News and Safety Tips
Disclaimer: While the content of this website has been compiled responsibly and carefully, The Faraday Centre Ltd and Thomas-Faraday Training Ltd disclaim all warrants, express or implied, as to the accuracy of the information contained in any of the materials on this website or on other linked websites or any subsequent links.
Angola in Teesside, again
Due to the successful training programme The Faraday Centre conducted back in October/November 2007, a second group of 12 candidates from Angola are now in Teesside to carry out a 4-week High/Low voltage safety training programme. The expertise of The Faraday Centre team supported by a wide range of training equipment and carefully designed competency-based training programmes meeting industry standard are the assets that make The Faraday Centre one of the leading specialist electrical training providers in the UK.
Created: March 2008
The Faraday Centre in Trinidad and Africa
February/March 2008. Meeting customers' needs require a high degree of business skill, experience and above all dedication to customer service. Five weeks of training has now been completed to two very renowned multinational companies in Trinidad and Africa. The training programmes were delivered on-site making use of the clients' equipment to provide ‘hands-on' practical training programmes to 47 electrical personnel. Challenging but successful and similar courses will be repeated again during the year.
Since 1991, The Faraday Centre continues to deliver training at its facilities in the UK, Cyprus as well as on-site in the UK and overseas. Courses have been delivered in Europe, the Middle East, South East Asia and North America.
Created: March 2008
Cyprus: Electrical Safety Seminar
On 30th January 2008, The Faraday training group hosted and presented a seminar focusing on electrical safety in the work place and at home. The event was aimed at the hazards of electricity and electrical safety covering various industrial sectors in Cyprus including construction, tourism and house electrical appliances. Some of the topics highlighted were:
• Electrical safety practices
• High voltage safety
• IEE 16th and 17th Editions of the Wiring Regulations
• Inspection and testing of electrical installations
The audience consisted of a wide cross-section of delegates from various local companies from Cyprus and other multinational organisations. The seminar was held at Thomas-Faraday Training centre in Limassol, Cyprus and was conducted in both English and Greek languages. The event also included a tour of the centre's practical training facility. A very well-attended seminar and due to the high demand, other seminars will be organised later in the year.
Created: February 2008
IEE 17th Edition Wiring Regulations; Changes in BS7671:2008
This revised standard will include the changes necessary to maintain technical alignment with European Harmonization Documents. It's important to note that all of the regulations have been renumbered to align with the International Electrotechnical Commission's (IEC) numbering system. This has also involved partial restructuring of the standard with Part 6 becoming Part 7 and vice-versa.
Part 1; additional regulations relate to the requirements to protect against voltage disturbances and to implement measures against electromagnetic influences. Part 2, ‘Definitions', includes a number of significant new and amended definitions. New requirements relating to safety services and continuity of service considered necessary during the intended life of the installation are addressed in Part 3.
There are several significant changes to Part 4, ‘Protection for safety'. Whilst the fundamental principles of shock protection remain the same, the changes to definitions such as basic protection for direct contact and fault protection for indirect contact, along with a partial restructuring of Part 4 (such as Part 41 now includes parts of Chapter 47) means that those readers familiar with the 16th Edition will need to spend time getting familiar with the revised Part 4. The provision of supplementary protection by RCD now comes under the heading additional protection and the requirements to provide RCDs have been extended.
The Tables in Chapter 41 for earth fault loop impedances are based on a nominal voltage of 230 V (not 240 V), hence the values are slightly changed. The Chapter also includes a new Table 41.5 giving maximum values of earth fault loop impedance for RCDs.
Chapter 42, Protection against thermal effects now includes the requirements for where particular risks of fire exist (previously in Section 482).Chapter 43, Protection against overcurrent now includes the requirements previously given in Section 473.
Protection against voltage disturbances (Chapter 44) has now been expanded including a new Section 442, ‘Protection of low voltage installations against temporary overvoltages due to earth faults in the high voltage system and due to faults in the low voltage system'.
