Fault Tracing Introduction

FAULT TRACING/ TROUBLE SHOOTING
 Planning and Scheduling

 Fault, Failure and Malfunction
 Causes of Machinery Failures
 Fault symptoms, diagnosis and remedies
 Trouble shooting of Pumps, I. C Engine and Steam Turbines.
Maintenance planning
 Planning is procedure of developing methodology to accomplish work, i.e. what work
will be accomplished and how?
 Scheduling identifies duration of work completion and personnel, i.e. when the work
will be completed and who will do it?
 Planning and scheduling are mutually dependent.
 Professionals, experienced, skilled and knowledge persons are preparing planners and
schedules.
Elements of planning
 Understanding Work
 Resource Required and Skill Levels
 Steps and Procedures
 Parts and Tools
 Understanding Work
 Identify what steps, procedures, specifications, and tools are required to
perform the job correctly
 If the work is too large or complicated, it may have to be broken down into
smaller sub-tasks
Resource Required and Skill Levels
 The skill level of the person required to perform the work must be identified with the
estimated time of task.
 It is difficult to identify estimated time for different skill level workforce.
 Planners must have good knowledge of workforce capabilities and the environment.
 High skill persons required less instructions
 Job estimating can become more accurate when the jobs are broken down into smaller
elements
Steps and Procedures
 Steps and procedures must be developed with specifications for quality work
 Instructions are prepared with sketches and drawing
 Which data should be collected is clearly mentioned in steps and procedure.
Parts and Tools
 Materials, including parts and kit lists, must be identified
 Special tools need to be identified on site before work starting.
Job template for panning a maintenance work
Work Order Requirement: Replace Electric Motor in Lathe
Job Estimated time: 2 hours - duration 4 Man-hours
(2 craft person x 2 hour)
Craft Type: Multi-craft technician or
Electrician
Parts Required: Part# 11111 Motor, Electric; Location: 22-11-XX
Optional Parts: Part# 2222 Coupling, Flex; Location: 11-00-YY
Part# 3311 Bolts, Coupling (9-16 x 3); Location:
Free Bin, Shop
Not for sell or reprint, educational purpose only

Special Tools: None
Procedure:
 Step 1: Lock out / tag out (see attached procedure for details).
 Step 2: Disconnect motor, mark/label wires.
 Step 3: Unbolt coupling, inspect coupling and remove motor bolts.
 Step 4: Remove motor using jib crane available.
 Step 5: Install new motor (check motor is rotating freely).
 Step 6: Bolt motor and check for soft foot. – record and correct any soft foot findings
 Step 7: Install coupling, bolt motor (torque bolts to xx ft. lbs) and align them using
dial gauge or laser within acceptable range +/- 0.xxx (organization standard).
 Step 8: Remove lock out / tag out.
 Step 9: Connect the motor and check for right rotation.
 Step 10: Test run.
 Step 11: Clean up and return asset to service.
 Step 12: Close out the work order in CMMS detailing what was done.(Computerized
Maintenance Management System)
Scheduling Process
 Scheduling insures that resources—personnel, material and the asset on which the job
is to performed—will be available for maintenance at a specified time and place.
 Jobs should be scheduled to have the least impact on normal operations
 Planners makes plans, scheduler fix time after consulting production
 When job scheduled, resources required will be ready
 Now some software CMMS/EAM are passing massage after completion of each work
(Enterprise asset magt)
Types of schedules
 Out year plan- Frequency of half year
 Annual plan- Frequency monthly
 90 days plan- Frequency weekly
 2 Week plant- Frequency weekly
 1 Week plant- Frequency Daily
 Daily
 Unscheduled maintenance
Priorities to schedule is given to preventive maintenance
Fault, Failure And Malfunction
Fault:
A fault is an unpermitted deviation of at least one characteristic property of system
from the acceptable, usual and standard condition.
Failure:
A failure is a permanent interruption of the system’s ability to perform a required
function under specific operating condition
Malfunction:
A malfunction is intermittent irregularity in the fulfillment of the system’s desired
function.
Causes of Machinery Failures

 Faulty design.
 Material defects.
 Processing and manufacturing deficiencies.
 Assembly or installation defects.
 Off-design or unintended service conditions.
 Maintenance deficiencies (neglect, procedures).
 Improper operation.
The Matrix Approach to Machinery Troubleshooting
 In machinery trouble situations where the cause is known, no diagnostics required

 Where the cause is unknown a troubleshooter will find the cause.
 Diagnosis, in turn, is simply another word for recognition of fault/failure
 This approach is apply to failure systems
Medical analogy for trouble shooting
 Trouble shooters finds some vital signs like physician identifying symptoms
 Physician unaided by suitable instrumentation, will often tell that "something" is
wrong, without being specific.
 In machinery troubleshooting quantity of nonspecific symptoms, that allows a valid
diagnosis
Trouble symptoms
 Taste/odor: gas, acid leakage, etc.

 Touch: overheating, vibration, etc.
 Sound: excessive noise, knocking, piston slap, rubbing, detonation, annunciator
alarms, etc.
 Sight:
1. Direct sight or observation: vapor, fume, and fluid leakage, vibration, loosening,
smoke, fire, etc.
2. Indirect sight or observation:
 Changes (up/down) in indicator readings:
 Pressure
 Temperature
 Flow
 Position
 Speed
 Vibration
 Changes (up/down) in performance:
 Pressure ratios
 Temperature ratios
 Power demand
 Product loss
 Efficiencies
 Internal inspection results.
 Failure analysis (post-mortem) results.
 List possible cause
Begin by listing the machine's major components, systems, and auxiliaries.

 Indicate tie-in or relationship of symptom to cause.
 Make use of experience by asking:
 What can and usually does go wrong with this component?
 What are the symptoms associated with this distress or malfunction?
 A typical aid for this effort will be a fault chart.
 Indicate symptom/cause probability ranking.
 For example,
 if port plugging, piston-ring sticking, excessive ash, and varnish and carbon
deposits are symptomatic of over lubrication in internal combustion engines
 Indicate remedial action
 After checking, inspection, adjustment, lubrication, cleaning, balancing,
replacing, and, of course, analysis and follow-up

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FAULT TRACING/ TROUBLE SHOOTING

 Planning and Scheduling

Not for sell or reprint, educational purpose only

Fault, Failure And Malfunction

Causes of Machinery Failures

Not for sell or reprint, educational purpose only

The Matrix Approach to Machinery Troubleshooting

 In machinery trouble situations where the cause is known, no diagnostics required

Medical analogy for trouble shooting

 Taste/odor: gas, acid leakage, etc.

Not for sell or reprint, educational purpose only

Not for sell or reprint, educational purpose only

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