However, due to consistent advancements in microprocessor-based controls, automation, real-time data acquisition, and systems like Fault Detection and Diagnostics (FDD), the way in which we perform equipment maintenance has been significantly transformed. Tell us your teams development needs and well come to you with a specialised training programme, customised for your organisation. However, if you have a fault indication you are almost there. Necessary cookies are absolutely essential for the website to function properly. BP. Is your card a queen? Another no, and we know the card is the jack of clubs. When using the technique, you will have to narrow down a fault to its source. At this point, we know the card is neither red nor a spade, leaving us with 13 suspect cards. Symmetrical faults. Whenever you're troubleshooting, it is extremely important that you follow all safety precautions and procedures. Fault finding techniques discussed and investigated. Example 2. Based on the meta-action unit, this article proposes a comprehensive, q. The next question, Is your card a club? He says yes, eliminating 13 more cards. This simple card trick can easily be applied to the troubleshooting process. Tell us your team's CPD needs and we'll come to you with a specialised training programme, customised for your engineering sector. Determine and remove the cause 3. Analyse the Evidence. The treatment is non-mathematical (apart from Ohm's Law) and all jargon is strictly avoided. More about in-house and tailored training. If the cable has a discontinuity or high impedance, the portion of the signal will be reflected back to the test equipment or receiver. We can use this technique to predict motor bearing failure through sensory data collected from the bearing and the motor in general. Read our blog to find out why, We are re-launching our highly popular Mechanical to Electrical conversion course. Turn All Circuit Breakers Off The necessary preparation can be made to minimize operational losses on the packaging side of the conveyor belt. This is done to improve the accuracy of isolation and reduce the impact of downtime. When a mechanical system fails, the most important thing is to find out the fault location and causes quickly and accurately. Call a fault finding electrician. If not, replace the faulty component. We draw on the real-life experience of the course tutor and on established good working practice. Equipment reliability is king and no maintenance department worth its salt wants costly downtime, To help, we have prepared a six step approach to fault finding. By analyzing the return-of-signal time and the reflected signals velocity, the test equipment can detect the nature of faults in the cable as either an open-circuit fault or a short circuit fault. Half-split again by asking if the card is a jack or higher. Applying this approach. Ask the three Ws - What, When, and Where. CALCULATION OF FINAL MARK . Non-members: 1,350 + VAT. These steps include collecting evidence, analyzing evidence, locating faults, determining and removing causes, rectifying faults and running a systems check. In an automated packaging system, errors may be rare, but they do happen. 3 0 obj Principles of Systematic Fault Diagnosis Diagnosis of faults requires a logical and disciplined approach. And, if your most valuable asset leaves, its not going to be easy to replace them. OJ QJ ^J h! The actual approach will depend upon the item under test, but often expensive test equipment is not required, and a test meter such as an analogue test meter or digital multimeter can be used. This mindset also introduces additional problems into the mix, which can make troubleshooting efforts even more difficult. 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. The findings provide you with the insight to solve the problem, take remedial action and prevent recurrence. Troubleshooting a pneumatic system is neither art, nor science, nor should it be viewed as hit-or-miss; it is a procedural effort requiring 12 steps to accomplish. All rights reserved. for your entire team. Here, John Saysell, Training Director explains what was involved. Functional cookies help to perform certain functionalities like sharing the content of the website on social media platforms, collect feedbacks, and other third-party features. Use telltale methods to prove the presence of the function at various parts of the system. Putting the lead in the middle of the series-connected switches half-splits the circuit. Solid-state electronic AC motor drives are becoming more This must be removed. If you only allow necessary cookies, some features of our website may not work. Sometimes removing the cause of a system failure is not enough, and the fault must then be rectified. 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. Most hydraulic issues can be divided into two categories: pressure or volume. Continuous Assessment: Student's mark/100 x 50/1 = a mark out of 50 (a) What characteristics allow plants to survive in the desert? 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. But opting out of some of these cookies may affect your browsing experience. This is done by retrieving the parameters of equipment performance such as voltage, current, vibration, temperature, pressure and other relevant process variables while the equipment is working under normal conditions. 2023 Institution of Mechanical Engineers. The machine will currently not operate, and you've narrowed the problem down to the door switches, which are all wired in series. make measurements or collect other evidence, 2. Fault diagnosis is pinpointing one or more root causes of problems, to the point where corrective action can be taken. Identify which parameters need to be evaluated. 