Electrical Troubleshooting in Seven Steps

Written by MT Staff
Thursday, 01 January 2004 15:23

A boiler feed pump being powered by two 3500 hp induction motors appears to be developing
a problem. Failure of this pump will result in the loss of a generator currently producing half of
the station’s power output. Operators are complaining that a large compressor on several
occasions has failed to start. A controller does not sound the way it used to. A cooling fan has
developed an audible “beat” sound during operation.

One of the most rewarding aspects of working as an electrician is taking such compelling
evidence as “appears to be developing a problem,” determining what is actually going on, and
making a sound decision on the correct course of action. Successfully troubleshooting a
complex piece of equipment gives a technician a tremendous sense of satisfaction. Having an
effective troubleshooting plan and following it can help obtain this feeling of satisfaction.

This article presents an overview of a simple, but effective, method of investigating an

electrical problem. Use this seven-step process when presented with a complex problem:

• Gather the information

• Understand the malfunction
• Identify which parameters need to be evaluated
• Identify the source of the problem
• Correct/repair the component
• Verify the repair
• Perform root cause analysis

1. Gather information
Gathering information is a logical first step in any troubleshooting endeavor. Ask about or
perform the following:
• What technical documentation about the equipment is available?
• How exactly is the equipment supposed to operate?
• Are there any previous lessons learned?
• Review any material history that exists for the equipment.
• Identify similar equipment to which you can compare the malfunctioning equipment. (This
can be especially helpful if there is limited technical data available for the equipment that is
malfunctioning.)

1/9
Electrical Troubleshooting in Seven Steps

Written by MT Staff
Thursday, 01 January 2004 15:23

Let us apply step 1 to the boiler feed pump example.

For a high-cost repair like a boiler feed pump, the importance of answering or performing as
many of the listed items before considering a repair activity is vital. Applying the first step
resulted in a review of the equipment’s current signature analysis (CSA) and vibration analysis
material history. During this review it was noted that the amplitude of the pole pass frequency
in the CSA had increased for both of the motors powering the pump. However, vibration
analysis did not indicate any possible problems, either mechanical or electrical.

Now that you have identified technical resources and equipment operation, you are in a
position to understand the malfunction.

2. Understand the malfunction

Understanding the malfunction means that you understand how or what the process is and
what portion of the process is operating incorrectly. Answer these questions:
• How is the process supposed to work?
• What is not functioning as it should?
• What would cause these results or malfunction?

Applying step 2, the boiler feed pump in question has not been reported by operations to have
a problem but the field technicians, through the use of predictive tools, have trended a possible
anomaly. Rotor defects, bearing misalignment, magnetic offset, or abnormal load fluctuations
were determined to be possible causes of the pole pass frequency trending upward.

3. Identify which parameters need to be evaluated

Identifying which parameters need to be evaluated requires a clear understanding of the
discrepancy and which signals affect the suspected component. Which input signals control
the component? What is the expected output from the suspect circuit? Is there a timing delay,
sequence, or set point that can be verified?

Identify the parameters that need to be recorded which could either confirm or refute your
suspicions regarding the problem. Identify the following:
• What parameters can you measure?
• What are the expected values for any measurements that are to be taken?

2/9
Electrical Troubleshooting in Seven Steps

Written by MT Staff
Thursday, 01 January 2004 15:23

• What test equipment is needed?

• Is there access for the required readings?
• Is there an alternative method to gather the required readings?
• Could other components have been affected by this fault?

For step 3, gaining access to the high voltage cables supplying the boiler feed pump motors
would prove to be difficult. However, testing from the current and potential transformers (CTs
and PTs) offers an easy alternative method to gather the required voltage and current signals
to assist in troubleshooting.

Having performed the first three steps, it is time to perform the required measurements and
observations to identify the faulty component. Ensure that all required safety procedures are
adhered to while performing any test.

4. Identify the source of the problem

Identifying the source of the problem requires the technician to isolate components and
evaluate circuit parameters, to isolate the circuit by group when dealing with a complicated
circuit (half-step approach), and to identify the malfunctioning component using the recorded
data.

