Maintenance

Schedule &
Trouble
shooting chart
Every
Needengineering
of trouble industry
shooting chart
(either Big, Medium or Small)
Need to maintain a trouble shooting chart
i.e. preventive, breakdown maintenance chart
,which will contain records of each & every
machine.
These records will ensure that the periodical
maintenance works are carried out according
to schedules laid down.
It gives information about the cause of long
standing complaints of unsatisfactory
operation.
The trouble shooting chart shall
consists of …….

Name plate details of machine (Rating,

voltage, current, speed, manufacturer ,
serial number)
Date of installation & Insulation
Resistance at the time of installation on
site.
It shall have columns for preventive
maintenance observations…. Monthly,
quarterly, ½ yearly, yearly.
It shall have columns for breakdown
maintenance, in which date of
breakdown maintenance, type of fault,
maintenance carried, parts replaced.

Periodical inspection of these charts or

cards will be most useful to indicate,
which machine /equipment are failing
frequently & what further action is
required in their case which will help in
overhaul programmes and ordering
spare parts.
Trouble shooting charts
Trouble shooting chart for D.C. motor
Trouble Possible causes

Fails to start Blown fuses Brushes may not touch commutator

Open field coils Open armature Excessive load

Over loaded s.c. in armature Clogged ventilating

Runs hot Brush may not be in MNA Voltage too high

Short circuit in field Weared bearings

Sparks at Brushes & commutator may be dirty

brushes Brushes not of proper grade
Brush tension high Open in armature

Commutator may be eccentric

Mica may be projecting out of copper strips
Excessive vibrations of machine
Shorts or reversal of commutating pole winding
Trouble shooting chart for D.C. motor
Trouble Possible causes
Voltage too high Differential connections in differential winding in
Runs fast compound motor
Open field coils Open armature Excessive load

Over loaded s.c. in armature Clogged ventilating

Runs hot ducts
Brush may not be in MNA
Voltage too high
Short circuit in field
Weared bearings

Sparks at Brushes & commutator may be dirty

brushes Brushes not of proper grade
Brush tension high Open in armature

Commutator may be eccentric

Mica may be projecting out of copper strips
Excessive vibrations of machine
Shorts or reversal of commutating pole winding
Trouble shooting chart for 3 Ø sq. cage induction motor
Trouble Possible causes

Fails to start Blown fuses Open circuits Overloads at start

Open rotor copper Bars

Over loaded High voltage Low voltage

Runs hot Low frequency Clogged ventilating ducts

Short circuit/ inter turn short in stator

winding
Single phasing Grounded stator

Uneven air gap Weared bearings

Over loaded Low voltage Low frequency

Runs slow
Broken rotor bars Inter turn short in stator winding

Incorrect winding connections

Harmonics in power supply (Crawling)

Trouble shooting chart for 3 Ø sq. cage induction motor
Trouble Possible causes

Vibrations Half coupling not in center or shaft misaligned

Rotor, pulley or half coupling unbalanced

Trouble shooting chart for 3 Ø slip ring induction motor
Trouble Possible causes

Fails to start Blown fuses One phase open Overload

Open in starting rheostat Inadequate brush tension

Brush do not touch collector ring Open in rotor winding

Overload Clogged ventilating ducts Low voltage

High voltage Uneven air gap Single phasing

Runs hot
Short circuit/ inter turn short in stator winding
Low frequency Grounded stator Weared bearings

Over loaded Low voltage Low frequency

Runs slow
Inter turn short in stator winding

Too much resistance in rheostat

Harmonics in power supply (Crawling)

Trouble shooting chart for 3 Ø slip ring induction motor
Trouble Possible causes
Part of rotor winding shorted to motor frame
Runs slow &
overheats at light Slip rings shorted to motor frame
loads

Motor fails to
start under load, Broken soldered joint in rotor winding, slip ring
is noisy & stator rotor winding connection or leads
current fluctuates

Brushes contaminated or improperly bedded

Excessive
sparking between Brushes blind in brush holder boxes
brushes and slip
rings Insufficient pressure on brushes of slip rings

