Unit: 4 (Troubleshooting Plans)

4.1 Internal and external causes for failure / abnormal operation of equipment.
4.2 List of mechanical faults, electrical faults and magnetic faults in the electrical
equipment and their remedies.
4.3 Preparation of trouble shooting charts for D.C. Machines, AC Machines and
transformers, batteries

Internal and external causes for failure/abnormal operation of equipment

Internal Causes:
1. In some unavoidable situation the machine may have to be run "over loaded" for a longer
period which causes temperature rise beyond the permissible limit.
2. During normal working shot-circuit may occur due to some reasons.
3. Some live terminal touches the metallic part developing phase to ground fault.
4. Rotating part and stationary part shall have uniform air-gap. If not, then the behaviour of
machine becomes abnormal.
5. Single phasing means one of the three phases become open circuited and the load is
shared by only two phases instead of 3-phases. Hence over loading on phases and
behaviour becomes abnormal.
6. Due to facing of stator and rotor teeth sometimes the teeth become magnetically locked and
motion of motor does that possible.
7. Phase winding may electrically touch each other may create problem.
8. Some turns of one or more phase windings get shorted.
9. Worn out bearings, oiling / lubrication may not have been done frequently involving more
mechanical / frictional losses.
10. Unbalance rotating weights and fault in rotor may also the cause of abnormal behaviour of
the machine.
11. These are the causes creating problems of smooth working of machine and the machine
show abnormal behaviour.

External Causes:
These causes are external to the machine from supply to the terminal box of the
machine.
1. A 3-phase machine is supplied with 3-line wires, and due to single phasing on distributor
side; the two lines supply the power to 3 phases of machine and two phases become
excessive of load and overheating take place and machine condition becomes abnormal
(single phasing on distributor side).
2. Sometimes due to wind, rains, birds etc. short circuit occurs in the supply system which
affects working of machine instantly.
3. If supply system generator working in generating station is subjected change in the speed of
prime mover, then supply frequency changes which affect the working of machine connected
to this supply system.
4. Sometimes in the generating station receiving station / substation there occurs over voltage
or under voltage which affect the normal working of the machine.
5. Sometimes negative sequence currents are developed due to unbalance supply system
which affects the normal working of the machine.
6. If external load on the machine is sustained for a length of period, the insulation may start
burning due to excessive temperature rise.
7. Carelessness of the user/operator of the machine.
8. Lack of schedule/preventive maintenance leads to a pre-schedule & unexpected failure.

List of mechanical faults, electrical faults and magnetic faults in the electrical
equipment and their remedies.

Faults of electrical machine

Electrical fault
1. External fault
2. Internal fault

External faults

1. No voltage
2. Under voltage
3. Break in one or more supply lead.
4. Fuse blown
5. Contact failure
6. Faults in starting/ controlling equipment
7. Atmospheric conditions, such as high temperature, dust, moisture, vapor -
influence the resistance of electrical circuit which directly influence machine
performance, and may cause faults.
8. Lightning or switching surge.

Internal faults

1. Open circuit faults

2. Short circuit faults.
3. Symmetrical and asymmetrical faults
4. Fusing problem
5. Circuit breaker not performing
6. Protective relays not performing
7. Earthing wire not proper working condition
8. Starting device not functioning.

Mechanical Faults

1. Load unbalanced
2. Shaft misaligned
 3. Gearbox fault
4. Bearing fault
5. Coupling faults
6. Foundation faults
7. Vibration faults

Magnetic faults

1. Poles demagnetize
2. Pole shoe broken
3. Irregular air gap
4. Exciter not functioning.

Troubleshooting chart for DC Machine

Sl. no Fault type Reasons

1 Fail to start Circuit open, Non contact between brush and

commutator, Bearing seized, starter not functioning

2 Change the direction Reverse the polarity of supply

3 Unable to reach rated over load, Voltage low, staring resistance exist
Speed during run.

4 Runs at high speed Supply voltage more than rated value, Load is too
low, shunt field coil is shorted

5 Motor runs very slow Low voltage, over loaded

6 Machine is too hot Overloaded & drawing excess current, defective

ventilation, shorted coil.

7 Brushes sparking Incorrect neutral, shorted commutating pole,

Open circuited coils

8 brushes worn out Brushes are wrongly selected, Commutator irregular

quickly surface, moisture contamination

9 Unusual vibration Misalignment of shaft, Foundation is incorrect, Pully

eccentric or loose.