In Part 5, ‘Selection and erection of wiring systems' will now include requirements for busbar trunking systems and powertrack systems. The requirements relating to cables concealed in a wall or partition have been altered so that protection by a 30mA RCD is an additional requirement for ‘unprotected' cables (e.g. twin and earth cables installed in a chase less than 50mm deep); it must be emphasised that such cables must still be installed in ‘safe' zones. Previously, the requirements for protection, isolation, switching, control and monitoring were covered in several different sections of BS 7671. In the 17th Edition, Chapter 53 now includes all the requirements relating to these issues. ‘Earthing arrangements and protective conductors', Chapter 54, now incorporates the requirements applicable to equipment with high protective conductor currents which were previously given in Section 607.
Chapter 55, ‘Other equipment', includes additional requirements to ensure the safe connection of low voltage generating sets, including small scale embedded generators. ‘Luminaires and lighting installations', Section 559, gives a new set of requirements for fixed outdoor lighting installations, extra-low voltage lighting installations, lighting for display stands and highway power supplies and street furniture (previously in Section 611).
In ‘Inspection and testing', Part 6, the requirements are generally similar to those in BS 7671: 2001. The minimum values of insulation resistance have been increased. Into Part 7, ‘Special installations or locations', there are significant changes and additions; Section 607 and Section 611 have been moved into the main body of the regulations (as Sections 543 and 559 respectively).
Perhaps the area causing much speculation prior to the launch of the 17th Edition is Section 701, relating to Locations containing a bath tub or shower basin An important change is that 30mA RCD-protected socket-outlets are permitted beyond a distance of 3m horizontally from the boundary of zone 1. They are prohibited within 3m of zone 1. Zone 3 is no longer defined and supplementary bonding is no longer required, providing the installation has main bonding in accordance with Part 41. Every circuit in the special location, including lighting circuits, must have 30 mA RCD protection.
In Section 704, ‘Construction and demolition site installations' and Section 705 ‘Agricultural and horticultural premises,' reduced disconnection times and the 25V equation are no longer included. The requirements relating to caravan parks can now be found in Section 708 and include the requirement that each socket-outlet must be provided individually with overcurrent and RCD protection. The requirements for electrical installations in caravans and motor caravans are now in Section 721.
Part 7 also includes the following new Sections:
• Section 709 Marinas and similar locations
• Section 711 Exhibitions shows and stands
• Section 712 Solar photovoltaic (pv) power supply systems
• Section 717 Mobile and transportable units
• Section 740 Temporary electrical installations for structures, amusement devices and booths at fairgrounds, amusement parks and circuses
• Section 753 Floor and ceiling heating systems.
Appropriate changes have been made to Appendices 1 to 7, in particular the methods and tables used in Appendix 4 and there are also several new Appendices.
Created: February 2008
AP/SAP High Voltage Competence Assessment
A carefully designed programme designed by The Faraday Centre to assess candidates' safe switching practices when operating high voltage power systems on land and marine/offshore-based equipment. It is intended for candidates requiring independent external assessment of their level of competence.
The programme is carried out individually and includes theoretical, paper and practical assessment, covering:
• Summary of electrical protection
• Operational & safety features of switchgear
• Switching programme
• Risk assessment
• Electrical permit to work
• Sanction for test
• Limitation of access / restricted work document
• Practical demonstration and exercises
A full confidential report is issued to include details of the assessment and the recommendations of the candidates suitability for electrical authorisation in accordance with the clients' procedures.
Created: January 2008
Kazakhstan in Teesside
A well planned and carefully organised electrical training programme was delivered at The Faraday Centre in Middlesbrough to a group of 27 Russians from a Kazakhstan oil company. The programme was delivered in English and Russian languages assist by a professional interpreter. The programme was very successful and met its objectives. This is not the first time The Faraday Centre delivers training in other languages. Previously, several courses were delivered in English and French to groups of candidates from an Algerian oil company.