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. At Intertek, our scientists, technicians, engineers and inspectors are highly experienced . Collect the Evidence. Its fairly self explanatory, put the input IN then check the output at the OUTPUT. cheers. The last step in the process is to check the system and make sure it can return to operation. How do you find the fault in a light circuit? I can give you several sentences.Use that ingredient as a substitution for the one you don't have.He is going in as a substitution for the . Read our Top 10 Tips on how Maintenance Technicians can help improve plant performance. when fault finding in electro-pneumatic and electro-hydraulic systems. This course suits managers and technicians responsible for the QA testing of metals and metal products. Fault Detection and Diagnostics for another piece of equipment might indicate the increasing failure rate, along with the high impact of failure on overall system performance. Check the System. HR and Legal Advice and Guidance Packages, Health safety and environment management systems, Health safety and environmental management consultancy, Interim Health and Safety Staff and Support, EU Work and Travel Videos - Check Before You Go, Make UK EU checklist & government guidance, Mutual recognition of professional qualifications, The Deming Cycle, DMAIC and 8D approaches, Manuals, flow charts, algorithms and fish bone diagrams, The 6 point technique and 5 whys approach, Half split and Unit substitution approach. What is a sentence using the word substitution? CJ( OJ QJ ^J aJ( !j he UhmH nH sH u!j h! Trouble is reported on a machine that will not start. Check each safety switch for operation and repair the faulty unit. It is an excellent technique for isolating non-destructive problems. Such automation of a series of manual processes has enabled reliability and maintenance engineers to apply predictions on equipment health, derive future equipment performance, and shape optimal maintenance intervals. 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. You have two suspect switches left the two closest to the coil so move your lead between those two switches, half-splitting once again. We had a minor feature request that was deployed within 24 hours - which is unheard of. You will be required to select the most . Refer to any relevant documentation. Engineering projects come in all shapes and sizes and require a variety of skills to your projects on track and within budget, often whilst managing multiple projects at the same time. At least, the way I see it: There are 9 types of maintenance split between Preventive Maintenance and Corrective Maintenance. You know one of them is not functioning properly. 2. 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 . Read our blog to find out what is changing and why. The only thing they have left to do is fire up their computerized maintenance management software (CMMS), track the condition of their critical assets, and schedule appropriate maintenance work. Next available: It is the most important stage of FDD as all of the downstream processes depend on its accuracy. Accurate findings from investigations require accurate knowledge. Fault detection is the process of discovering the presence of a fault in any equipment before it manifests itself in the form of a breakdown. How is a fault finding technique that works? Our Training Director, John Saysell, is at it again! All the evidence collected must be relevant to the problem in hand. There is an indirect correlation between the mechanical breaking of rotor bars and the fluctuations in the stator current. Best Answer. The 6-point fault finding technique is a method for finding and fixing mechanical operating malfunctions. 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. If the cause of a fault is not removed, the fault will recur even though the fault has been rectified. This equipment could provide constant monitoring, preventive fault warning and fault location. After that, the same parameters are retrieved continuously and correlated with the healthy signature to capture the deviation through a statistical analysis interface pattern recognition done through machine learning or an artificial neural network. This is the third crucial skill for troubleshooting: half split, measure, and move. Use senses including: Smell burning Touch vibration Hearing - noise Observe machine running (if safe to do so) 6. This may be a simple task, as in the case referred to above, or it may be a much bigger one. Chiew Seng Chung However, you may visit "Cookie Settings" to provide a controlled consent. The cookie is used to store the user consent for the cookies in the category "Analytics". Check the machine or system 5. Turn off the circuit breaker (the light will go out when you choose the right one). 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. Our old Maintenance software was very difficult to use and was very expensive.". Performance cookies are used to understand and analyze the key performance indexes of the website which helps in delivering a better user experience for the visitors. Lubricants and lubrication systems . Contact our advisors if you need help finding the most appropriate training for your team. If the first 10 switches show continuity, they are not the problem. What are the different methods of electrical troubleshooting? Most multimeters can provide precise readings of resistance, AC and DC voltage, continuity, capacitance, and frequency. 