Electrical Troubleshooting Quiz — Jan. 15, 2019
The plant manager came onboard three months ago and just hired you. During the interview, he seemed interested in your troubleshooting abilities. Your first assignment is why.
A few years ago, the plant installed a custom-built manufacturing line that is complex. Among other things, it includes several 3D printers. The line is considered critical, but as the plant manager pointed out, “They are always fixing something. If it’s not a bearing that went bad, it’s a motor. Or some electronics gizmo.”
The plant manager also told you that he personally reviewed the maintenance procedures and records against the manufacturer’s recommended maintenance found no deficiencies. How might you provide the solution?
Troubleshoot the maintenance and repair practices, not just the equipment. For example, bearings are failing. So, suspect incompatible lubricants and/or poor lubrication practices. Clear this up, and you’ll probably also reduce motor failure rates. You’ll need a lubrication expert to review the lubrication program in depth.
Go through the repair records and compile a chart of failure modes by frequency. Contact the manufacturer about reviewing this and recommending revisions to the maintenance practices.
Failures of electronics, bearings, and motors may have a common cause; the most likely candidate is improper bonding. This is often an area of confusion. Instead of having a low impedance path back to the source, there’s a hodgepodge of impedances in the way. Significant current thus flows through equipment.
About the Author
Mark Lamendola
Mark is an expert in maintenance management, having racked up an impressive track record during his time working in the field. He also has extensive knowledge of, and practical expertise with, the National Electrical Code (NEC). Through his consulting business, he provides articles and training materials on electrical topics, specializing in making difficult subjects easy to understand and focusing on the practical aspects of electrical work.
Prior to starting his own business, Mark served as the Technical Editor on EC&M for six years, worked three years in nuclear maintenance, six years as a contract project engineer/project manager, three years as a systems engineer, and three years in plant maintenance management.
Mark earned an AAS degree from Rock Valley College, a BSEET from Columbia Pacific University, and an MBA from Lake Erie College. He’s also completed several related certifications over the years and even was formerly licensed as a Master Electrician. He is a Senior Member of the IEEE and past Chairman of the Kansas City Chapters of both the IEEE and the IEEE Computer Society. Mark also served as the program director for, a board member of, and webmaster of, the Midwest Chapter of the 7x24 Exchange. He has also held memberships with the following organizations: NETA, NFPA, International Association of Webmasters, and Institute of Certified Professional Managers.