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

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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

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  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.

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  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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