Visually inspect the system and look out for damaged wires and possible faulty components. The perplexed repairmen from the previous shift told me that no matter what they did, the machine continued to blow a small control fuse. If there is no fault, proceed to the next step. Lets use a high voltage and high power three-phase AC induction motor as an example. Moreover, the necessary alarms can be triggered and fault diagnosis can be conducted, so the operator/technician can take appropriate action. Example 1: You're working on a CNC machine tool with X, Y, and Z-axis drives. Must be done before returning to service or re-starting production Must be taken after step 4 If not removed, fault will recur Based on analysis of evidence Consider all evidence and its validity Consider history of machine including: Past break down (history) Modifications Planned maintenance Use test equipment (built-in or otherwise) Refer to manufacturers manual (look for fault-finding aids) Question operator (use good social skills) Consider Packaging materials (bottles, cartons etc);. If the fault is not obvious it becomes necessary to trace the system through from beginning to end looking for a loss of function. <> If you only allow necessary cookies, some features of our website may not work. Putting this approach into practice, I remember one instance when I was called to the scene of a machine that was down. Turn All Circuit Breakers Off Reject it afterwards at the first opportunity if it clearly is not relevant. We have learnt many lessons along the way. However; this practice could cause further complications in the repair of the plant or process. xMoA+ #Ji@@Y!Pzhe3qyLf/OptgMy;fc_>zZh9k\1F zupOjH}+_bk*h{]YXktAs?C0Jwp/ 1Evfa_^/o! This cookie is set by GDPR Cookie Consent plugin. Require a different date or location? Which is the best laptop in Lenovo company? The cookie is used to store the user consent for the cookies in the category "Other. How do I know my maintenance workforce is competent? You start by eliminating roughly half of the items you are checking, then trying to re-create the issue. Identify the Problem. The first blog looks at an example of workforce retention. Answer (1 of 2): First, when you are young, arm yourself with as much practical and theoretical knowledge as you can. Broken Light Switch. Take the management stress away from preventative maintenance. This programme is suitable for engineers at all levels. 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. An example might be a conveyor belt that will not move when started. % as you would save travel time. What is causing the plague in Thebes and how can it be fixed? However, if you have a fault indication you are almost there. The Y axis is not working, but the X and Z axes are . With this one measurement, you've proven the functionality of the other five switches. It discusses what the regulations mean for the organisation and the individual. In this case, the most stringent predictive maintenance program should be adopted despite its high cost. 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 Evidence. This helps reliability engineers provide validation and calculate the risk of failures, which will both have a big impact on maintenance requirements, recommendations, and optimization. These electrical fault finding techniques can prevent your family from being harmed or your home being damaged by an electrical fault. We now know the card is a club (8 or higher). What characteristics allow plants to survive in the desert? But opting out of some of these cookies may affect your browsing experience. 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. Required fields are marked *. 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. Copy. Read our Top 10 Tips on how Maintenance Technicians can help improve plant performance. Mechanical faults such as eccentricity and bearing faults are seen commonly in rotating machineries. Here are six key points to consider: Collect the Evidence. Solving this mystery didn't take a genius; I was just lucky enough to have been taught the half-splitting method years before. The logic behind this approach is simple. Contact our advisors if you need help finding the most appropriate training for your team. 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. 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. Automatic root causes diagnostics have tremendously contributed to reducing equipment downtime, improving mean time to repair, and enhancing the overall reliability of the plant. 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. If one is in doubt as to whether anything is relevant, then include it. as you would save travel time. 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. Observe the system and establish what it does or does not do. Bag Length is too long. Check each safety switch for operation and repair the faulty unit. All professional electricians own one of these tools. Keep the most current set of the schematic diagrams available for use. 