A conveyor develops a noise. Pump runs hot. The motor breaks down mid production.
Repair or replace?
There are many considerations to help with this decision. Sometimes a repair can appear cost effective but the fault occurs again. Replacing a ageing industrial equipment machine that is still capable of doing its job can also be costly if modifications are required to the surrounding installation.
It all boils down to the failure, what the ageing industrial equipment requires to continue working and the costs to the company.
What you’ll learn:
- Understand the Fault Before Choosing a Fix
- Check the Motor and Its Working Conditions
- Count the Costs That Quotes Leave Out
- Decide How Much Downtime You Can Risk
- Use the Same Tests Every Time
- Wrapping It Up
Understand the Fault Before Choosing a Fix
Ageing industrial equipment shouldn’t be your first port of call when deciding to repair or replace.
A gearbox may show age and have worn seals but still be economical to repair. Pumps that continually develop shaft failures may require further investigation. Or a motor that is running hot may need the rest of the drive examined.
Always get an engineer who knows what they are doing to establish a probable cause before you obtain prices. Look at previous maintenance records and test data. Has the same component failed in the past? Have vibrations increased since a change in load? Signs of heat, dirt and lubrication can all give you information about a machine’s condition.
It’s all about knowing if you can repair the fault or if the machine is unsuitable for its application. Changing bearings will not solve an incorrect alignment and changing the motor will not solve the overloading of a pump.
You should be able to obtain from your engineer what the damage is, why it occurred and what tests can be performed to ensure a good repair. This can then be compared to a new machine.
Check the Motor and Its Working Conditions
Motors are a great example of this as there can be many different applications that use the same motor. The motor could be working 1 hour per day or could be running many hours across multiple shifts in a hot environment with high dust levels.
When looking at a replacement ensure you know the application’s nameplate data and actual working conditions. Output, speed, voltage, mounting position and environment should be noted. You will also need to know what it drives and if there are any speed control applications.
RJW Motors & Inverters have a wide selection of motors to suit many different applications and mounting positions. Once you have determined a replacement may be beneficial, this can help identify what type of motor may be required. But as mentioned, make sure the replacement can carry out the task required.
Make sure the motor can be rebuilt if it’s worth it. Bearings may be worn but if the motor has severe damage to the core, rotor or casing it may not be possible or economical to repair the machine.
There may be an opportunity to rewind a motor. Follow the guidance from the Association of Electrical and Mechanical Trades on repairs to ensure good practice. Enquire with your workshop what checks and tests can be done to ensure your motor is back to good working order.
Count the Costs That Quotes Leave Out
It’s not just about comparing the cost of a repair to the price of a new unit. There are many things that need to be considered when looking at getting a machine back into working order.
Costs can be compared when you break them down into categories.
- Cost of repair/replacement, parts, labour, freight, installation and commissioning.
- Changes to the current installation, controls, cable, fixings etc.
- Running costs, energy, maintenance, etc.
- Cost of down time, if production is lost due to downtime how much is it costing?
As stated earlier, energy usage can be a factor when considering your options. According to the IEA 4E Electric Motor Systems Platform Electric motor systems consumed 72% of global industrial electricity in 2023. Again this is global figures and relates to motor driven systems, not just the electric motor itself.
By ageing industrial equipment identifying how much power your machine will consume you can compare the repair and replacement. Using hours of running per week and the cost of electricity on your premises can help calculate the running costs of your machine. Perhaps the replacement uses less energy, however will this offset the additional cost of a replacement? Again, it depends on your application and may be more economical to repair.
When obtaining prices, be aware of what is included in the cost. Sometimes repair jobs can be cheaper if certain tasks are left out, such as testing. You want to ensure you are comparing like for like, so make sure you know what is included in both options.
Decide How Much Downtime You Can Risk?
Some pieces of equipment are more vital than others, you may not mind if a motor that drives a fan in your workshop goes down, but if it was the only conveyor supplying product to your process, this could be very different.
What length of time can you allow this piece of equipment to be out of action?
Consider the lead time for parts, workshop repair, delivery and commissioning of your machine. You may find it quicker to repair a piece of equipment that may have a longer lead time to replace. Having the ability to repair a machine can sometimes save you days of down time, if the replacement isn’t readily available.
Another point to consider, if the machine fails again, is it going to affect other processes or products? You may need to consider keeping a spares item on hand or replacing your equipment even if you have been able to repair it.
Before work begins, securely isolate the equipment from all energy sources and have a competent person carry out the work.
If the repair can not be done to a standard that allows it to operate safely, don’t allow price to influence your decision.
Use the Same Tests Every Time
Once you have gathered your information, here are some steps that can help you with your decision.
- Can the failure be repaired?
- Is there a way to properly repair the equipment?
- Will the replacement machine do the job?
- Which is more economical?
- If the equipment fails, what options are available?
Know the difference between repairable and worth repairing. Your workshop may be able to repair your machine, but you may benefit from a replacement that can do the job more efficiently. However if the machine is undersized for the job, a correctly specified replacement may be more suitable than another repair.
There are always more considerations you can add to this list, such as,whether a replacement part could serve as a spare and what warning signs to monitor after a repair.
Remember, if you keep records of what you did and why, next time you can refer to them instead of trying to work it out yourself.
Wrapping It Up
As you can see there are many factors to consider when deciding to repair or replace a machine. Don’t assume that because your equipment is old it needs replacing, or that because it can be repaired it’s the best option.
Find out what the failure was, can your equipment still perform to the task it is meant for and compare your costs, downtime and safety requirements.
Also Read :- How Smart Design Is Changing the Outdoor Equipment Industry
