Opinion

Repair or replace: are you getting the right advice?

Matt Fletcher gives his perspective on the age old question; whether it is better to repair or replace an electric motor. He suggests that the answer you get may well depend on who you ask.

I don't know who first asked the question ‘should I repair my electric motor, or should I replace it?’, but I do know that, around the world, this question is asked every day. And the answer? Well, the answer you will get depends on who you ask. And, if you are responsible for getting your plant back up and running again, the answer might not be in your best interests either.

Just consider this for a moment. You ask two people that same question. One is your local electric motor rewinder, and the other is an electric motor stockist. I’m fairly sure that you will get a different opinion from each of them. The rewinder might want to keep the workshop team busy, so they will be likely to suggest the motor is repaired, the motor stockist probably works on commission, so they will want the sale. So, it’s back to you to choose.

So, who is right? Well, I’m in no position to tell you what is best for your business, but I can offer you some things to consider and some questions to ask, to help you to make your own opinion.

It could be said that it’s too late to ask whether a motor should be repaired or replaced when it has failed. In many facilities, this question should be asked proactively in readiness for when the motor needs to be removed from service. It could be as simple as recognising that the motor is an older, less efficient type of motor and that a new IE3 or higher motor would be a better option. There are those of us in the industry who can survey your installed plant, then offer suggestions based on running costs and motor availability to help you make a decision proactively.

The most usual scenario is a reactive one though, when you have a failure and you are considering your options. This is where I believe productivity should drive your decision. If production output is critical and there is a new motor available to you quickly, then that is probably your best option. I’m sure there will be rewind companies reeling in horror at this. Our industry’s reputation is built on providing quick turnrounds with us working through the night to get a motor rewound and back into service as quickly as possible. That is all well and good, and as an industry we’ll continue to do this; however production demands should always come first.

But if you have a spare motor available or you can live with downtime, the ‘repair or replace’ question still needs to be answered. This is where a conversation with your repairer is valuable. If your motor is old and a replacement is offered because ‘it’ll be more efficient’, ask to see the running cost comparisons to make your own decision. Every repair company should be able to offer you this.

There are also times when the failure mode of a motor causes it too much damage; then it really is better to replace. We can all perform miracles, but sometimes the recycling bin is the best place.

When someone suggests to you that either a repair or a replacement motor is better for you, ask them why.

Let’s look at the most common scenario. When a motor needs a rewind, I wouldn’t automatically look to replace it. If it’s already an IE2 or IE3 motor, then a rewind carried out in line with the ISO60034- 23 repair standard will bring that motor backto a ‘zero hour’ rebuild. It can be as good as new. I would always offer a repair price and a replacement price. A cost-based decision about whether to repair or replace can then be made. But then we have to watch out for the purchasing department, who with little engineering input might say that if the repair is a certain percentage of new, then they won’t repair. Why is this though? If you are getting a repair that is as good as new, with the same guarantee as new, and for less money, then why not repair?

When someone suggests to you that either a repair or a replacement motor is better for you, ask them why. You’ll hopefully get a reasoned technical, and cost-based answer, if not you’ll soon figure out who’s interests are best being served.

And in the interest of full disclosure, my business has an active interest in repairing motors, and selling new motors as an ABB value provider. I believe that companies which offer repairs and stock replacement motors will give you the best impartial advice on whether to repair or replace your electric motors when they fail.

Matt Fletcher is the Managing Director of Fletcher Moorland Ltd.