10 Unusual noise Brush chattering, mounting loose, Armature rubbing

with pole faces, Bearing problem.
Trouble shooting charts for AC Machines

Troubleshooting chart for single phase and three phase induction motor

Electrical

Sl. no Fault type Reasons

1 Motor stalls Open circuit, low terminal voltage, overloading,

poor electrical contact.

2 Motor start-up failure Low voltage, 1Φ open (3Φ motor), overloading,

mechanical locking in air gap.

3 Over heating Rotor rubs in stator bore, improper voltage,

under load condition shorted stator coil, unbalanced terminal voltage,
single phasing, ventilation (blocked duct)
problem.

4 Motor runs but Overloading, power failure, insufficient pull-up

slows and stop torque.

5 Motor takes more time Low applied voltage, excessive loading, high
to accelerate inertia of the load.

6 Motor unable to move Primary circuit open, low voltage, resistance

with rated speed exists in wound rotor, defective rotor bars.

7 Wrong direction of Reverse phase sequence (3Φ motor),

rotation Reversal of starting and running coil (1Φ motor)

8 Speed reduced after Wrong connection in stator, Defective contact

Loading overloading, defective lead connection.

9 Unbalanced line current Unequal phase resistance, unequal terminal

during normal operation voltage, single phasing, soldering failure.

10 Low insulation Wet and damp atmospheric condition,

resistance Motor submerged in flood water.

11 Breaker tripped Phase lead open circuited, locked Rotor,

at starting winding short circuited, improper tripping
setting.

12 Sparking at slip rings Overloading, poor maintenance, rough/ dirty

slip rings.

13 Noise Non uniform air gap, rotor unbalanced, loose

bearing
Mechanical fault
Sl. no Fault type Reasons

1 Excessive vibration Misalignment of shaft/ coupling, Foundation

levelling problem, defective bearing.

2. Hot bearing Misalignment, excessive belt pulling,

bent shaft, low pulley diameter.

3 Oil leakage Loose cover, overflowing of lubricant.

4 Knocking in bearing Mechanical mismatch, presence of foreign

element in bearing.

5 Shaft does not rotate Misalignment, excessive belt pressure,

with load improper grease in bearing.

Trouble shooting charts for Synchronous motor

Sl. no Fault type Reasons

1 Fails to start Wrong connection, more friction, low terminal

voltage

2 Motor trips Exciter circuit open, Field short circuited

Circuit breaker

3 Unable to attain over loaded, Field over excited

Rated speed

4 Motor is hunting Fluctuating load

5 Starter not working open circuited phase

Trouble shooting charts for transformer

Sl. no Fault type Reasons

1 General overheating Overloading, poor ventilation, oil level below

the standard level, sludge in oil/ tank.

2 Overheating High primary voltage, low frequency

on load

3 Local heating Excess Eddy current.

4 Unequal phase voltage Internal/ external faults in star/delta bank

(for 3Φ) 1 unit may reverse connected in parallel run.

5 Low secondary voltage Wrong tapping, reluctance of coil increases.

6 Excessive overheating Short circuit between coils

7 Low insulation, Unwanted moisture entry, overheating,

between winding & Line surge, lightning discharge.
between winding and core

8 Noise, Loose bolts, poor core material

during operation

9 Tank corrosion Acidity in oil increases

10 Low dielectric Excess moisture in oil

strength of oil

11 Excessive sludge Wrong grade of oil, overheating

in oil

Trouble shooting charts for batteries

Lead –Acid type

Sl. no Fault type Reasons

1 Unable take charging current Open charging circuit, open

fuse, loose connection

2. Low output than rated value plates are outdated, contaminated

electrolytes, sulphation of plates, self
discharge rapidly, abnormal ambient temp.

3 No voltage at terminals terminals short circuited, heavy leakage,

Sulphation

4 Excessive temp at charging time High C rate, A-hr not set properly, short
circuit within a cell

5 Heavy gassing at initial charging Sulphation, High charging current, Very low
period ambient temp.

6 High temp at discharging period High ambient temp, excessive load compare
battery rating, electrolytes level is low

7 Heavy gassing at discharging time contaminated electrolytes

8 Electrolytes level reduced early Mechanical crack at frame, irregular topping

of electrolytes, Heavy charging

9 Unequal cell voltages Over discharging, one or more cell short-

circuited, +ve plate worn out, low
electrolyte level, incorrect connection