Practical Troubleshooting of Electrical Equipment and Control Systems Course
Electrical and Power Engineering

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Practical Troubleshooting of Electrical Equipment and Control Systems Course
Course Overview:
This course provides practical troubleshooting skills which can help resolve electrical issues within a plant with ease which bluntly helps in minimizing any electrical idle time making a case for greater plant effectiveness.
Starting with the essentials, the course covers rotating machines, transformers, cables, switchgear, circuit breakers, control circuits, PLCs, and power electronics devices.
Participants will be able to select appropriate instruments, diagnose the faults, and analyze proper preventive measures. Power quality troubleshooting, wiring practices, and an introduction to ladder logic are included in practical sessions.
The course is aimed at engineers, electricians, and maintenance staff and focuses on the application of theory through industrial case studies to enhance problem-solving capabilities.
Course Objectives:
Upon the successful completion of the workshop, each participant will be able to:-
- Troubleshoot electrical equipment and control circuits
- Diagnose electrical problems “right first time”
- Reduce downtime
Who Should Attend?
This course is designed for personnel who want to understand the design and engineering principles involved in process plant layout and piping design. Those who will benefit the most from this course include the following; Consulting engineers, Electrical and electronics engineers, Electricians, Maintenance engineers, Plant maintenance personnel, Production managers, and Project engineers.
Course Outlines:
TYPES OF PROBLEMS
- Introduction
- Problems and their genesis
- Problem categories
TROUBLESHOOTING FUNDAMENTALS
- Basics of troubleshooting
- Drawings
- Documentation and historical records
- Skill sets for troubleshooting
- Relationships between the early resolution of problems and plant productivity
USE OF APPROPRIATE INSTRUMENTS
- Instruments for troubleshooting
- Insulation tester (Megger)
- Continuity testers
- Voltage indicator
- Multimeter
- Clamp-on meters
- Ohm-meter and ducter
- Special instruments
TROUBLESHOOTING ROTATING ELECTRICAL MACHINES
- Basic principles of electrical machines
- Rotating machines - AC
- Rotating machines - DC
TROUBLESHOOTING TRANSFORMERS
- Basic principles
- Transformer failures
- Monitoring of transformer parameters and oil properties
- Early warning of internal failures
- Use of dissolved gas analysis for problem detection
- Use of partial discharge detection/measurements
- Use of furan analysis/degree of polymerization tests for residual life prediction
- Failures in auxiliary systems and tap changers
- Case studies of typical transformer failures, analysis, and remedial measures
TROUBLESHOOTING CABLE PROBLEMS
- Construction of HV and LV cables (overview)
- Joints and terminations
- Types of cable failures and reasons
- Detecting cable failures
- Prevention of failures by proper jointing/termination quality and by periodic testing
- Use of thermo-graph for hot spot detection
- Case studies of typical failures and detection
TROUBLESHOOTING OF SWITCHGEAR AND CIRCUIT BREAKERS
- Overview of HV, MV, and LV switchgear
- Basics of circuit breakers
- Problems faced in power circuits of panels, remedies, and prevention
- Problems faced in circuit breakers
- Problems caused by bad contacts
- Internal short circuits due to rodents
- Problems due to dust accumulation
- Useful role of thermo-graphic examination in pre-empting problems
- Case studies of failures/malfunctions and remedial measures
PROBLEMS CAUSED BY POOR POWER QUALITY
- Overview of power quality
- Effects of poor power quality on equipment
- Voltage limits and equipment tolerance
- Power factor and its effects
- Problems due to frequency drifts
- Voltage unbalance (negative sequence)
- Harmonics (waveform distortion) and its effects on equipment
PROBLEMS ASSOCIATED WITH ELECTRICAL CONTROL CIRCUITS
- Devices and symbols
- Language of control circuits
- Reading and understanding electrical drawings
- Reading and understanding ladder logic
- Wire and terminal numbering
- Motor control circuits
- Motor control strategies
- Problems due to incorrect wiring
- Problems due to poor terminal connections and contacts
- Problems in power and control (Auxiliary) contactors
- Tracking problems using drawings and continuity/voltage tester
- Precautions while performing insulation tests on control circuits
TROUBLESHOOTING PLCS
- Principles of programmable control
- Programming tools
- Typical controls using PLC
- Problems experienced in PLC controls
- Use of status lamps in I/O cards to troubleshoot
- Rectification approach
- Internal failures and diagnostics
TROUBLESHOOTING POWER ELECTRONIC EQUIPMENT
- Power electronic devices
- Power electronic applications in industry
- AC variable speed drive fundamentals
- Controllers used for power electronic equipment
- Device failures and checking of devices using simple instruments
- Common problems faced in power electronic equipment, reasons and remedial measures
- Examples/case studies