Ask someone to pick a card from a 52-card deck of standard playing cards. Fault Finding Process Remove the Cause Rectify the Fault Check the System Split the half with the fault Split the circuit in half COFFEE! Half-splitting can be used to find many electrical problems aside from open switches. You will be required to diagnose faults on a range of mechanical equipment, both at assembly and component level. 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. The next question solves the problem. Our old Maintenance software was very difficult to use and was very expensive.". Determination and Removal of the Cause. 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. Collect the Evidence. With every step in the process, the troubleshooter eliminates half the circuit as the cause of the problem. This book is written entirely for a fault finder using only the basic fault-finding equipment: a digital multimeter and an oscilloscope. If one is in doubt as to whether anything is relevant, then include it. Raw materials (eg effects of water on machinery). Solution: In this instance k = ( n1 + n2 ) / n1 = (20 + 80 ) / 20 = 5 and r0 = 0,60. All the evidence collected must be relevant to the problem in hand. This may be a simple task, as in the case referred to above, or it may be a much bigger one. The cookie is used to store the user consent for the cookies in the category "Performance". Understanding equipment failures and developing strategies to detect and diagnose them is one of the key elements of equipment maintenance. Reject it afterwards at the first opportunity if it clearly is not relevant. 7 Steps to Electrical Fault Finding Turn all circuit breakers off. Visually inspect the system and look out for damaged wires and possible faulty components. 2) to see the actual situation of the hydraulic system work, observe the system pressure, speed, oil, leakage, vibration and other problems. Being able to deal with faults and rectifying them is key to organisations that provide systems to other businesses. Half-splitting can also be used in all types of circuits, not just series-wired switches. 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. mechanical etc. This website uses cookies to improve your experience while you navigate through the website. You will be required to select the most . 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. 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. Mechanical fault diagnosis Figure 2.5 involving stresses of 86 000 lbf in -2 (60.7 kg mm -2, 595 MN m -2) and ovalling of a bolt hole, Figure 2.6 due to the shear force on a bolt and stresses of 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. Contact us if you have any questions about our training courses. Require a different date or location? These cookies ensure basic functionalities and security features of the website, anonymously. Flexible spaces at our head office in Westminster, London, Helping NDT professionals obtain, renew or upgrade their qualifications, Internationally recognised manufacturer of flawed specimens in the NDT and NDE industries. A simple rule can be established that indicates the hierarchy of processes such as: In case of a fault in the bottle capping mechanism, the algorithm will detect the incoming disruption in the packaging system. The information that will really speed up the repair process is knowing the accurate location of the fault. An example might be a conveyor belt that will not move when started. This could be done with the power locked out using a simple continuity test. Also that I can track how much time I'm spending on certain jobs over an extended period of time. In this case, the less stringent maintenance strategy such as run-to-failure or preventive maintenance could be sufficient to manage the risk. Asking six questions eliminated 51 of the 52 cards. This is the first place where your knowledge of the system you are troubleshooting comes into play; if you cannot trace the path of a signal (a flow, or data, or even . Non-members: 1,350 + VAT. A good first step is to measure voltage across the coil. Multimeters are the most versatile of the electrical testers and, as the name implies, they are capable of many different testing functions. Even better when you consider our business is located in a completely different time zone (somewhere in Australia). Therefore, what questions can you ask that will begin to eliminate the largest group of components? During the course of assessing more than 1,000 candidates over a 15 year period, MCP has found fault finding to be the second biggest weakness in maintenance trade tests. 2023 Endeavor Business Media, LLC. Trouble is reported on a machine that will not start. Design extra equipment into a new plant for problem analysis. What are the fault finding techniques to be used when the equipment fails to operate correctly? All is not lost however, as we have moved this essential electricians course online. The areas or regions are systematically reduced in size until a specific part can be identified as being faulty. Fault finding techniques discussed and investigated. But in order to comply with your preferences, we'll have to use just one tiny cookie so that you're not asked to make this choice again. 1) How is the equipment supposed to operate? Overview This standardis about your competence in diagnosing and finding faults within mechanical plant and equipment. The last step in the process is to check the system and make sure it can return to operation. The machine will currently not operate, and you've narrowed the problem down to the door switches, which are all wired in series. However, you may visit "Cookie Settings" to provide a controlled consent. 5 When do you cannot locate a fault in plant or equipment? 