One test recommended for confirming a possible anomaly and establishing a severity is a
current profile comparison between two like machines. This is sometimes referred to as a
process analysis test. Fig. 1 shows current samples from two identical machines. The
MCEMAX in-rush/start-up test is a capture of a single channel of RMS enveloped current for
up to 60 seconds. The test has a sampling rate of 3600 samples per second and produces a
digital strip chart of RMS current.

In this example there is a considerable difference between the Unit 3 and Unit 4 motors. With
this limited information, a technician would at least have strong evidence that further
investigation and possible action on the Unit 4 motor is necessary.

The current modulations seen in Fig. 1 will create torque variations and possible degradation
of electrical and mechanical components if left alone. Step 4 calls for more detailed analysis of
the data available to isolate the source of the problem. To provide further analysis from the

3/9
Electrical Troubleshooting in Seven Steps

Written by MT Staff
Thursday, 01 January 2004 15:23

current spectrum, Advanced Spectral Analysis (ASA) uses current demodulation to identify
and separate each of the specific frequencies that are modulating the current. By correlating
these frequencies to the electrical and mechanical components of the motor pump assembly,
the technician can determine which component is creating the largest impact.

The demodulation process removes the 60 Hz frequency component from the captured current
signal. Removing that component allows repetitive torque variations developed by mechanical
items such as belts and gears, which were previously lost in the signal-to-noise ratio of the
spectrum, to be identified. These mechanical frequencies are transmitted to the current
signature via the air gap flux of the motor during operation.

Applying step 4 to the boiler feed pump, Fig. 2 shows the demodulated current spectrums
from one of the motors taken approximately 1 year apart. The pole pass frequency (FP) has
been isolated for evaluation of the change in amplitude over time. The other motor had similar
results. It was the increase in the FP amplitude that raised concern over the condition of the
equipment.

Additional testing was performed with particular attention to evaluating the condition of the
motor’s rotor. It was determined after gathering additional vibration, motor circuit analysis, and
current signature data that the equipment needed to be removed from service for repairs.
What made this decision especially difficult was that the vibration data was inconclusive. Of
several surveys taken on the equipment at different times, only one showed any signs of
increased vibration levels.

Armed with data, you now can determine what needs to be done with the suspect component.
Many times after the first round of troubleshooting, the first three steps may need to be
repeated; however, now you have additional data to work with.

5. Correct/repair the component

Correct or repair the component identified as damaged based on the recorded data. Perform
the required repairs to the circuit. Completing step 5 can range from simple adjustments to a
complete component replacement.

For the boiler feed pump, when inspecting the two motors, the technicians found that one

4/9
Electrical Troubleshooting in Seven Steps

Written by MT Staff
Thursday, 01 January 2004 15:23

motor had bent/damaged rotor bars. The damage to the rotor was no surprise due to the
elevated pole pass frequency indications during the current signature analysis. But why only
one of the rotors when both of the motors had elevated values? Technicians felt that since
both motors were mounted to a common shaft, it would not be unusual for the elevated pole
pass frequency of one motor to be transmitted through the shaft to the other.

In addition to the rotor bar degradation, technicians discovered severe damage to the load end
bearings of each motor. During initial installation, the magnetic center was not properly set for
one, or possibly both, of the motors, which led to axial thrusting of the drive shaft, causing the
bearing damage. Technicians conducted inspections of similar boiler feed pump installations to
ensure that both motors were properly aligned with regard to magnetic center.

6. Verify the repair

Verify the repair after completion. Ensure the equipment is operating as designed. Perform
another round of testing to verify the equipment is in fact running correctly and that no other
discrepancies exist.

Following the repair and installation of the boiler feed pump motors, or the installation of
replacement motors, retest to ensure the installation will not result in the same failure
mechanism in the future. Looking at another example, a high resistance joint in the connection
box of a 460 V ac induction motor was identified (see “ High Resistance Connection Test
Results ”). The motor lugs were
replaced and retaped, resulting in a 3 percent reduction in resistive imbalance and a cleared
alarm.

7. Perform root cause analysis

Performing root cause analysis, even though mentioned last, began in the first step of the
troubleshooting process. You should use the knowledge gained throughout the
troubleshooting process in determining what could have possibly caused the component to
fail.