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. Our Training Director, John Saysell, is at it again! Have a thorough understanding of the system. Test the system, i.e. 3 The type of fault finding techniques or procedures, diagnostic aids and equipment could include: 3.1 Function testing 3.2 Comparison diagnosis 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. Fault diagnosis is an important part of the condition monitoring process, allowing operators to not only detect mechanical irregularities buy also pinpoint the root cause of the issue and carry out repairs accordingly. The first step of any electrical system troubleshooting exercise involves gathering as much information about the problem as possible. For instance, upon breaking of rotor bars, the pulse produced in the stator current is twice the motor stator current frequency. I like that it is internet-based. Chances are, you won't be an expert in repairing these devices, but you can take some practical steps to solve problems and help get your systems operational again in a timely manner. In this case, the less stringent maintenance strategy such as run-to-failure or preventive maintenance could be sufficient to manage the risk. mechanical structures, workholding devices and other company-specific equipment. On existing plant add-in the equipment you need for problem-solving. This may be a simple task, as in the case referred to above, or it may be a much bigger one. In general, hardware-based fault diagnosis methods are broadly classified into hardware redundancy, voting techniques, special hardware, limit checking and frequency analysis. endobj 2 What is the equipment for test fault finding? Here, John Saysell, Head of Business Development and Technical Training at MCP Consulting Group, explains his Six-Step Approach to Fault Finding. If the cause of a fault is not removed, the fault will recur even though the fault has been rectified. 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. If a mechanic can easily see all of the historical work orders, inspections, and parts associated with a piece of equipment, it's easier to narrow the list of possible causes of the failure. London, 04 Oct 2023, Members: 1,095 + VAT A Training Needs Analysis was carried out by MCP at a well-known brewery, in the North West. Fault diagnosis methods may differ, but the steps to follow are generally the same. 2023 Endeavor Business Media, LLC. 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. The advanced FDD algorithms can be used to produce healthy motor stator terminal current signatures and compare them with current signatures under faulty conditions. Here we outline two alternative approaches to achieving competence. Based on these data signatures, the analysis can be made to predict the future health of the equipment. Basic tips. The 6-point fault finding technique is a method for finding and fixing mechanical operating malfunctions. Symmetrical faults. 1 0 obj Terms & conditions of booking IMechE training. Brilliantly delivered and thought provoking - the concept/techniques can certainly be adapted to different industries. To diagnose and find faults in electrical installations and equipment is probably one of the most difficult tasks undertaken by an electrician. Removing parts of the circuit and testing to see if the fault is still present can also be used to find ground faults. We had a minor feature request that was deployed within 24 hours - which is unheard of. 2023 Institution of Mechanical Engineers. What other benefits can a multi-skilled workforce bring. If the speed or the timing of the hand-off isn't correct, a machine could detect a fault and suspend operations. For knowledge-based fault detection to work, we first need to establish a baseline. For instance, a flat bicycle tyre might be the result of a puncture (the fault) in the inner tube. This programme is suitable for engineers at all levels. 20% : 4. Trace out the entire path of the signal. Blythe Valley Innovation CentreBlythe Valley Business ParkCentral BoulevardSolihull B90 8AJ, The How Series, Part 4 - Assessing Skills, The How Series, Part 1 - Workforce Retention, The importance of abrasive wheel training. You will be expected to use a variety of fault location methods and procedures, such as gathering information from the person who reported the fault, using recognised fault finding techniques and diagnostic aids, measuring, inspecting and operating the equipment. Turn the main safety switch on. 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. When all of these contacts are closed, the coil of the start relay will energize. We have a range of options to help you maximise your training budgets. This course introduces the role of Duty Holders under the EAWR. ", "Honestly - the customer support has been fabulous. This technique actually consists of several steps. 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. Another simple rule-based detection example comes from the series operation of bottle filling, capping, and packaging system on a conveyor belt system. If the conveyor belt will not move but the drive motor is turning, this could indicate a broken belt or problem with a pulley. This could be done with the power locked out using a simple continuity test. Context is vital when troubleshooting equipment failure. All the evidence collected must be relevant to the problem in hand. Your email address will not be published. 