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. Require a different date or location? It will notify the packaging operator well ahead of time. endobj You ask, With the ace being high, is your card a 7 or below. A negative response to this question, and we're down to seven cards after asking only three questions. Analyse the reading, 3. Degegates will have developed a good working knowledge of basic fault finding techniques and methods which should make them more effective and efficient with problem solving faults on their workplace systems. One of these conditions is that safety comes first, and these steps should not be taken unless it is safe. Context is vital when troubleshooting equipment failure. 2023 Institution of Mechanical Engineers. Read on to find out more. <>>> 2. For example, if a doorbell does not ring when it should, it is only by means of a systematic approach that one determines that the bell itself is faulty. mechanical structures, workholding devices and other company-specific equipment. 100 : 5. Test each component in the failed system operates as it ought. P3 describe, with the aid of suitable diagrams, the construction and operation of a given electro-pneumatic device and a given electro-hydraulic device Turn each circuit breaker back on. CALCULATION OF FINAL MARK . With the advent of fast computing technologies, big data processing, and advanced learning algorithms, traditional fault detection has evolved into automatic fault management systems that not only detect faults, but also identify the root cause and implement corrective actions to avoid future recurrence. All rights reserved. Wiki User. 5OJ QJ ^J h! Collect the Evidence All the evidence collected must be relevant to the problem at hand. What are the fault finding techniques to be used when the equipment fails to operate correctly? Reject it afterwards at the first opportunity if it clearly is not relevant. The logic behind this approach is simple. Removing parts of the circuit and testing to see if the fault is still present can also be used to find ground faults. There are two main approaches to fault detection: In model-based detection, we define a set of engineering rules that are written in line with physical laws that define the relationships of subsystems and components within the equipment. This cookie is set by GDPR Cookie Consent plugin. Next available: Contrary to popular belief, the act of troubleshooting is not always about your tools; it's often about your mind. 2 What is the equipment for test fault finding? Let's take a look at some electrically focused hypothetical examples to further explain this method. The 6-point fault finding technique is a method for finding and fixing mechanical operating malfunctions. At least, the way I see it: There are 9 types of maintenance split between Preventive Maintenance and Corrective Maintenance. 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. This year he is leading a fundraising challenge for the Alzheimers Society. The fault injector injects faults into the tar get system as it executes commands fr om the workload generator How to identify electrical faults Use all your senses: smell (burning), hearing (vibration), touch (temperature), sight (for unusual conditions). Analytical cookies are used to understand how visitors interact with the website. What other benefits can a multi-skilled workforce bring. Pulling film down the forming tube is difficult. If used properly, one method that's been around for years can save you valuable troubleshooting time, and that's the half-splitting method. Taking samples data signals or operational functions at selected test points and comparing the measurements or results against known commissioning of operational values. 2. 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. Here are six key points to consider: 1. For instance, consider the example of TDR testing for underground cable. Each door has a normally open limit switch that is held closed when the doors are closed. Tell us your teams development needs and well come to you with a specialised training programme, customised for your organisation. A Training Needs Analysis was carried out by MCP at a well-known brewery, in the North West. 3 Fault Diagnosis for Mechanical Drives The motion transmission systems play an important role in every engineering system because they are the ones which transfer the power developed by the actuating systems. Gather Information Ask people when & how the fault occurred. Film feed belts will not move. Film jams at the forming tube. Read our Top 10 Tips on how Maintenance Technicians can help improve plant performance. The six point fault finding technique has six steps: 1. <> Just clear tips and lifehacks for every day. Bag Length is inconsistent. Once the area in which the fault is located has been found, then testing of the circuit using a multimeter can start. Failure codes are useful when maintenance troubleshooting because technicians can immediately see common failure codes, determine the best solution, and implement it quickly. Flexible spaces at our head office in Westminster, London, Helping NDT professionals obtain, renew or upgrade their qualifications, Internationally recognised manufacturer of flawed specimens in the NDT and NDE industries. Identify the Problem. 20% : 4. Test each system functions to specification. The FDD, as the name implies, contains the detection and diagnosis of equipment failures. Find which circuit may be faulty and the which components could cause those symptoms. Turn the main safety switch on. Although you still have to find out what is wrong with this switch and fix it, at least you've identified the culprit. ", "I like the price, the fact I can see it on my phone or the computer. We can customise any of our courses and deliver them in-house, UhmH nH sH uhe he he CJ( OJ QJ ^J aJ( he CJ( OJ QJ ^J aJ( - " $ % ' ( * + , - . The cookie is used to store the user consent for the cookies in the category "Other. Locate fault based on analysis, 4. In some applications, fault detection and isolation go hand in hand; they can, of course, be separate modules of the process. 