The Faraday Centre are very well versed in international customer service and meeting various clients' electrical training needs.
Created: December 2007
The Faraday Centre in Qatar
Qatar is one of the richest countries in the world with GDP per capita of £32,000 is the highest in the world. Qatar is heavily investing in a number of major projects to ensure continued growth. The government is also investing heavily in the training and educational sector because it sees the creation of a knowledge-based economy as central to the country's future.
The Faraday Centre delivered a series of HV/LV training programmes to the country's main oil company, QP. 50 candidates attended the courses and showed keen interest and participation to the bespoke course that was specifically designed to meet the training objectives.
Created: November 2007
Angola in Teesside
October/November 2007. A group of 11 candidates from a multinational oil company in Angola visited Teesside to carry out a 4-week High/Low voltage training programme at The Faraday Centre. The competency-based training programme covered high voltage safety operations, maintenance of electrical switchgear, transformer testing and maintenance and cable termination & splicing. The candidates carried out various practical training exercises using a wide range of equipment at The Faraday Centre training facilities. A special ‘certificate presentation' event took place at the end of the training programme.
It was a pleasure to work with the group as they all showed great and keen interest in learning and taking active participation in the training and the workshop exercises and they have certainly enjoyed the British ‘fish n chips'.
Created: November 2007
Safety First: Electrical Safety Procedures
Responsible employers recognise that electricity can pose serious hazards to personnel when working on high voltage apparatus. To minimise these risks, they use high voltage safety rules in accordance with the requirements to the Electricity at Work Regulations. However, the regulations do not specify the detail, but simply the dangers to be avoided. Consequently, each company may determine the style and complexity of their procedures. Nevertheless, safety is always paramount and the basic principles are liable to be similar. The following items should be included in any high voltage safety rules:
• Authorisation. The employer should appoint, in writing, suitable individuals to carry out specific duties on the high voltage system. Before doing so, he must ensure each person is competent to carry out his/her specific duties.
• Operational Control. An effective means of monitoring all system activities must be maintained to ensure that the integrity of system supplies is not adversely affected and, more importantly, that personnel are not placed at risk.
• Identification. High voltage equipment must be identified by clear unambiguous, permanent labels placed at all points of approach. Safety documents should use the same titles and avoid the use of abbreviations (where practicable). Any abbreviations that are used must be unambiguous. Failure to do so can result in personnel working on the wrong apparatus with serious consequences.
• Isolation. Proper isolation means that the apparatus to be worked upon cannot be made live by switching and requires the withdrawal of appropriate circuit breakers or opening isolators. It is not sufficient just to open the circuit breakers associated with the apparatus. Isolation is usually coupled with the requirement to lock off the apparatus from live conductors and from dead conductors that may become live.
When practical, all high voltage transformers normally connected to the apparatus must be disconnected or made safe by the withdrawal of fuses.
• Earthing. Where practical, it should be verified that the apparatus to be earthed is dead by means of a voltage indicator, which must also be tested before and after use. Where possible, the earth should be applied by means of a circuit breaker or specifically provided earthing switch. Where this is not possible, an earth should be applied using properly devised earthing leaks, so as to ensure at all times an immediate discharge of electrical energy without danger.
• Screening. Where necessary to prevent danger, screens must be applied, together with suitable caution/danger notices fixed to the apparatus. Such screening may include switchgear shutters that automatically close, but which should be locked closed.
• Electrical Permit to Work. A permit is a form of declaration signed and given by a person authorised to issue permits to work, to the person in charge of the work. The purpose of this form is to make known to the recipient exactly what apparatus is dead, that it has been isolated from all live conductors, has been discharged, is connected to earth and on which it is safe to work, and the task to be carried out. The authorised person should identify the equipment at the point and demonstrate to the person receiving the permit to work that the apparatus is safe to work on.
