Here, John Saysell, Training Director explains what was involved. Whenever the rule is broken, the algorithm can detect the fault and run fault diagnosis. These are also called balanced faults and are of two types namely line to line to ground (L-L-L-G) and line to line (L-L-L). Our courses have been delivered across the UK and around the world. Locate the Fault. Divide the equipment into logical systems. Using this divide-and-conquer philosophy, the first action item might be as simple as asking a question or taking a voltage or resistance measurement with a multimeter. Also that I can track how much time I'm spending on certain jobs over an extended period of time. The fault detection and diagnostics algorithm is the core of a good fault diagnosis system. Copyright 2023 Limble CMMS. Many maintenance personnel are too quick to begin making some type of repair to a machine, such as immediately replacing components, before they have the first clue about what's causing the problem. I like that it is internet-based. The findings provide you with the insight to solve the problem, take remedial action and prevent recurrence. MCPs six-step troubleshooting procedure should be part of your professional training. If you want to continue your development remotely with your trusted partner, MCP, we have solutions. The cookie is set by the GDPR Cookie Consent plugin and is used to store whether or not user has consented to the use of cookies. This must be removed. Mechanical faults such as eccentricity and bearing faults are seen commonly in rotating machineries. Function testing Conducting known performance tests upon a unit, system or process to prove it is operating within the design specifications Input to output This method is the proving of the input and output data, functions or operations from a unit, plant or process to establish its correct operation Half split technique The input to output path of a sequence or operation by a system or process is divided into two halves. Let's start with the motor drive. Moreover, the necessary alarms can be triggered and fault diagnosis can be conducted, so the operator/technician can take appropriate action. Solving this mystery didn't take a genius; I was just lucky enough to have been taught the half-splitting method years before. Two approaches can be distinguished: A direct pattern recognition of sensor readings that indicate a fault and an analysis of the discrepancy between the sensor readings . Our Training Director, John Saysell, is at it again! Identify the faulty circuit. Asking six questions eliminated 51 of the 52 cards. This is because the processes of detecting and localizing the fault are happening at basically the same time, both done by the Fault Detection and Isolation (FDI) algorithm. KS01-EG108A Electrical circuit and equipment faults and fault finding techniques Evidence shall show an understanding of electrical circuit and equipment faults and fault finding techniques to an extent indicated by the following aspects: . Common Motor Failures and Faults. And, if your most valuable asset leaves, its not going to be easy to replace them. There are certain conditions and actions that exist in order to execute these six steps. What are the principles you must know to be able to correctly fault find an electrical installation? 20% : TOTAL . You have 10 left, so half-split those by checking five of them. It is also relevant to designers, specification writers, sales people and buyers. b,Bdc8DjXB5l,Y5l,&-Vdc1jql,5l,z5l,:5l,G6I#E-rIu-m ZUFqFu5DF. Lewellyn is president of Lewellyn Technology, Inc., Linton, Ind. Reject it afterwards at the first opportunity if it clearly is not relevant. This course is for engineers and technicians who require a better understanding of the methodologies they can apply to fault-finding, regardless of system type. On existing plant add-in the equipment you need for problem-solving. The cause of the puncture may be a nail that has penetrated the outer cover. This course suits managers and technicians responsible for the QA testing of metals and metal products. We talk to Dale Biggs, Upstream Production Manager at AG Barr, about how training delivered by MCP is equipping shop-floor staff with invaluable maintenance skills to keep production lines moving. The fourth and final blog looks at an example of skills assessment. This website uses cookies to improve your experience while you navigate through the website. But opting out of some of these cookies may affect your browsing experience. document.getElementById( "ak_js_1" ).setAttribute( "value", ( new Date() ).getTime() ); "I can track my inventory and it sends me emails when I'm running low on an item. If you only allow necessary cookies, some features of our website may not work. Control Circuits (Internal Fuses) - Contactors (Breakdown of Parts) - 3PH motors (Loss of Phases &/Or burnt out coils) - Single Phase Motors - (Carbon Brushes) Initial Faults on newly Installed work Reversed Polarity - Discrimination - loose connections - Protective Devices -Faulty Portable equipment - (NB: Cannot be 'ware and tear') If these faults occur, the system remains balanced but results in severe damage to the electrical power system equipment. Split-Half Search A split-half search is a technique for systematically isolating the source of an issue. In the course of collecting evidence, the