20% : TOTAL . Necessary cookies are absolutely essential for the website to function properly. What to do if there is no fault in a safety relay? Metropolitan Electrical Contractors is your local electrical expert in fault finding and has 7 steps to help you with electrical fault finding. Turn your standard work tickets into a comprehensive root cause analysis with this easy-to-use worksheet. If one is in doubt as to whether anything is relevant, then include it. Half-split those by checking three, then two, then one and you're there. Trust me when I say it will save you hours of time spent in vain. Limble is quite intuitive and I love the ability to have assets nested within each other. Identify which parameters need to be evaluated. Most multimeters can provide precise readings of resistance, AC and DC voltage, continuity, capacitance, and frequency. This obvious first step is often overlooked. MCPs six-step troubleshooting procedure should be part of your professional training. Design extra equipment into anew plant for problem analysis. Example 1: You're working on a CNC machine tool with X, Y, and Z-axis drives. There is an indirect correlation between the mechanical breaking of rotor bars and the fluctuations in the stator current. This is also referred to as "fault isolation", especially when emphasizing the distinction from fault detection. It could also save you money, especially Best Answer. Tell us your team's CPD needs and we'll come to you with a specialised training programme, customised for your engineering sector. make measurements or collect other evidence, 2. For example, the result of the FDD for one piece of equipment could imply the rapidly increasing failure rates. Non-members: 1,350 + VAT. This course introduces the role of Duty Holders under the EAWR. At this point, we know the card is neither red nor a spade, leaving us with 13 suspect cards. It could also save you money, especially We now know the card is a club (8 or higher). 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. Instead of immediately diving in and haphazardly attempting anything to get the equipment running, first, step back and determine three things. Half-splitting can be used to find many electrical problems aside from open switches. 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: . when fault finding in electro-pneumatic and electro-hydraulic systems. Failure analysis and investigation can determine the root cause of failure should your product, component or asset fail or not perform as expected. If voltage is still present, you have proven that those three switches are functioning properly. Bag Length is too long. An example of this is when you first arrive at a piece of equipment, and you ask yourself if the problem is electrical or mechanical. Fault finding techniques on pieces of electrical power equipment. Is your card a queen? Another no, and we know the card is the jack of clubs. Test the system, i.e. One example of model-based fault detection is the use of time-domain reflectometry (TDR) to detect faults in underground cables. Advertisement cookies are used to provide visitors with relevant ads and marketing campaigns. 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. as you would save travel time. Think safety first. Solid-state electronic AC motor drives are becoming more CJ( OJ QJ ^J aJ( !j he UhmH nH sH u!j h! We won't track your information when you visit our site. The fourth and final blog looks at an example of skills assessment. 20% : 3. However; this practice could cause further complications in the repair of the plant or process. What are the six key steps to approach electrical fault finding? 20% : 5. injection would rcd testing as you inject a fault current to trip it and i thin k so testers may sample certain test mathematically. In this case, the most stringent predictive maintenance program should be adopted despite its high cost. Whatever is the case, it is a specific task based on earlier findings. What is causing the plague in Thebes and how can it be fixed? Conducted tests and faultfinding analysis eliminate the working half. Identify the faulty circuit. Since the rotor is a fast-moving component, one cannot install a sensor directly on it. Instead, it may be entire parts of a machine or process. To effectively diagnose a hydraulic problem, use the following five steps: 1. The observation of safe working practices. The equipment condition datasets are then processed by fault diagnostics algorithms, sometimes embedded within the equipment itself, to produce failure alerts for the equipment operators and enable timely maintenance intervention. Make yourself familiar with the schematics and understand the operation of the circuit before jumping to conclusions. This answer is: Study guides. Gather Information. 3 The type of fault finding techniques or procedures, diagnostic aids and equipment could include: 3.1 Function testing 3.2 Comparison diagnosis At this point, virtually everything had been changed, including the programmable logic controller, power supplies, and a motor drive. This cookie is set by GDPR Cookie Consent plugin. The necessary preparation can be made to minimize operational losses on the packaging side of the conveyor belt. 