In some circumstance, e.g. small plants/ships, only one electrical person exists, but this should not be taken as an excuse not to issue a permit to oneself. The act of writing out the safety document will focus the mind upon the safety requirements of the job.
Before work is carried out
As a minimum, any high voltage rules must ensure before any work is carried out, that the apparatus is:
• Dead
• Isolated from all supplies including voltage transformers
• Earthed so as to safely discharge any electrical energy
• Screened from all live conductors
• Locked off to ensure safety features remain in place
• Warning notices fitted wherever appropriated
• Safety document issued such as electrical permit to work and isolation certificate
• Conversant; all persons are familiar with the equipment and their duties
• Identification: the apparatus must be labelled and identified to the competent person at the point of work
Created: October 2007
New Electrical Courses
Due to an increasing demand on electrical qualification and training in the UK and Cyprus, The Faraday Centre will be introducing a number of courses designed for personnel requiring introductory level in electrical engineering. The courses aim to provide an understanding and knowledge of low and high voltage equipment used in the generation and distribution of electrical power systems.
Other courses aim to raise the safety awareness of personnel working with electricity and involved in the maintenance of industrial electrical plants and equipment. Topics covered include:
• Earthing of fixed electrical equipment
• AC measurements
• Motors, batteries and battery chargers
• Cable colour coding and potential of hazards
• Electrical equipment in hazardous areas
• Safe use of hand and power tools
• Testing of electrical installation and equipment
• Maintenance and troubleshooting of electrical equipment
For further information, please contact The Faraday Centre.
Created: September 2007
A Busy Summer in Cyprus
It is a tradition and common practice that most businesses including some government offices close during the hot month of August. The exception is obviously the tourism industry.
However, Thomas-Faraday Training (Faraday's regional training centre in Cyprus) had a busy time delivering training to various groups of candidates from Oman and Kuwait. The courses focused on practical training on the safe operation of high voltage switchgear of 11000 - 33000 volts. Special care and attention are always required when dealing with electricity and the carefully installed high voltage training equipment at the centre's practical facility allows candidates to experience ‘hands-on' training in safe environment, supervised by high calibre lecturers.
Competency assessments were carried out to all 23 candidates using the high voltage switchgear training equipment, which simulate various workplace scenarios and conditions. Successful candidates received The Faraday Centre Certificate of Competence as well as EAL's ‘Certificate of Verified Achievement'.
Created: August 2007
Safety First: Avoiding Electrical Hazards
There are three basic electrical hazards that cause injury and death: shock, arch-flash and arc-blast. This could be avoided by:
• Providing training
• Anticipate unexpected results
• Use procedures as tools
• Assess people's abilities
• Providing an electrically safe work conditions
Use the right tool for the job. Use the appropriate tools for the job at hand. Keep them accessible and in good working condition. Using a screwdriver for a job that requires a fuse puller is an invitation to an accident.
Isolate the equipment. The best way to avoid an accident is to reduce exposure to the hazards present. Keep doors closed. Keep barricades in place. Install temporary voltage-rated blankets covering exposed live parts. Put the equipment in a safe working condition prior to performing maintenance. Lock out the disconnected.
Protect the person. Use the proper personal protection equipment for the job. This may include safety glasses or goggles, head protection, voltage-rated gloves, safety belts and harnesses or flame-resistant clothing.
Minimise the hazard. If it is impossible to establish an electrically safe work environment, be sure to shut down every possible energy source. Understand that circuit can become re-energised and do something to lessen the risk.
Created: July 2007
Investing in the Future
More and more training programmes are becoming dependant on the use of IT and computer technology to increase quality and efficiency, but also to reduce paperwork. The Faraday Centre continues to invest in training equipment and has updated its "IT Online Facility". A new suit of networked computer system has been installed to accommodate the increasing demand on online examinations.
Several qualification examinations are carried out "online" and candidates can find out the result almost immediately after the examinations. This includes various City & Guilds courses such as PAT Testing C&G2377), 17th Edition Wiring Regulations (C&G2382), Inspection & Testing (C&G2392) as well as EAL Part P course.