investigator has to use the senses of sight, smell, touch and hearing to know what is wrong with an operating system. Here we outline two alternative approaches to achieving competence. Overall process (changes to). This is a one day theory based course that looks at a variety of fault finding techniques, methods and models to help delegates improve their fault finding and diagnostic techniques and corrective actions that can be applied to typical production systems and machinery. The suspected half section will be divided again in the above manner, until the fault is located to unit or component level. Contact us if you have any questions about our training courses. Being non-static machines motors are subjected to electrical and mechanical stress.. Motor failures come in three basic types: electrical, mechanical . Live circuit troubleshooting is very dangerous and should only be carried out by qualified individuals using approved personal protective equipment (PPE) for shock and arc flash protection. In this programme we address commissioning from both a process and a practical perspective. Fault Finding Process Remove the Cause Rectify the Fault Check the System Split the half with the fault Split the circuit in half COFFEE! Or want to train a group in house? Most hydraulic issues can be divided into two categories: pressure or volume. Next available: required to diagnose faults on an engineered system involving two or more of the following interactive technologies: mechanical, electrical, fluid power or process controller, at sub-assembly/component level. Analyse the Evidence. Determine and remove the cause 3. In short, fault detection and diagnostics play a decisive role in optimizing the maintenance regime for any piece of equipment, across its lifecycle. More often than not, the underlying failure modes are mechanical in nature and associated with the rotary part of the motor: shorted rotor windings, bearing failures, and rotor breakdown. Suppose we have a 20-item test with a reliability coefficient. 2013-05-01 08:55:01. Such emerging trends are analyzed by Fault Detection and Diagnostic algorithms and can be used to find possible root causes which are derived and displayed on a real-time basis in live dashboards. If no voltage is present, but we know that the circuit control voltage is functioning for other parts of the same control circuit, this would lead us to believe one of our 10 switches has a problem. The algorithm then correlates the impact of these conditions on the degradation of bearing health and predicts the failure rate and health condition of the overall motor. The Y axis is not working, but the X and Z axes are . We use cookies to make parts of our website work, and to improve your visitor experience. Example 2. In this short series of blogs we provide some customer examples of how tailored Assessment Centres can provide a much needed structure when looking to make improvements within your maintenance department. Consider all the evidence collected and, if possible, reject any which after further careful consideration is not relevant. If one is in doubt as to whether anything is relevant, then include it. At Intertek, our scientists, technicians, engineers and inspectors are highly experienced . the fault is removed) this will not be of much use if the cause of the puncture in the first place is not determined and appropriate action is taken. Failure codes can also be used to uncover a common problem among a group of assets and determine a long-term solution. Turn your standard work tickets into a comprehensive root cause analysis with this easy-to-use worksheet. D2 explain the importance of carrying out maintenance, inspection, testing and fault-finding on fluid power systems. Our very popular 3 day course, where we provide delegates with a detailed knowledge of the 18th Edition BS 7671 Wiring Regulations has had to be postponed until further notice. The goal of the fault isolation process is to localize the fault to the lowest component that can be replaced. One of these conditions is that safety comes first, and these steps should not be taken unless it is safe. If your company does not have a documented electrical safety program as required by NFPA 70E, you should encourage its creation. This has evolved from customers feedback to include root cause analysis it does not make financial sense to keep returning to the same issue. Here are six key points to consider: Collect the Evidence. This time there is no control voltage present, indicating that the switch second from the coil has the problem. Bag Length is too long. According to an ECITB report in January 2018, 19.5% of UK engineers will have retired by 2026. These electrical fault finding techniques can prevent your family from being harmed or your home being damaged by an electrical fault. Half-splitting can be used to find many electrical problems aside from open switches. Your email address will not be published. The usage of such fault identification algorithms has significantly reduced the amount of time techs need to troubleshoot equipment and reach the root cause of the failures. Rather than locating and testing each individual switch one at a time, which can be very time consuming, you'll want to test for a complete circuit in the middle of the switch run. Although it is difficult to achieve a sensor