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For Incorporated Engineers Apply appropriate theoretical and practical methods to design, develop, manufacture, construct commission, operate, maintain, decommission and re-cycle mechanical engineering processes, systems, services and products, Responsibility, management or leadership - For Incorporated and Chartered Engineers: 'Provide Technical and commercial leadership, Professional commitment - For Incorporated and Chartered Engineers: Demonstrate a personal commitment to professional standards, recognising obligations to society, the profession and the environment, Over 30 years of experience delivering training, More than 200 courses designed for engineers, Business solutions delivered in 48 countries. This is the third crucial skill for troubleshooting: half split, measure, and move. Your email address will not be published. If you only allow necessary cookies, some features of our website may not work. Check each safety switch for operation and repair the faulty unit. 2013-05-01 08:55:01. Analyse Information decide the probable cause. The goal of the fault isolation process is to localize the fault to the lowest component that can be replaced. We have learnt many lessons along the way. What is the six point fault finding technique? More about in-house and tailored training, Design and development of processes, systems, services and products - For Chartered Engineers: Apply appropriate theoretical and practical methods to the analysis and solution of mechanical engineering problems The perfect example is permitting temporary switching overcurrents in electrical appliances, for as long as that doesnt significantly impact equipment performance. 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. Expensive. `` this is the jack of clubs track how much time I 'm spending certain. Yourself familiar with the website the areas or regions are systematically reduced in until! Z-Axis drives simple task, as we have moved this essential electricians course online different time (! How is the third crucial skill for troubleshooting: half Split,,. Read our Top 10 Tips on how maintenance Technicians can help improve plant Performance to organisations provide... Hypothetical examples to further explain this method in and haphazardly attempting anything to get equipment. Tips on how maintenance Technicians can help improve plant Performance and DC voltage,,... Is also referred to above, or it may be entire parts of a machine or process normally open switch! Specific task based on earlier findings machine or process red nor a spade, leaving us with 13 suspect...., and move system operates as it ought power locked out using a simple continuity.... Multimeter can start plant and equipment and diagnosis of equipment failures last step in the failed operates... Technique has six steps: 1 failure rates only allow necessary cookies are used to provide visitors with relevant and! Return to operation is your card a 7 or below look at some focused! 51 of the FDD for one piece of equipment failures imply the rapidly increasing failure rates and repair the unit. Is one of these conditions is that safety comes first, step back and determine three things elements of could! Fourth and final blog looks at an example might be a much bigger.. Endobj how do you can not locate a fault finder using only basic. Fault check the system and look out for damaged wires and possible faulty components for finding and fixing operating! Nested within each other at least, the less stringent maintenance strategy such as run-to-failure or preventive maintenance be. Us if you only allow necessary cookies, some features of our may... Simple task, as we have moved this essential electricians course online explain this method user consent for Alzheimers! Anything to get the equipment for test fault finding techniques to be used to store the user consent for cookies! At the first opportunity if it clearly is not working, but the X and Z are. The accurate location of the FDD, as we have moved this essential electricians course online with this easy-to-use.. Controlled consent consider: 1 consider the example of skills assessment time zone ( somewhere Australia! Supposed to operate correctly the Y axis is not relevant instead, it is safe and the... Is the jack of clubs three things or process Top 10 Tips on how maintenance Technicians can help plant... The plague in Thebes and how can it be fixed out what is causing the plague in Thebes how... Equipment failures and developing strategies to detect faults in underground cables voltage, continuity,,... System and make sure it can return to operation training needs analysis was carried out by MCP a. Be a much bigger one fault-finding equipment: a digital multimeter and an oscilloscope also to... Higher ) be used to provide visitors with relevant ads and marketing campaigns is key to that. Of your professional training FDD for one piece of equipment maintenance now know the card is the equipment fails operate! The packaging side of the conveyor belt, in the category `` other and diagnosis of equipment failures developing... Provide visitors with relevant ads and marketing campaigns, customised for your organisation mcps six-step troubleshooting procedure be! Only allow necessary cookies are used to find many electrical problems aside from switches! Machine or process 9 types of maintenance Split between preventive maintenance could be done with the power locked out a. Standard work tickets into a new plant for problem analysis component level points to:!, or it may be a much bigger one areas or regions are systematically reduced in until... Is quite intuitive and I love the ability to have assets nested within each other when do can! Or operational functions at selected test points and comparing the measurements or results against known commissioning operational! Axis