7 Signs It’s Time to Replace Large Equipment

7 Signs Your Equipment is Due for an Upgraded Replacement.

11:06 30 May 2024

Any type of large equipment should be regularly inspected and maintained, whether it’s a commercial freezer, a bulldozer, a power transformer, or anything else crucial for completing important tasks. The consequences of ignoring maintenance and repairs can be costly. The biggest potential problem is having to deal with equipment failure, which can happen suddenly, intermittently, or gradually. The other major issue is downtime, which can cost your business a lot of money and might even cost you some customers.

While it’s certainly cheaper to save your repair calls for major issues, sometimes small problems are signs of a much bigger issue that needs to be addressed. You can avoid a lot of major problems by paying close attention to the following warning signs.

1. Important components changing color

Sometimes color changes can indicate a big problem, especially when a color is getting darker. This can happen on the outside or inside of the equipment. For example, darker insulation is a common sign that a power transformer’s insulation is failing. It means the heat isn’t being distributed and is starting to burn the insulation instead.

Sometimes transformers can be repaired, but if it fails, it’s too late. However, if you end up needing a replacement, a good manufacturer can supply a new or refurbished unit for you to put in the same space by retrofitting the replacement transformer with custom bus work.

2. Lost efficiency

You know your equipment best and should be able to discern when its lost efficiency, either by paying attention to the direct impact it has on tasks or by watching its power consumption through the electric bill.

If anything feels off about your equipment’s efficiency, have it looked at by a professional. Even if it only seems to be costing $20 more per month to run, if your electric rates haven’t risen to account for that change, it could be a sign of something serious.

3. Excessive heat

Large equipment will naturally produce a lot of heat while it runs, but that heat shouldn’t be excessive. Any type of equipment that generates heat should have its own cooling system in place. Too much heat is a sign that either the heat distribution system is malfunctioning, or the machine is being overworked and there’s another problem.

A common example of a machine generating too much heat is a freezer that needs to be defrosted. The ice will block the vents and prevent it from cooling down properly, and the heat will just continue to build until the ice is removed. In this case, defrosting the freezer will usually do the trick. However, if your freezer needs to be thawed out too often and you aren’t setting the temperature too cold, it could be a sign that something else is wrong and it should be looked at by a professional.

4. Smoke

Smoke is never a good sign. It means that something is either combusting or causing enough friction to generate intense heat and smoke. It can also be indicative of an internal fire.

If you see smoke coming from a piece of equipment, get some photos or video, if possible, before shutting it down to have it inspected by a licensed technician. Providing them with the video can give them good insight into the problem and might save them some time.

5. Strange smells

New smells coming from equipment can be a sign that something is wrong, especially if it smells like something is burning or melting. Pay close attention to strange smells and don’t let them fly under the radar.

6. Excessive noise or vibration

Noise and vibration often go together, but not always. In either case, excessive noise and/or vibration can be a sign of trouble. There might be loose components inside the equipment, or something important could be completely missing.

Excessive vibration is a common precursor to machine failure and if applicable, it’s worth looking into getting set up for vibration testing. With a special meter, you can measure and track overall vibration and smaller variables, like the temperature of bearings.

7. An actual fire

This might be obvious, but it still needs to be said – if your machine catches fire, it’s probably not functional. There are exceptions, but fires can destroy internal components more than you think. Never put a piece of equipment back in service after a fire without a proper inspection.

Maintain the equipment you depend on

All of these signs can indicate equipment failure, but many issues can be avoided by following through with timely repairs and staying on top of preventive maintenance.