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Free Motor Repair/Replace Policy Maker

This online Motor Repair/Replace Policy Maker produces a written document for your company that you can post or circulate to staff responsible for your plant's motors. If you contract out your maintenance, send the memo to the contractor.

Fill out the following form and click Submit.  A page will appear that you can print.

    Company Name:  
    Your Name:  

What kind of facility are you setting the policy for? Check one

The type of facility usually determines what types of motors you have.

    Commercial or institutional building  
    The motor repair replace policy for commercial buildings is very short and simple, since it covers only Open Drip Proof (ODP) motors. ODP Motors typically power Heating Ventilating and Air-conditioning (HVAC) equipment such as rooftop units, pumps, and fans. Note: for the ODP motors covered in the commercial policy the electric rate, operating hours and rebates don't effect the policy.

    Industrial plant  
    Covers Totally Enclosed Fan Cooled (TEFC) motors that are quite common in industrial facilities. TEFC motors are more rugged and more expensive to construct than ODP motors. This policy also covers ODP motors since the HVAC systems serving the plants often are powered by ODP motors.

Hours motors operate Check all that apply

Note: for motors 10 hp and smaller the tear down, inspection and bearing work is usually more than 60% of the cost of a new energy-efficient motor. Totally Enclosed Fan Cooled (TEFC) motors this size and smaller are usually not worth rewinding even if they only run a few hours per day. Hours per year are rounded to the nearest thousand.
      Motors that run less than one shift (4 hours per day, 5 days per week, 1000 per year)
      Motors that run one shift (8 hours per day, 5 days per week, 2,000 per year)
      Motors that run two shifts (16 hours per day, 5 days per week, 4,000 per year)
      Motors that run three shifts, five days per week (24 hours per day, 5 days per week, 6,000 per year)
      Motors that run 22 or more hours per day, 7 days per week (8,000 hours per year)
Verify Electric cost: $ /kWh (blended average including demand charges)

Does your utility offer rebates for new energy-efficient motors?

CAUTION: The procedure developed by AEL and promoted by the DOE Motor Challenge Program for establishing a motor repair replace policy does not factor in the rebate from your utility. Likewise, if you get more than a 40 % discount on motors, the policy will not be accurate. Contact us for a more appropriate policy.

*Research done by Applied Energy, a research organization in North Carolina that specializes in applied industrial motors.
Motor Policy Benefits

Research indicates that, new energy-efficient motors are 5% more efficient on average than older motors that get rewound.*

Establishing a Motor Repair/Replace policy saves time and reduces confusion when the line is shut down because of a motor failure. During an unplanned outage plant staff does not have time to search for a critical motor replacement or calculate life-cycle costs.

You'll be ready for unplanned motor emergencies.  Set the policy ahead of time and identify critical motors, then consider stocking them yourself, or find a vendor in your area who is willing to stock them for you.

 


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