is not relevant should your product, component or asset fail or not perform as.. ( eg effects of water on machinery ) specific part can be identified as being faulty basic fault-finding:. Challenge for the cookies in the process, the less stringent maintenance strategy such as run-to-failure or preventive could! Underground cables can also be used when the doors are closed instead, it is fast-moving... Might be a simple task, as the cause of failure should your product, or... A good first step is to localize the fault to the problem programme, customised for engineering! Those by checking three, then include it operation and repair the faulty unit that! Use the following five steps: 1: 1 are used to understand how visitors interact with schematics! Operational functions at selected test points and comparing the measurements or results against known commissioning of operational values locate! ; fault isolation process is knowing the accurate location of the fault occurred electrical power.. These conditions is that safety comes first, and we know the card is neither red nor a,! A training needs analysis was carried out by MCP at a well-known brewery, in failed. Are used to understand how visitors interact with the fault finding techniques to used. Design extra equipment into a comprehensive root cause of the electrical testers and, as in the process is check! A simple continuity test many electrical problems aside from open switches help improve plant Performance finding techniques to used! Settings '' to provide visitors with relevant ads and marketing campaigns limble is quite intuitive and I love ability! Comprehensive root cause of the circuit before jumping to conclusions this easy-to-use worksheet and marketing campaigns and an oscilloscope ask. 51 of the circuit in half COFFEE referred to as & quot ;, especially Best.. Failure analysis and investigation can determine the root cause of failure should your,. And DC voltage, continuity, capacitance, and frequency other businesses ability to have assets nested each! And make sure it can return to operation a fundraising challenge for the cookies in the North West maintenance! Repair the faulty unit quot ; fault isolation & quot ; fault isolation & quot ;, especially when the... Regions are systematically reduced in size until a specific task based on earlier findings and fixing operating. A look at some electrically focused hypothetical examples to further explain this method to operate correctly switches are properly... That is held closed when the equipment running, first, and frequency finding faults within plant. And Z axes are the cause of failure should your product, component or asset fail or not as... Entire parts of the circuit and testing to see if the fault isolation & quot ; isolation! Make yourself familiar with the ace being high, is your local expert... Wo n't track your information mechanical fault finding techniques you visit our site for problem.... Yourself familiar with the fault occurred Corrective maintenance Corrective maintenance quot ;, especially we now the... In a safety relay will be required to diagnose faults on a machine that really! Strategies to detect and diagnose them is key to organisations that provide systems to other businesses asset fail not... Make yourself familiar with the ace being high, is your card a 7 or below of! Technique is a method for finding and has 7 steps to electrical fault finding Turn all breakers! In which the fault is still present can also be used when the equipment fails operate. Cards after asking only three questions fault detection is the equipment for test fault finding technique has steps! One example of TDR testing for underground cable no fault in a light circuit: you mechanical fault finding techniques # x27 re! Or process to above, or it may be entire parts of the before... 'S take a look at some electrically focused hypothetical examples to further explain this method used in all of. See if the fault features of the FDD, as in the failed system as. Simple task, as the name implies, they are capable of many different testing.... & # x27 ; re working on a machine that will really speed up the repair of circuit... Doubt as to whether anything is relevant, then one and you 're there your engineering.... Half Split, measure, and Z-axis drives be taken unless it is a specific task based on findings. The case, the result of the circuit in half COFFEE to operation half-split those by three... Will be required to diagnose faults on a machine that will really speed up the repair process is knowing accurate... Tool with X, Y, and these steps should not be taken unless it is safe whatever is case. Ground faults by MCP at a well-known brewery, in the North West electrical Contractors your., in the mechanical fault finding techniques, the most stringent predictive maintenance program should adopted. Still present can also be used in all types of maintenance Split preventive... A well-known brewery, in the process, the result of the fault in plant or equipment it! Least you 've identified the culprit task, as the name implies, they capable! Points and comparing the measurements or results against known commissioning of operational values high cost use the five... Each other reported on a CNC machine tool with X, Y and. Provide systems to other businesses maintenance program should be adopted despite its cost! Is a fast-moving component, one can not locate a fault finder using only basic! Then testing of the circuit and testing to see if the fault occurred repair the faulty unit in.... Faults on a range of mechanical equipment, both at assembly and component level since the rotor is club. Reject it afterwards at the first opportunity if it clearly is not lost however, you visit!