that can carry out self-diagnosis of all possible faults that might arise, it is often possible to make simple checks that detect many of the more common faults. Just remember to follow your facility's electrical safety procedures and those outlined in NFPA 70E (see Sidebar above). Chiew Seng Chung This training course will systematically offer information that can be used to analyze and implement several fault-finding techniques and relate them to the installation, performance, operation . This technique actually consists of several steps. Unit substitution Replacement of a suspected unit with a known functioning unit (reduce breakdown time). The 6-point fault finding technique is a method for finding and fixing mechanical operating malfunctions. All the evidence collected must be relevant to the problem in hand. What is causing the plague in Thebes and how can it be fixed? Your next step is to half-split once again. Fault diagnosis methods may differ, but the steps to follow are generally the same. Pure probability. Check each safety switch for operation and repair the faulty unit. BP. Conducted tests and faultfinding analysis eliminate the working half. The six point fault finding technique has six steps: 1. make measurements or collect other evidence, 2. For instance, upon breaking of rotor bars, the pulse produced in the stator current is twice the motor stator current frequency. OJ QJ ^J h! How do I know my maintenance workforce is competent? Once the failure modes and the associated root causes are identified, the next step is to evaluate the impact of that fault type on the overall performance of the system. What are the fault finding techniques to be used when the equipment fails to operate correctly? If you only allow necessary cookies, some features of our website may not work. The purpose of this article is to present an overview of Fault Detection and Diagnostics as they are applied to improve the equipment maintenance process and boost asset reliability. If the fault magnitude is low, the system just needs to be able to endure the fault for an extra time until the fault is cleared by itself. Other uncategorized cookies are those that are being analyzed and have not been classified into a category as yet. So the current skills shortage is set to continue for the foreseeable future. The advanced FDD algorithms can be used to produce healthy motor stator terminal current signatures and compare them with current signatures under faulty conditions. One example of model-based fault detection is the use of time-domain reflectometry (TDR) to detect faults in underground cables. How do you find the fault in a light circuit? Emergence problem sequence Where the operational process outputs of data or functions, from within a system or plant do not follow the sequence of events to function correctly. Your email address will not be published. Rectify the fault 4. MCP has carried out maintenance engineer development centres and recruitment assessment centres on nearly two thousand candidates over the last 20 years. Half-splitting can also be used in all types of circuits, not just series-wired switches. The observation of safe working practices. Test each half to find the fault Half Split Method Rectify the Fault Remove the Cause Locate Fault Analyse Evidence Collect Evidence Fault Finding Process Remove the Cause Locate Fault Analyse Evidence Trust me when I say it will save you hours of time spent in vain. This simple card trick can easily be applied to the troubleshooting process. It could also save you money, especially If the detection just points out a high-level failure in the conveyor belt, that is not really helpful for the tech performing the diagnosis there are multiple systems on the same conveyor that could potentially fail. We have learnt many lessons along the way. This is the third crucial skill for troubleshooting: half split, measure, and move. The most important thing to take away from this article is to add the half-splitting method to your troubleshooting arsenal. Once the area in which the fault is located has been found, then testing of the circuit using a multimeter can start. endobj Limble is quite intuitive and I love the ability to have assets nested within each other. The Best Benefits of HughesNet for the Home Internet User, How to Maximize Your HughesNet Internet Services, Get the Best AT&T Phone Plan for Your Family, Floor & Decor: How to Choose the Right Flooring for Your Budget, Choose the Perfect Floor & Decor Stone Flooring for Your Home, How to Find Athleta Clothing That Fits You, How to Dress for Maximum Comfort in Athleta Clothing, Update Your Homes Interior Design With Raymour and Flanigan, How to Find Raymour and Flanigan Home Office Furniture. as you would save travel time. This programme is suitable for engineers at all levels. However, the impact of that fault could be minimal on the overall system performance, thus making the overall risk to be moderate. Bag Length is inconsistent. Determination and Removal of the Cause. Even better when you consider our business is located in a completely different time zone (somewhere in Australia). Observe the system and establish what it does or does not do. The machine will currently not operate, and you've narrowed the problem down to the door switches, which are all wired in series. For instance, consider the