Did the component fail prematurely? Why are the motor windings failing after only four years of
service? These are just a couple of the questions that may come to light when evaluating the
whole repair process. Without identifying the possible cause that led to the failure, the repair
will always be only temporary. While working through the troubleshooting process, ask
yourself, “Is this the root cause or just a symptom of the problem?”

5/9
Electrical Troubleshooting in Seven Steps

Written by MT Staff
Thursday, 01 January 2004 15:23

When attempting to determine the cause of increased motor running temperature, a technician
recorded the RMS current to the motor. The process powered by the motor involves constantly
changing speeds and loads, shown in Fig. 3 . With the in-rush/start-up current capture
providing a graph of current throughout the repetitive cycle, it was readily apparent why the
motor temperature was running so high. The level horizontal line indicates nameplate full load
current.

Using this data, the technicians determined that the motor was undersized for the varying load
it was driving. Repairing the heat-damaged motor would not have been a permanent solution
to the problem. Installing a motor only slightly larger than the original resulted in an installation
where motor operating temperature is well within the temperature ratings of its insulation
system.

By following a well thought-out systematic process when challenged with an electrical

troubleshooting problem, you will greatly enhance your effectiveness. Invest a little time up
front doing your research and determining your troubleshooting plan of action. A benefit of
newer test equipment packages, which combine multiple testing technologies in one unit, is
how much they increase the flexibility and capability of a technician’s troubleshooting toolbox.

Inventory your test equipment and determine what you have available when the opportunity to
use the seven-step troubleshooting process presents itself. MT

Information supplied by PdMA Corp. , 5909-C Hampton Oaks Pkwy., Tampa, FL 33610; (800)
476-6463; e-mail pdma@ pdma.com

6/9
Electrical Troubleshooting in Seven Steps

Written by MT Staff
Thursday, 01 January 2004 15:23

between
back
Fig. 1.
to RMS
article
the units’
current
motors.
captures from two identical machines show a considerable difference

7/9
Electrical Troubleshooting in Seven Steps

Written by MT Staff
Thursday, 01 January 2004 15:23

current
identified.
feed
for
back
Fig.
evaluation
pump
2.
tosignal,
Aarticle
demodulation
These
taken
of
allowing
the
two
approximately
change
demodulated
repetitive
process
in amplitude
1removes
torque
year
current
apart.
variations
over
the
spectrums
The
60
time.
Hz
pole
developed
frequency
are
pass
from
frequency
by
one
component
mechanical
of the
(FP)
motors
from
has
items
the
been
ontocaptured
the
be
isolated
boiler

8/9
Electrical Troubleshooting in Seven Steps

Written by MT Staff
Thursday, 01 January 2004 15:23

HIGH
speeds
the
In
Test
7/16/1998
7/13/1998
Motor
500
Voltage
1685
1651
Measured
35
28
Corrected
1100.0
>2000
pF
780.0
OVR
34500
34250
ohm
0.07450
0.07700
0.07500
0.07300
1.590
mH
1.580
1.595
1.585
%
0.45
3.52
$
0.31
0.32
Condition
7.90
63.23
Good
back
460
retaped,
Fig.
Power RESISTANCE
retesting
Res.
Ind.
RMS
technician
Ph
Ph
VPh
Date
ID:
3.
to
Temp
ac
1Imbalance
and
1
2
To
Imbalance
article
1to
2 current
Loss
resulting
to
induction
Code
to
Mohm
determine
Gnd
after
loads.
23
3 aCONNECTION
2determined
repairs,
toin
The
the
motor
a3motor.
red
reason
percent
awas
that
high
horizontal
The TEST
identified.
the
for
resistance
reduction
motor
increased
process
linewas
TheRESULTS
indicates
joint
in
powered
motor
resistive
undersized
motor
in the
nameplate
running
lugs
by
connection
imbalance
the
were
formotor
temperature,
the
replaced
fullvarying
and
involves
load
box
a current.
cleared
and
of
load
aa
constantly
technician
it was
Using
alarm.
driving.
changing
this
recorded
data,

9/9