Similar invest has also been made at The Faraday's regional training in Cyprus and has proven very successful.
Created: May 2007
Safety First: Work safely
Make sure that people who are working with electricity are competent to do the job. Even simple tasks such as wiring a plug can lead to danger - ensure that people know what they are doing before they start.
Check that:
• suspect or faulty equipment is taken out of use, labelled ‘DO NOT USE' and kept secure until examined by a competent person;
• where possible, tools and power socket-outlets are switched off before plugging in or unplugging;
• equipment is switched off and/or unplugged before cleaning or making adjustments.
More complicated tasks, such as equipment repairs or alterations to an electrical installation, should only be tackled by people with knowledge of the risks and the precautions needed. Work on or near exposed live parts of equipment must not be allowed unless it is absolutely unavoidable and suitable precautions have been taken to prevent injury, both to the workers and to anyone else who may be in the area.
People operating, inspecting, maintaining and testing your switchgear will need to be made familiar with the procedures, safety rules and safety documents (particularly for high voltage switchgear). You will also need to tell them their responsibilities to ensure safety and safe working. As a user of switchgear you are required by law to ensure the people you have selected to be competent persons or authorised persons receive the necessary training so that they are able to carry out their duties in safety and without risk to health. The Electricity at Work Regulations 1989 emphasise the need for persons undertaking the maintenance or repair of electrical apparatus to be ‘competent' stating that: "No person shall be engaged on any work activity where technical knowledge or experience is necessary to prevent danger or, where appropriate, injury, unless he possesses such knowledge or experience or is under such degree of supervision as may appropriate having regards to the nature of the work".
The Health & Safety at Work Act 1974 and the Management of Health & Safety at Work Regulations 1999 impose general duties on employers to ensure the health and safety of employees and others as well as to undertake "suitable and sufficient" risk assessments to identify significant risks to health and safety and enable measures to be taken to remove or reduce the risks.
Created: April 2007
Electrical Inspection & Testing Seminars
An electrical installation is the wiring system of a building from the mains position to items of electrical equipment, sockets, light fittings and everything in between and is the system which all the electrical equipment is, or may be, electrically connected to a common source of electrical energy. Testing of electrical installations is also referred to as BS7671, periodic inspection, fixed appliance testing, circuit testing, etc.
The Faraday Centre delivered a series of awareness seminars and presented the importance of periodical inspection and testing of electrical installations. The seminars took place in Middlesbrough, Newcastle and Leeds.
"Every year some 28000 fires are started through faulty electrical wiring and accessories causing death and injury. Look out for warning signs of dangerous wiring. Hot plugs and sockets or scorch marks. Fuses that blow for no obvious reason and old style fuse boards with rewireable fuses, lights flickering, extension leads and adaptors used because of lack of socket outlets". Suhail Mitoubsi, Group Business Manager.
Created: March 2007
Accredited High Voltage Courses & AP/SAP
Safety procedures with well-designed and maintained equipment go a considerable way to avoiding danger when installing, operating or maintaining high voltage equipment. However, the most important link in the safety chain is the competence of the personnel involved.
