Troubleshooting instrumentation and Control Systems

Introduction

Accurate troubleshooting and subsequent repair of electrical equipment are necessary for today’s sophisticated industrial environments to ensure continued efficient operation and productivity of the equipment. Delegates are encouraged to raise queries both during and at any time after attending the course. Delegates are also encouraged to bring any specific issues that they may wish to raise to this course.

Objectives

• To develop a structured approach to electrical troubleshooting using common terminology and to provide troubleshooting methods and solutions for various electrical equipment and control systems problems.
• To develop a better understanding of various test equipment used in electrical troubleshooting.
• To develop a better understanding of various electrical equipment and control systems design, functionality, and failure modes.
• To better understand work practices, which allow for successful troubleshooting including job plans.
• To provide examples of successful troubleshooting techniques and ‘hands-on’ experiences plus case studies and group problem-solving exercises.
• To provide troubleshooting methods and solutions for various electrical equipment and control systems problems.

Organizational Impact:
Following the attendance at this course, participants will return to their respective organizations equipped with new skills and knowledge to enable them to more effectively troubleshoot and repair failed electrical equipment.

This in turn will reduce downtime, improve equipment availability and reliability and allow the transfer of these skills to the participant’s co-workers.

On successful completion of this course, participants will have:

• A better understanding of troubleshooting procedures
• An improved capability in the use of test equipment
• An understanding of the importance of logical and timely attendance to electrical problems through the use of troubleshooting procedures
• A better understanding of failure modes and failure analysis
• Improved awareness of the safety concerns associated with electrical apparatus

What the Participant will learn (Competencies)

• the ability to comprehend the 5 basic steps of formal troubleshooting
• the ability to identify and work with electrical safety hazards
• the ability to understand and interpret test equipment data
• the ability to develop troubleshooting job plans
• the experience of exchanging ideas, problems, and solutions with the other delegates
• the improved ability to read and understand electrical and process drawings

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations. The online course is conducted online using MS-Teams/ClickMeeting.

Who Should Attend?

This course is intended for Electrical Maintenance Engineers, Supervisors, and Technicians working in maintenance related roles who need either a greater awareness of, or to become more proficient in, the troubleshooting of electrical equipment and control systems and electrical maintenance activities. Because the methods and examples are generic, personnel from all industries will benefit.

Course Outline

THE TECHNOLOGY OF ELECTRICAL EQUIPMENT

 Definitions and descriptions of electrical equipment used in industrial applications including:

• Source Equipment – transformers
                                  power supplies (UPS)
                                  batteries
                                  generators
• Switching Equipment – switchgear
                                  motor control center (MCC)
                                  disconnects
                                  contactors
                                  overload relays
                                  starters
                                  neutral ground resistors (NGR)
• Control Equipment –  variable frequency drives (VFD)
                                  programmable logic controllers (PLC)
                                  distributed control systems (DCS)
                                  power monitoring and control
                                  relays and timers
                                  limit switches
                                  temperature switches
                                  pressure switches
                                  level switches
                                  speed switches
                                  vibration switches
                                  safety and shutdown switches
                                  motor/feeder protective devices
• Load Equipment –  motors (AC induction, asynchronous, DC)
                                  heaters
                                  solenoids
                                  valve actuators
                                  signaling and alarm devices

TROUBLESHOOTING APPLICABLE TO THE ABOVE LIST

• methods
• terminology
• principles
• special techniques

TEST EQUIPMENT

• digital voltmeter (DVM)
• oscilloscope or oscillograph
• megger
• hi-pot tester
• frequency meter
• ammeter (inline, clamp-on)
• power meter (watt, VAR)
• current transformer
• specialized equipment

TYPICAL PROBLEMS/FAILURES

• common-mode failures
• phase imbalance
• contact pitting/arcing
• electronic control component failure
• blown fusing
• damaged windings
• worn bearings
• damaged brushes
• burnt ballasts
• damaged excitation circuits
• battery cell failure
• inverter/rectifier failure
• high voltage bushing failure
• switch failure
• ground fault

TYPICAL TROUBLESHOOTING JOB PLAN DEVELOPMENT

• identify troubleshooting step sequence
• prepare procedures
• documentation
• follow-up
• regulatory requirements
• training

TYPICAL ELECTRICAL DRAWINGS AND SYMBOLS

• single-line
• control wiring
• distribution
• symbols