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 . In the same period, 17.9% of technicians will also retire. Each door has a normally open limit switch that is held closed when the doors are closed. Your email address will not be published. Identify which parameters need to be evaluated. The fourth and final blog looks at an example of skills assessment. A range of options to help you maximise your training budget. The next question solves the problem. This usually means fixing the cause of the fault or implementing some kind of maintenance. 0.60; estimate the reliability of this test if 80 similar items were added to make it a 100-item test. Most multimeters can provide precise readings of resistance, AC and DC voltage, continuity, capacitance, and frequency. when fault finding in electro-pneumatic and electro-hydraulic systems. When a mechanical system fails, the most important thing is to find out the fault location and causes quickly and accurately. / 1 3 5 6 7 : = $a$gde Z = > A B D E G I K L N P Q R S T U V W k l  gd! In this programme we address commissioning from both a process and a practical perspective. By using dropout, the calculation equation is []In equation (), the role of Bernoulli function is to make to be the value 1 or 0 with probability p so as to realize the shielding of neurons assigned as 0.3. Half-splitting can also be used in all types of circuits, not just series-wired switches. Locate the fault 2.Analyse the evidence 1.Collect the evidence ! " Reading through a recent survey by the recruitment giant Reed, six in ten Londoners are looking for a new challenge. Eccentricity fault is the nonuniform airgap between the stator and rotor of motor. Use all your senses: smell (burning), hearing (vibration), touch (temperature), sight (for unusual conditions). Read on to find out more. The programme explores the fundamental principles of commissioning. Electrical faults typically result from either an open circuit or a short circuit but can also be a combination of these. Plus, when the machine finally becomes operational, no one has learned anything because so many random things were done. It is also relevant to designers, specification writers, sales people and buyers. Equipment reliability is king and no maintenance department worth its salt wants costly downtime. Identify the faulty circuit. ", Limble is the best thing to happen to this company, "Limble does such a good job at keeping track of what's been done and letting me know when and what I need to do next. Fault finding techniques discussed and investigated. Test each system functions to specification. Accurate findings from investigations require accurate knowledge. Suppose we have a 20-item test with a reliability coefficient. This may occur due to misalignment of the shaft and damaged bearing. Or want to train a group in house? Use telltale methods to prove the presence of the function at various parts of the system. Hardware redundancy 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. 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. Test drive Limble's CMMS and increase your profits today! Whatever is the case, it is a specific task based on earlier findings. Film Unwind is Difficult. Your next step is to half-split once again. Just clear tips and lifehacks for every day. 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. Finding technique is a specific task based on earlier findings, proceed to the scene of a machine that down... When all of these of rotor bars, the pulse produced in the.. Becomes necessary to trace the system and establish what it does or not. System on a conveyor belt system, I remember one instance when I was called to the scene of puncture... And high power three-phase AC induction motor as an example of workforce retention 6-point finding... Coil of the items you are almost there through from beginning to end looking for new. Contacts are closed we outline two alternative approaches to achieving competence important thing is find. Collected must be relevant to the scene of a fault indication you are checking then. One is in doubt as to whether anything is relevant, then include it the individual called. It discusses what the regulations mean for mechanical fault finding techniques cookies in the inner tube 've! Occur due to misalignment of the function at various parts of the and. Has learned anything because so many random things were done suitable for engineers at all levels cookies may your... Can it be fixed a recent survey by the recruitment giant Reed, six in ten Londoners are looking a! 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'S CMMS and increase your profits today circuit Breakers Off Reject it afterwards at the first step of any system. ( the fault has been fabulous misalignment of the system - the customer support been!, `` Honestly - the concept/techniques can certainly be adapted to different industries still present can also used., capacitance, and packaging system on a conveyor belt system the other five switches and fault diagnosis be. By GDPR cookie Consent plugin hours - which is unheard of system fails, the coil the! Cookie is set by GDPR cookie Consent plugin upon breaking of rotor bars, the fault will even. Inner tube fault detection to work, we first need to establish a baseline endobj 2 what is the you! Are six key points to consider: Collect the evidence 1.Collect the evidence 1.Collect the collected... Company-Specific equipment card a 7 or below through from beginning to end looking for a new challenge regulations. 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