As a testimony of the high quality training offered by The Faraday Centre, several of Faraday's high voltage safety courses have been accredited by EAL (EMTA Awards Ltd). From January 2007, candidates successfully completing the competence assessment of the training programme will receive an EAL certificate. The accredited courses are:
• Introduction to the Safe Operation of High Voltage Power Systems (course code S1)
• Awareness of the Operation of High Voltage Power Systems (course code S2)
• Basic Refresher in the Safe Operation of High Voltage Power Systems (course code S3)
• Fundamentals of the Safe Operation of High Voltage Power Systems (course code S4)
• Advanced Refresher (Consolidation) Training in the Safe Operation of High Voltage Power Systems (course Code S5)
• Fundamentals of the Safe Operation of Marine/Offshore High Voltage Power Systems (course code MAR4)
• Principles of the Safe Operation of Marine/Offshore High Voltage Power Systems (course code MAR5)
• Protection of Electrical Power Systems (course code P1)
Created: January 2007
Cyprus Regional Centre: Accredited Qualifications
The Faraday's Cyprus regional training centre receives accreditation to run several City & Guilds course and other high voltage training programmes accredited by EAL (EMAT Awards Ltd). Candidates successfully complete the courses would receive relevant City & Guilds qualifications and certificates and EAL's "Certificate of Verified Achievement". The courses are:
• Portable Appliance Testing, City & Guilds 2377-001
• Portable Appliance Testing, City & Guilds 2377-002
• IEE 16th Edition Wiring Regulations, City & Guilds 2381
• Inspection, Testing & Certification of Electrical Installations, City & Guilds 2391
• Introduction to the Safe Operation of High Voltage Power Systems (course code S1), EAL certificate
• Awareness of the Operation of High Voltage Power Systems (course code S2) , EAL certificate
• Basic Refresher in the Safe Operation of High Voltage Power Systems (course code S3) , EAL certificate
• Fundamentals of the Safe Operation of High Voltage Power Systems (course code S4) , EAL certificate
• Advanced Refresher (Consolidation) Training in the Safe Operation of High Voltage Power Systems (course Code S5) , EAL certificate
• Fundamentals of the Safe Operation of Marine/Offshore High Voltage Power Systems (course code MAR4) , EAL certificate
• Principles of the Safe Operation of Marine/Offshore High Voltage Power Systems (course code MAR5) , EAL certificate
• Protection of Electrical Power Systems (course code P1) , EAL certificate
Created: January 2007
Cyprus Regional Training Centre
"It took a little longer than anticipated, but it's all completed now. Thomas-Faraday Training Ltd in Limassol, Cyprus, is probably the first electrical training centre of its kind in Cyprus. The regional training centre is fully operational and offers a wide range of high and low voltage training, not only to Cyprus, but also to other regions including Central ^ East Europe, North Africa and the Middle East ". Suhail Mitoubsi, Group Business Manager.
Occupying over 7,000 square feet of purpose-designed training facility and fully equipped with a wide range of industrial electrical switchgear training equipment, the new regional centre provides high quality competency-based practical electrical training. All the training programmes focus on operational safety and competency development. Trainees have the opportunity to experience ‘hands-on' practical electrical training in safe and controlled environment.
Training programmes include high voltage safety to 11000 volts applicable to land-based as well as marine/offshore power systems, electrical protection, testing, switchgear maintenance and a wide range of low voltage safety courses.
Created: December 2006
Marine Electrical Safety Training
The use of electrical power on vessels is a vital and obedient tool and with correct training can provide safe and reliable energy to a craft's crew.
Since its establishment in 1991, The Faraday Centre have been delivering electrical safety training to the marine and offshore industries and have built an excellent reputation worldwide for high quality competency-based electrical training. Some of The Faraday Centre major clients are multinational cruise liners and container vessels, in addition courses have been delivered to electrical personnel from the Shell Bonga FPSO and on board the LNG carrier Granita at dry dock in Lisnave, Portugal.
Created: November 2006
Safety First: Office Electrical Safety
Electrical equipment used in an office is potentially hazardous and can cause serious shock and burn injuries if improperly used or maintained. Electricity travels through electrical conductors which may be in the form of wires or parts of the human body. Most metals and moist skin offer very little resistance to the flow of electrical current and can easily conduct electricity.
