then….
Question #2 – What is the condition of the stator core? If the answer to that question is that there is significant damage or high losses, then ask yourself if the cost to repair is greater than the cost to replace?
a) If that answer is no, then repair and you are done. If the answer is yes, then ask yourself if replacement funds and motors are available, and if the replacement lead times are acceptable? If those answers are no then you should repair. If those answers are yes then you should replace. You are done.
b) But if the answer is that the condition of the stator core is OK, then…
Question #3 – Has a catastrophic failure occurred, or is there evidence of prior catastrophic failure?
a) If the answer is yes, then repeat #2a above and you are done.
b) If the answer is no, then….
Question #4 – Is the rotor damaged, or is there severe damage to other mechanical parts?
a) If the answer is yes, then repeat #2a above and you are done.
b) If the answer is no, then….
Question #5, is it an EPACT/EFF1 motor?
a) If the answer is yes, then repeat #2a above and you are done.
b) If the answer is no, then….
Question 6, is the return on investment of EPACT/EFF1 acceptable?
a) If the answer is yes, then replace the motor.
b) If the answer is no, repair the motor
Create the best practices Repair/Replacement Plan
Creating a “Best Practices Repair/Replacement Plan” on the front-side, before a failure occurs, will allow you to be prepared for when it does happen. You’ll know what to do and won’t risk compromising long-term reliability for temporary fixes.
Having the right plan in place will allow you to:
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Maximize plant availability
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Periodic services can go a long way in reducing equipment failure in-service. Seems like a good idea.
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Save time by automating tasks on the go and get equipment up and running as quickly as possible at best practice.
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Motor inventories can be improved over time by using a systematic approach.
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Allow you to predict possible outcomes when dealing with equipment breakdowns
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Result in the lowest overall cost to your business.
Repair/ Replacement plan
Not having a Repair/Replacement plan in place could lead to costly emergency repairs, late responses to equipment failures, and increased costs for replacement equipment. These problems can be solved by investing in Repair/Replacement plans that provide the information you need when failures occur.
Your motor and plant inventory, if properly set up, will serve as a centralized source of all the information you need to make quick judgments. When a failure occurs, the inventory generates guideline statements on the optimal replacement alternative or repair specification, which will point you in the proper route.
We get calls for motors all the time and are only given minimal information. The time spent waiting for new, and more accurate, information is then wasted. Obtaining the necessary information up front will expedite the procedure and ensure that the correct motor is located.
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One of the most important aspects of a well-functioning electric motor is that it never needs to be replaced. And if you’ve just discovered that you need to replace one, keeping your requirements in appropriate detail will ensure that you get exactly what you need.
Be sure you can provide this info:
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Complete nameplate information (Picture of nameplate)
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Description of Driven Application
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Maintenance History
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Bigger motors will need more information, like:
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Speed v/s Torque curves
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Load Inertia (wk2)
Reasons Why You Might Need to Replace Your Motor Quickly if It’s Still Under Warranty
A motor is a machine that converts one type of energy into mechanical energy. It is usually powered by electricity, and it can also be powered by another form of energy such as gas or steam. When a motor is not working properly, it can cause a lot of damage to the equipment that it’s powering, and this can lead to costly repairs.
If you’re still within the warranty period for your motor, then you might be wondering if you should replace it or not. If the warranty has expired, then you may want to replace your motor right away so that you don’t have to worry about expensive repairs in the future.
How Much Does It Cost To Replace Or Repair A Bad Motor?
The cost of replacing a bad motor varies depending on what type of motor has failed. For example, if the motor is an AC induction motor, it can cost anywhere from $4,000 to $6,000 to replace.
When you are considering how much it will cost to repair or replace a bad motor, it is important that you know what type of motor has failed. The type of motors in your system will affect the price range for repairs and replacements.
How do you know when a motor needs to be repaired?
Motor repair is a complicated process and it is important to know when the motor needs to be repaired. There are a few signs that indicate that the motor needs repair:
– A grinding sound coming from the engine
– The engine overheating
– The engine being unable to start up
how much blower motor replacement
Blower motors are used in a variety of heating, ventilation, and air-conditioning (HVAC) systems to move air through the home or office.
Blower motors are used in a variety of heating, ventilation, and air-conditioning (HVAC) systems to move air through the home or office. The blower motor is typically located near the furnace or water heater. They come in various sizes according to the amount of airflow needed for the system.
The average cost for a blower motor replacement ranges from $150-$500 depending on the size and model chosen.
how much starter motor replacement
The starter motor is a small electric motor that is connected to the engine. It starts the engine by turning over the flywheel so that it can turn over and start the engine. The starter motor is activated when you push down on your car’s accelerator pedal or press down on your car’s clutch pedal.
There are two types of starter motors: mechanical and electrical. Electrical starter motors are more common because they don’t require any maintenance, while mechanical starters need to be replaced every few years as they wear out.
how to window motor replacement
Replacing window motors is usually a fairly simple process. With the right tools and a little knowledge, you can have your window back up and running in no time.
1. Remove the old window motor
2. Purchase a new window motor
3. Install the new window motor
how much is a motor replacement
A motor replacement is an operation performed by a qualified auto mechanic to replace the engine of a vehicle. The cost of this service depends on the type of the car and the location where it is being done.
The cost of a motor replacement can vary from $500 to $5000, depending on the type and make of your vehicle, as well as on where you are located. For instance, if you live in an urban area, then there are more mechanics around to do it for you in comparison to rural areas.
how much is wiper motor replacement
The cost of a wiper motor replacement can vary depending on the make and model of the car. The labor cost is typically included in the price, but it may be more expensive if a technician has to be called in for installation.
The average price for a wiper motor replacement is around $150-$200, but this may depend on whether or not you have to call in a technician for installation.
how long to replace blower motor
This section is about how long it takes to replace a blower motor.
Most people don’t know how to do it themselves, and it can be a big job. A blower motor is an electric device that moves air into the furnace through ducts to distribute heat throughout your home. There are many reasons why you might need a new one, such as dust or rust accumulating on the motor’s coils which makes it difficult for the motor to operate properly.
is it hard to replace a blower motor
The blower motor is a component of the heating and cooling system. It is responsible for moving air through the ducts in your home.
It is not hard to replace a blower motor, but you will need to find the right one for your needs.