Brushes contaminated or improperly bedded

Slip rings out of round Open in brush circuit

 Trouble shooting chart for transformer
Trouble Possible causes Remedies
Overheating * Overloads Check cooling system, whether fans are
* Failure of cooling operating whether oil / water is
system. circulating. Reduce the load on the
High ambient temperature transformer. If temperature of coil high,
switch-off the transformer till safe
temperature is reached. If overload
problem is occurring for long durations,
install another transformer in parallel. If
ambient temperature is higher than that
considered in specifications of
transformer change the transformer.
Sustained Poor voltage control of Transformer fail due to sustained
higher power system use of over voltage. Provide over fluxing
voltage on shunt reactance and protection and over-voltage
primary tap changing transformer protection for bus-bar. Flux density
resulting in to control bus bar voltage depends upon V/f ratio. Generator
overheating within specified limit. transformers, get over fluxed during low
of core due to frequency operation.
over fluxing.
Trouble shooting chart for transformer
Trouble Possible causes Remedies
frequent Insufficient clearances Transformer windings should be
external on overhead lines, capable of withstanding repeated
short-circuits accumulation of dust external short-circuits without failure.
on insulation. Transformer should be provided with
over current protection.
Short-circuit Sharp corners on Buchholz relay should operate
between conductors cutting into and sound alarm. Over-current
adjacent insulation. and differential protection should
turns, usually External short circuit operate and open the circuit
high voltage Moisture in oil. breaker
winding • Fluctuating loads.
• Transient over voltage.
 Trouble Possible causes Remedies
Internal Sustained overload and insulation Over current protection
short- circuit failure. Fault in tap changer Earth fault protection
Failure of end turns of coil due to Differential protection
over voltage Surges Bad solder
joint causing local
overheating and open circuit.
Ageing of insulation, abrasion of
insulation resulting in internal
short Circuits
Moisture in the oil while filling oil should be filtered. Silica gel
moisture in oil Breather saturated Defective seals should be replaced, gaskets
should be replaced. Transformer
should be dried out.
Rapid Excessive overloading. Presence Cause should be determined and
deterioration of Moisture. Poor quality of oil corrective action to be Taken
of oil
Carbon and Sparking in oil, excessive Conducting particles line up on
other temperature of oil insulation surface causing
conducting reduction in insulation resistance
particles in oil and failure by tracking. transformer
needs overhauling.
Trouble shooting chart for alternator
Trouble Possible causes
Low Voltage Output Loose drive belt; low battery state of charge.
Load on system is greater than alternator
can produce.
Defective wiring or poor ground path;
Low regulator setpoint.
Defective alternator or regulator.
High Voltage Output Wrong regulator.
High regulator setpoint.
Defective regulator.
Defective alternator
No Voltage Output Broken drive belt.
Low battery/Excitation
Defective alternator or regulator.
Loss of residual magnetism (self-excited alternator)
 Trouble shooting chart for alternator
Trouble Possible causes
NO VOLTAGE 1) Voltmeter connected
(NO LOAD) incorrectly, or faulty.
2) Loose broken or corroded
connections.
Residual magnetism is stored in
LOSS OF the laminated steel core of the
RESIDUAL Exciter Stator, and is used on run
MAGNETISM up to energise self excited AVR
systems. Loss of residual can
occur after :- (i) Many years
storage prior to use. (ii) Reversal
of the Exciter Stator magnetic field
while ‘flashing’ with a battery. (iii)
Rewind of the Exciter Stator. (iv)
Mechanical ‘shock’ to the Exciter
Stator laminated core, (where
magnetism is stored).
Remedies
Check and verify voltage at
Generator terminals with a
multimeter.
Check all auxiliary terminals.
Check the AVR push on terminals
for tightness. Repair or renew
where necessary
‘Flashing’ the Exciter Stator:- With
Generator running at rated speed,
without load, briefly connect a 12
volt D.C. battery supply. Maximum
connection time 1 second.
CAUTION! Never connect a
battery to the AVR terminals,
without a blocking diode. In most
cases this will destroy the AVR
power devices. Battery polarity
MUST be correct!
Trouble shooting chart for alternator
Trouble Possible causes
NO VOLTAGE 4) Very low insulation resistance
(NO LOAD) to earth (ground), on exciter stator
or main stator.
5) Surge suppressor on main
rotating rectifier short circuit.
6) Main rectifier diode(s) short
circuit.
7) Winding fault. Open circuit or
short circuit on any winding in the
machine.
8) Exciter stator polarity reversed
by battery tests. Also see "Loss of
Remedies
Check the insulation resistance
value with a Megger . (Disconnec
AVR during this test, and remove
any Neutral earth connection).
Check surge suppressor
resistance (see Section 3 Test
Method A).
Carry out Test Method A, Section
3. Replace where necessary.
Check diodes (See Section 2)
Carry out all tests as listed in Test
Method A. Check winding
resistance values.
Carry out all tests as listed in Test
Method A. Check winding
Trouble shooting chart for alternator