If a part of the body comes in contact with electrical circuit, a shock will occur. The electrical current will enter the body at one point and leaves at another. The passage of electricity through the body can cause great pains, burns, destruction of tissue, nerves and muscles and even death. Factors influencing the effects of electrical shock include the type of current, voltage, resistance, amperage, pathway through the body and the duration of contact. The longer the current flows through the body, the more serious the injury. Injuries are less severe when the current does not pass through or near nerve centres and vital organs. Electrical accidents usually occur as a result of faulty or defective equipment, unsafe installation or misuse of equipment on the part of the office workers. Types of electrical hazards found in an office environment include:
• Unearthed equipment
• Overloaded outlets
• Unsafe/non-approved equipment
• Improper placement of cords
• Electrical cords across walkway
• Pulling plugs to shut off power
• Working on "live equipment"
Created: October 2006
Safety First: Troubleshooting Approach
The 5 Step Troubleshooting Approach consists of the following:
Preparation
Step 1 Observation
Step 2 Define Problem Area
Step 3 Identify Possible Causes
Step 4 Determine Most Probable Cause
Step 5 Test and Repair
Follow-up
Preparation
Before you begin to troubleshoot any piece of equipment, you must be familiar with your organisation's safety rules and procedures for working on electrical equipment. These rules and procedures govern the methods you can use to troubleshoot electrical equipment (including your lockout/tagout procedures, testing procedures etc.) and must be followed while troubleshooting.
Next, you need to gather information regarding the equipment and the problem. Be sure you understand how the equipment is designed to operate. It is much easier to analyse faulty operation when you know how it should operate. Operation or equipment manuals and drawings are great sources of information and are helpful to have available. If there are equipment history records, you should review them to see if there are any recurring problems. You should also have on-hand any documentation describing the problem (i.e. a work order, trouble report or even your notes taken from a discussion with a customer.)
Step 1 - Observe
Most faults provide obvious clues as to their cause. Through careful observation and a little bit of reasoning, most faults can be identified as to the actual component with very little testing. When observing malfunctioning equipment, look for visual signs of mechanical damage such as indications of impact, chafed wires, loose components or parts lying in the bottom of the cabinet. Look for signs of overheating, especially on wiring, relay coils and printed circuit boards.
Don't forget to use your other senses when inspecting equipment. The smell of burnt insulation is something you won't miss. Listening to the sound of the equipment operating may give you a clue to where the problem is located. Checking the temperature of components can also help find problems but be careful while doing this, some components may be alive or hot enough to burn you.
Pay particular attention to areas that were identified either by past history or by the person that reported the problem. A note of caution here! do not let these mislead you, past problems are just that - past problems, they are not necessarily the problem you are looking for now. Also, do not take reported problems as fact; always check for yourself if possible. The person reporting the problem may not have described it properly or may have made their own incorrect assumptions.
When faced with equipment which is not functioning properly you should:
• Be sure you understand how the equipment is designed to operate. It makes it much easier to analyse faulty operation when you know how it should operate;
• Note the condition of the equipment as found. You should look at the state of the relays (energised or not), which lamps are lit, which auxiliary equipment is energised or running etc. This is the best time to give the equipment a thorough inspection (using all your senses). Look for signs of mechanical damage, overheating, unusual sounds, smells etc.;
• Test the operation of the equipment including all of its features. Make note of any feature that is not operating properly. Make sure you observe these operations very carefully. This can give you a lot of valuable information regarding all parts of the equipment.
Step 2 - Define Problem Area
It is at this stage that you apply logic and reasoning to your observations to determine the problem area of the malfunctioning equipment. Often times when equipment malfunctions, certain parts of the equipment will work properly while others not.
The key is to use your observations (from step 1) to rule out parts of the equipment or circuitry that are operating properly and not contributing to the cause of the malfunction. You should continue to do this until you are left with only the part(s) that if faulty, could cause the symptoms that the equipment is experiencing.
To help you define the problem area you should have a schematic diagram of the circuit in addition to your noted observations.
Starting with the whole circuit as the problem area, take each noted observation and ask yourself "what does this tell me about the circuit operation?" If an observation indicates that a section of the circuit appears to be operating properly, you can then eliminate it from the problem area. As you eliminate each part of the circuit from the problem area, make sure to identify them on your schematic. This will help you keep track of all your information.
