MCP's technical training specialises in practical learning programmes for upskilling technicians and operators. It will notify the packaging operator well ahead of time. 1 What are the fault finding techniques to be used when the equipment fails to operate correctly? Context is vital when troubleshooting equipment failure. This piece of equipment has 10 safety switches that have to have their contacts in the closed position before the machine can operate. Fault finding techniques discussed and investigated. In TDR, the signal is sent across the test cable and is received after being reflected from the point of fault. Film is Sticking to the Vertical Seal. 5OJ QJ ^J h! Visually inspect the machine. Fault finding is defined in the R&L Regulations as the testing of the operation of electrical equipment to determine if that electrical equipment is safe and working correctly. zPFM-H*3TMreU,hVN:$jia9q8^ ]UC(^7YXg88$dc9jqH6G6G6G6Y#eTURl,ZaXz Overall process (changes to). A circuit enable light on the control cabinet tells you that the start or circuit enable relay is not energized. This may occur due to misalignment of the shaft and damaged bearing. No open courses currently scheduled, but in-company delivery can be arranged. There are certain conditions and actions that exist in order to execute these six steps. 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. In a sense, this is a continuation of the process of analysis. This is also where I would have a quick look at the safety relay which has indication lights on it to indicate ready state or fault state. Determination and Removal of the Cause. 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. When you visit or interact with our sites, services or tools, we or our authorised service providers may use cookies for storing information to help provide you with a better, faster and safer experience and for marketing purposes. Here are six key points to consider: 1. Upon completion, the technician will display skills in methodical electrical troubleshooting and PLC fault-finding techniques. Once the collection is complete, an analysis to consider the validity of the information collection begins. These steps include collecting evidence, analyzing evidence, locating faults, determining and removing causes, rectifying faults and running a systems check. 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. Fault finding using the 5 step approach Manuals, flow charts, algorithms and fish bone diagrams Set boundaries model The 6 point technique and 5 whys approach Sensory inputs to fault finding Half split and Unit substitution approach Input to output method Function testing method Recording of methods Outcomes In some applications, fault detection and isolation go hand in hand; they can, of course, be separate modules of the process. 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. make measurements or collect other evidence, 2. Most multimeters can provide precise readings of resistance, AC and DC voltage, continuity, capacitance, and frequency. What other benefits can a multi-skilled workforce bring. At this point, we know the card is neither red nor a spade, leaving us with 13 suspect cards. Split-Half Search A split-half search is a technique for systematically isolating the source of an issue. 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 This is because the increased cost of maintenance is warranted to prevent major fallout that will be way more costly. All the evidence collected must be relevant to the problem at hand. Or want to train a group in house? 3 0 obj We draw on the real-life experience of the course tutor and on established good working practice. Here w share our Ten Top Tips for a successful training programme. We use cookies to make parts of our website work, and to improve your visitor experience. 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. 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. Terms & conditions of booking IMechE training. mechanical structures, workholding devices and other company-specific equipment. Based on the meta-action unit, this article proposes a comprehensive, q. Suppose we have a 20-item test with a reliability coefficient. The Y axis is not working, but the X and Z axes are . Injection and sampling Location of a defect or fault found through inserting known data signals or functions at selected test points of the system or process. 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. On existing plant add-in the equipment you need for problem-solving. Their capability to collect, store and analyze data on equipment health and performance was simply too limited. At every juncture there will be an electronic hand-off, in which the next piece of equipment is to take over. Ask someone to pick a card from a 52-card deck of standard playing cards. However, if you have a fault indication you are almost there. Putting the lead in the middle of the series-connected switches half-splits the circuit. 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. Proposed Method. In this article, written by John Saysell, Head of MCP Technical Training, he explains how businesses can safely introduce basic maintenance skills into the operator workforce, starting with leaving their brains at the factory gate! This cookie is set by GDPR Cookie Consent plugin. With more sophisticated equipment or systems, it may necessary to fine-tune the system in order to return it to optimum working conditions. However, you may visit "Cookie Settings" to provide a controlled consent. 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.. Other faults may include improper operating voltage, mechanical failure of components, and excessive heating or corrosion. Only 2-5 percent of system faults are symmetrical faults. We draw on the real-life experience of the course tutor and on established good working practice. Plan for exceptions. What device can be used for checking electrical problems? To help technicians get to the cause of a fault faster, MCP has developed a course focusing on a logical approach to fault finding. 9. If these faults occur, the system remains balanced but results in severe damage to the electrical power system equipment. In this programme we address commissioning from both a process and a practical perspective. 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. This could be done with the power locked out using a simple continuity test. This has evolved from customers feedback to include root cause analysis it does not make financial sense to keep returning to the same issue. Is your card a queen? Another no, and we know the card is the jack of clubs. If the fault is not obvious it becomes necessary to trace the system through from beginning to end looking for a loss of function. Lets use a high voltage and high power three-phase AC induction motor as an example. This answer is: Study guides. Example 2. Non-members: 1,350 + VAT. The next question, Is your card a club? He says yes, eliminating 13 more cards. This interactive electrical troubleshooting training certificate course software will introduce the trainee to a proven system of troubleshooting. Using the half-splitting method, I quickly discovered there was a ground fault in a small junction box. 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. stream 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. Put the other lead in the middle of the switches. Another simple rule-based detection example comes from the series operation of bottle filling, capping, and packaging system on a conveyor belt system. Fault detection, isolation, and recovery (FDIR) is a subfield of control engineering which concerns itself with monitoring a system, identifying when a fault has occurred, and pinpointing the type of fault and its location. 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. This programme is suitable for engineers at all levels. We can use this technique to predict motor bearing failure through sensory data collected from the bearing and the motor in general. 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. Lubricants and lubrication systems . 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. 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. 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