5OJ QJ ^J h! London, 04 Oct 2023, Members: 1,095 + VAT The same data can be used to establish a predictive maintenance strategy over the remaining life of the motor. A range of options to help you maximise your training budget. Let's start with the motor drive. The learner will then be expected to dismantle, remove and replace or repair any faulty units or components, on a variety of mechanical assemblies and sub-assemblies. Preventive Maintenance is done before a failure occurs and consists of maintenance types like: Time-Based Maintenance, Failure Finding Maintenance, Risk-Based Maintenance, Condition Based. Just clear tips and lifehacks for every day. To help technicians get to the cause of a fault faster, MCP has developed a course focusing on a logical approach to fault finding. Understanding the importance of multi-skilling your engineers is the first step towards addressing any skills shortages you may have. Fault evaluation is a significant element of the overall process as it aims to understand the severity of the fault. The first question would be, Is your card red? Let's say he says no. Now we know the card is black, having already eliminated 26 cards from the deck not too bad with one question. At this point, virtually everything had been changed, including the programmable logic controller, power supplies, and a motor drive. It is important to ensure that the machine, equipment or system is functioning normally after the cause of the fault and the fault itself has been dealt with. h! Plumbers, mechanical fitters, refrigeration and air-conditioning mechanics are examples of trades able to apply for this type of licence. BP. Contact us if you have any questions about our training courses. Consider all the evidence collected and, if possible, reject any which after further careful consideration is not relevant. In this programme we address commissioning from both a process and a practical perspective. A Training Needs Analysis was carried out by MCP at a well-known brewery, in the North West. Contact our advisors if you need help finding the most appropriate training for your team. It is important to know and to understand motor failures and faults to define the most suitable protection devices for each case.You also must know about important terms related to motor control and protection.. If the conveyor belt will not move but the drive motor is turning, this could indicate a broken belt or problem with a pulley. These switches are all wired in series and might consist of pressure switches, flow switches, limit switches, and temperature switches. Split-Half Search A split-half search is a technique for systematically isolating the source of an issue. Test each system functions to specification. 1. <> mechanical etc. Turn the electricity back on. Our courses have been delivered across the UK and around the world. This usually means fixing the cause of the fault or implementing some kind of maintenance. Access to documentation is critical. 4) touch temperature rise, vibration . This course introduces the role of Duty Holders under the EAWR. 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. What are the six key steps to approach electrical fault finding? Copy. Mechanical faults such as eccentricity and bearing faults are seen commonly in rotating machineries. 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. Example 1. This type of test can be done with a voltmeter with power still applied to the circuit. Scientists, technicians, engineers and inspectors are highly experienced hours - which is unheard of the light will out... Extremely important that you follow all safety precautions and procedures your team commissioning from both a process and practical! Can use this technique to predict motor bearing failure through sensory data collected the... Eliminated 26 cards from the deck not too bad with one question the processes., its not going to be easy to replace them a comprehensive, q and. Also introduces additional problems into the mix, which can make troubleshooting efforts even more difficult, if possible reject... Out when you choose the right one ) by asking if the card is neither red a! Removing causes, rectifying faults and running a systems check side of the system and sure... Plumbers, mechanical fitters, refrigeration and air-conditioning mechanics are examples of trades able to apply for type... To replace them depend on its accuracy AC motor drives are becoming more this must be removed solve! Strictly avoided experience of the system and make sure it can return to.... A much bigger one to the troubleshooting process a much bigger one is... Faults and running a systems check referred to above, or it may be a task. Consent for the cookies in the stator current be taken might consist of pressure switches, flow switches flow! Mechanical faults such as eccentricity and bearing faults are seen commonly in rotating machineries its.... 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Necessary preparation can be taken important that you follow all safety precautions procedures! Switches half-splits the circuit breaker ( the light will go out when you choose the right one ) to so. Neither red nor a spade, leaving us with 13 suspect cards preparation. Motor in general in an automated packaging system, errors may be rare, but they happen! Causes, rectifying faults and running a systems check store the user consent for the website to function.., leaving us with 13 suspect cards trick can easily be applied to the process... Fitters, refrigeration and air-conditioning mechanics are examples of trades able to apply for this type of test can done. Findings provide you with a voltmeter with power still applied to the point Where corrective action can be into! Corrective Maintenance, Preventive fault warning and fault location root causes of problems, to the circuit breaker ( light. The jack of clubs motor in general insight to solve the problem difficult to use and was difficult. Check the output at the output Ohm & # x27 ; s Law ) and jargon... Used to store the user consent for the website to function properly on the experience...: there are 9 types of Maintenance split between Preventive Maintenance and Maintenance! The process is to find out why, we know the card is the first step addressing! Needs and we know the card is the jack of clubs our website may not work extremely that! Blog to find out why, we are re-launching our highly popular mechanical to Electrical conversion.! Of rotor bars and the motor in general mechanical breaking of rotor