Step 3 - Identify Possible Causes
Once the problem area(s) have been defined, it is necessary to identify all the possible causes of the malfunction. This typically involves every component in the problem area(s).
It is necessary to list (actually write down) every fault which could cause the problem no matter how remote the possibility of it occurring. Use your initial observations to help you do this. During the next step you will eliminate those which are not likely to happen.
Step 4 - Determine Most Probable Cause
Once the list of possible causes has been made, it is then necessary to prioritise each item as to the probability of it being the cause of the malfunction. The following are some rules of thumb when prioritising possible causes.
Although it could be possible for two components to fail at the same time, it is not very likely. Start by looking for one faulty component as the culprit.
The following list shows the order in which you should check components based on the probability of them being defective:
• First look for components which burn out or have a tendency to wear out, i.e. mechanical switches, fuses, relay contacts or light bulbs. (Remember, that in the case of fuses, they burn out for a reason. You should find out why before replacing them.)
• The next most likely cause of failure are coils, motors, transformers and other devices with windings. These usually generate heat and, with time, can malfunction.
• Connections should be your third choice, especially screw type or bolted type. Over time these can loosen and cause a high resistance. In some cases this resistance will cause overheating and eventually will burn open. Connections on equipment that is subject to vibration are especially prone to coming loose.
• Finally, you should look for is defective wiring. Pay particular attention to areas where the wire insulation could be damaged causing short circuits. Don't rule out incorrect wiring, especially on a new piece of equipment.
Step 5 - Test and Repair
Testing electrical equipment can be hazardous. The electrical energy contained in many circuits can be enough to injure or kill. Make sure you follow all your company's safety precautions, rules and procedures while troubleshooting.
Once you have determined the most probable cause, you must either prove it to be the problem or rule it out. This can sometimes be done by careful inspection however, in many cases the fault will be such that you cannot identify the problem component by observation and analysis alone. In these circumstances, test instruments can be used to help narrow the problem area and identify the problem component.
There are many types of test instruments used for troubleshooting. Some are specialized instruments designed to measure various behaviours of specific equipment, while others like the multimetres are more general in nature and can be used on most electrical equipment. A typical multimetre can measure AC and DC Voltages, Resistance, and Current.
A very important rule when taking metre readings is to predict what the metre will read before taking the reading. Use the circuit schematic to determine what the metre will read if the circuit is operating normally. If the reading is anything other than your predicted value, you know that this part of the circuit is being affected by the fault.
Depending on the circuit and type of fault, the problem area as defined by your observations, can include a large area of the circuit creating a very large list of possible and probable causes. Under such circumstances, you could use a "divide and eliminate" testing approach to eliminate parts of the circuit from the problem area. The results of each test provide information to help you reduce the size of the problem area until the defective component is identified.
Once you have determined the cause of the faulty operation of the circuit you can proceed to replace the defective component. Be sure the circuit is locked out and you follow all safety procedures before disconnecting the component or any wires.
After replacing the component, you must test operate all features of the circuit to be sure you have replaced the proper component and that there are no other faults in the circuit. It can be very embarrassing to tell the customer that you have repaired the problem only to have him find another problem with the equipment just after you leave.
Please note, testing is a large topic and this article has only touched on the highlights.
Follow up
Although this is not an official step of the troubleshooting process it nevertheless should be done once the equipment has been repaired and put back in service. You should try to determine the reason for the malfunction.
• Did the component fail due to age?
• Did the environment the equipment operates in cause excessive corrosion?
• Are there wear points that caused the wiring to short out?
• Did it fail due to improper use?
• Is there a design flaw that causes the same component to fail repeatedly?
Through this process further failures can be minimised. Many organisations have their own follow-up documentation and processes. Make sure you check your organisation's procedures.
Adopting a logical and systematic approach such as the 5 Step Troubleshooting Approach can help you to troubleshoot like an expert!
Created: August 2006