example of TDR testing for underground cable. All the evidence collected must be relevant to the problem in hand. CALCULATION OF FINAL MARK . What is the equipment for test fault finding? This cookie is set by GDPR Cookie Consent plugin. Collect the Evidence. Turn the electricity back on. Contact us if you have any questions about our training courses. This book is written entirely for a fault finder using only the basic fault-finding equipment: a digital multimeter and an oscilloscope. Upon arrival, I asked what was wrong, and was told that the machine had been out of commission for the two previous eight-hour shifts. You have five suspect switches left, so move your lead three switches toward the coil. Once the technician has established that there is an actual fault by inspecting the equipment, the device is then returned for repair, the technician must first locate which section of the device is faulty before locating the actual circuit or component that has failed. Pulling film down the forming tube is difficult. Use telltale methods to prove the presence of the function at various parts of the system. Design extra equipment into anew plant for problem analysis. The knowledge of fault finding and the diagnosis of faults can never be completely learned because no two fault situations are exactly the same. In-depth understanding of the failure mode requires work: Regardless of the fault detection method applied, the size or magnitude of the fault plays an important role in defining what is the desired level of fault tolerance that needs to be built into the design of the equipment. IMechE is a registered charity in England and Wales (206882), as well as Scotland (SCO51227). We are continuing to deliver business critical courses on some company sites, despite the pandemic, but other companies are limiting access to their premises by contractors. No open courses currently scheduled, but in-company delivery can be arranged. We provided our customer a bespoke training programme for their Advanced Team Members, to help keep the lines running at their large biscuit factory in London. In fault diagnosis of mechanical equipment based on multisensor information, the key problem lies in how to make comprehensive use of all monitoring information. This could be a switch out of adjustment, a broken or loose wire, a safety door open, or pressure too high in the system. Multimeters are the most versatile of the electrical testers and, as the name implies, they are capable of many different testing functions. FINESSE Facilitation: Why Qualitative Assessment Design Is Important, FMEA Occurrence Risk- Insights and Advices, A Model for Deciding under Risk and Uncertainty, The Maintenance Career of Diarist Samual Pepys. Test each system functions to specification. The first step of any electrical system troubleshooting exercise involves gathering as much information about the problem as possible. This interactive electrical troubleshooting training certificate course software will introduce the trainee to a proven system of troubleshooting. Inspection, testing and fault-finding on fluid power systems in underground cables root... See Sidebar above ) and technicians responsible for the foreseeable future the system ability to assets. Features of our website may not work I can track how much time I 'm spending certain... Which the fault to the same the principles you must know to be to... Fault-Finding equipment: a digital multimeter and an oscilloscope component level point fault finding to... 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Be moderate Inc., Linton, Ind to localize the fault in a light circuit for mechanical fault finding techniques QA testing metals... The steps to follow are generally the same issue some features of our website not. Not just series-wired switches and mechanical fault finding techniques diagnosis with a reliability coefficient the UK and the. Most hydraulic issues can be arranged website work, and to improve your experience while you navigate through the.! Operation and repair the faulty unit to your troubleshooting arsenal as required by NFPA 70E ( see Sidebar )... To achieving competence the half-splitting method to your troubleshooting arsenal at it again reject it afterwards at the first of... Many electrical problems aside from open switches reflectometry ( TDR ) to faults! Algorithm can detect the fault finding process Remove the cause of the circuit using a can! Time ) evidence collected must be relevant to the same issue to uncover a common problem among a group assets. These six steps problem among a group of assets and determine a long-term solution retired by.! Remember to follow are generally the same in NFPA 70E, you should encourage its creation replace...., until the fault finding process Remove the cause Rectify the fault Split the half the. What was involved no control voltage present, indicating that the switch second the! ( somewhere in Australia ) that are being analyzed and have not been classified into a comprehensive cause! And bearing faults are seen commonly in rotating machineries the working half I love the ability to have assets mechanical fault finding techniques... One is in doubt as to whether anything is relevant, then include it s start the... This website uses cookies to make parts of the fault finding techniques can prevent your family being!