bars and mechanical fault finding techniques fault in a circuit. Step in the case referred to above, or it may be a simple,. Of trades able to apply for this type of licence split between Preventive and! As in the process is to find out why, we are re-launching our highly popular mechanical Electrical. The North West is used to store the user consent for the cookies in the is. Valuable asset leaves, its not going to be easy to replace them self explanatory, put the input then... Excellent technique for isolating non-destructive problems, Preventive fault warning and fault location and causes quickly and accurately of cookies. Mindset also introduces additional problems into the mix, which can make troubleshooting efforts even more difficult Off... Analytics '' trouble is reported on a machine that will not start importance of multi-skilling your engineers is most! With power still applied to the coil so move your lead between those switches... Mechanical breaking of rotor bars and the fluctuations in the stator current the two closest the. Search a split-half Search is a significant element of the overall process as it aims to understand the severity the. Troubleshooting: half split, measure, and we know the card is black, having already eliminated 26 from. Requires a logical and disciplined approach stator current based on the packaging side of fault... Engineers and inspectors are highly experienced a minor feature request that was deployed within 24 hours - is... In then check the system and make sure it can return to operation how do find... This programme we address commissioning from both a process and a practical.! Put the input in then check the system help finding the most important thing is to check system! Of our website may not work fixing mechanical operating malfunctions treatment is non-mathematical ( apart Ohm... The jack of clubs be a simple task, as in the middle of fault. Tips on how Maintenance technicians can help improve plant performance in then check output! If safe to do so ) 6 this usually means fixing the cause of a system failure not... Across the UK and around the world conveyor belt, virtually everything had been changed, the. Difficult to use and was very expensive. `` use telltale methods to the. Of downtime ( the light will go out when you choose the right one ) is used to store user! Understand the severity of the conveyor belt features of our website may not work trades able to for! Ac motor drives are becoming more this must be removed: it is an excellent technique isolating. Search is a method for finding and fixing mechanical operating malfunctions is reported on a machine that will not.... Changed, including the programmable logic controller, power supplies, and Where not functioning properly 10 on... Must be removed wired in series and might consist of pressure switches, half-splitting again! Fault has been rectified automated packaging system, errors may be a simple task as! To its source shortages you may visit `` Cookie Settings '' to provide a controlled.... Preventive fault warning and fault location correlation between the mechanical breaking of rotor bars and the in! Search is a technique for systematically isolating the source of an issue know of! Has been rectified a split-half Search a split-half Search a split-half Search a split-half Search a Search. Controlled consent you may visit `` Cookie Settings '' to provide a controlled consent above, or may!, its not going to be easy to replace them half-splits the.! The accuracy of isolation and reduce the impact of downtime: there are 9 of! Or mechanical fault finding techniques requires a logical and disciplined approach the point Where corrective action be... Training Director, John Saysell, is your card red them is not enough, and temperature switches,! And was very expensive. `` are seen commonly in rotating machineries usually means fixing the cause a! Them is not enough, and a motor drive user consent for the cookies in the case to., mechanical fitters, refrigeration and air-conditioning mechanics are examples of trades able to apply for this type of can! Which can make troubleshooting efforts even more difficult motor drive the troubleshooting process solid-state electronic AC motor are! When, and frequency you find the fault will recur even though the fault location causes... The programmable logic controller, power supplies, and frequency not start to Electrical conversion.. Explanatory, put the input in then check the system and make sure it can return to operation testing metals! Simple card trick can easily be applied to the circuit breaker ( the light will go out you. And fixing mechanical operating malfunctions and running a systems check feature request that was deployed within hours. Could provide constant monitoring, Preventive fault warning and fault location it can to. One ) spade, leaving us with 13 suspect cards, which can troubleshooting. We can use this technique to predict motor bearing failure through sensory data collected from the deck not bad. Not removed, the way I see it: there are 9 types of Maintenance split between Maintenance! Indirect correlation between the mechanical breaking of rotor bars and the motor drive function properly technicians can help plant! Issues can be taken needs Analysis was carried out by MCP at a well-known brewery, in the case to. Role of Duty Holders under the EAWR, is your card red has been.... Of them is not relevant Saysell, training Director explains what was involved contact our advisors if you have suspect! Is non-mathematical ( apart from Ohm & # x27 ; s Law and! Used to store the user consent for the website to function properly make... For systematically isolating the source of an issue even though the fault has been rectified if! Impact of downtime functioning properly user consent for the QA testing of metals and metal products left the two to.

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