Trouble Possible causes Remedies

LOW 1) Engine speed low. Under Check AVR LED. If lit, UFRO is
VOLTAGE frequency protection (UFRO) activated, indicating low speed.
(NO LOAD) circuit activated. Check speed with tachometer.
Adjust governor control to nomina
speed, or up to maximum, (+4%)
of nominal speed.
2) AVR 'VOLTS' adjust, or external Adjust voltage on AVR 'volts' trim,
hand trimmer control incorrectly or remote trimmer. Ensure that
set. speed is correct, and UFRO is
OFF. (See above).
3) Voltmeter faulty or sticking. Check and verify voltage across
machine output terminals, with a
Multimeter.
4) Fault in AVR. Replace AVR and re- test

. 5) Loose broken or corroded Check the wiring for poor

connections. connections. Repair or replace
 Trouble shooting chart single phase I.M.
Trouble Possible causes
Fails to start 1. Blown fuses.
2. Defective starting mechanism.
3. Open in auxiliary winding.
4. Open in main winding.
5. Shorted capacitor.
6. Overload.
Runs hot 1. Overload.
2. Starting mechanism does not operate.
3. Low voltage.
4. High voltage.
5. Clogged ventilating ducts.
6. Shorted stator coils.
7. Worn bearings.
8. Low frequency
Runs slow 1. Overload.
2. Low voltage.
3. Low frequency.
4. Broken rotor bars.
5. Shorted stator coil.
Condition monitoring (or, colloquially, CM) is the process of
monitoring a parameter of condition in machinery (vibration,
temperature etc.), in order to identify a significant change which is
indicative of a developing fault. It is a major component of predictive
maintenance. The use of condition monitoring allows maintenance to
be scheduled, or other actions to be taken to prevent consequential
damages and avoid its consequences. Condition monitoring has a
unique benefit in that conditions that would shorten normal lifespan
can be addressed before they develop into a major failure. Condition
monitoring techniques are normally used on rotating equipment,
auxiliary systems and other machinery (compressors, pumps,
electric motors, internal combustion engines, presses), while
periodic inspection using non-destructive testing (NDT) techniques
and fit for service (FFS)[1] evaluation are used for static plant
equipment such as steam boilers, piping and heat exchangers.
Condition monitoring technology[edit]
The following list includes the main condition monitoring techniques
applied in the industrial and transportation sectors:
•Vibration Analysis and diagnostics [2]
•Lubricant analysis [3]
•Acoustic emission (Airborne Ultrasound)
•Infrared thermography [4]
•Ultrasound testing (Material Thickness/Flaw Testing)
•Motor Condition Monitoring and Motor current signature analysis
(MCSA)
•Model-based voltage and current systems (MBVI systems)
Rotating Equipment (This industry umbrella term includes
gearboxes, reciprocating and centrifugal machinery)[edit]
The most commonly used method for rotating machines is
vibration analysis.[6][7][8][9] Measurements can be taken on machine
bearing casings with accelerometers (seismic or piezo-electric
transducers) to measure the casing vibrations, and on the vast
majority of critical machines, with eddy-current transducers that