UNIT-4

Internal and External Causes for Failure of Equipments

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 behavior 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 behavior 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 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 behavior of the machine.
These are the causes creating problems of smooth working of machine and the machine show abnormal
behavior

External Causes :
1. A 3-phase machine is supplied with 3-line wires L.L.L. These are called as lines. If the fault is developed
in the feeder / Distributor line only two lines will supply the equipment. The two lines supply the power
to 3 phases of machine and two phases become excessive of load and over heating 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 affects 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. Some times 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.
Mechanical and Electrical Faults and Causes in Case of Electrical Machines
Mechanical Faults :
Sr. No. Fault
1 Bent shape
2 Snapped binding
3 Trouble in bearning
Mismatching of brush and
4 brush holders on slip rings.
Transformer
( i ) Brushing developed
5 cracks
( ii ) Tap changer not
working properly
( iii )Damaged gaskets
Reasons Remedial measures
Drawback in shaft
coupling machine to
machine or machine to
load shaft. Concentric Due care during storage,
coupling very tight transportation must be taken.
fitting of nuts and bolts Loosening properly the nut
having no flexibility. bolts fittings. Do the alignment
Wrong and crowed of coupling and adjust nut bolt
storage of machine one moving it till feel free
over the other. movement of two coupled
Damages in transport. shafts.
Sometimes centrifugal
force developed on the
armature winding is
greater. Take the proper measures.
Lubrications, greasing,
maintenance scheduled Load the machine properly.
not fooled. Machine Check coupling. Replace
load coupling miss bearing. Stop machine if
alignment. vibrations are excessive.
If holders are not
proper as per the brush
size and spring tension
is loose then vibrations
are created. Adjust properly.
Change in atmospheric
conditions too cold, too
hot, heavy rains affect
the brushing.
Electrostatic stress may
be cause cracks on
burning. This may also Maintenance schedules must
be due to pressure of be followed for clearing dust,
connecting rod used for dirt. Connections of supply
connecting supply. line must observed.
Contact might have
been damaged due arcs During breakdown
developed when tap maintenance, clean the
changer is used contacts, remove carbon.
frequently on load. Replacement of gasket
Gasket makes the air periodically
 tight seal of tank
containing oil in full
level. Atmospheric
conditions and reaction
of oil with gasket
material damages the
gasket.

Electrical Faults :
Sr.
No. Fault Reasons Remedial measures

Field winding connections may be

wrong. Field-Armature winding
connection might be wrong. 3-
wrong electric phase motor phase sequence Check the connection. Check direction of rotation.
1 connections connection R-Y-B may be wrong. Interchange connection for working.

Dry soldering, improper and loose

Contact, soldering of joints. Melting of
connections contacts. Break due to opening of Resolder the joint etc. Clean the contacts. Dry
2 opening. soldering. soldered joints be opened are again to be joint.

Damaged Over voltage storage long running, Dry the insulation. Check the voltage, reduce load.
3 insulation over loading, entry of moisture. Stop the machine intermittently for some time.

Due to dirt / Dust accumulation

offering low resistance path to the
flow of current from positive brush
to negative brush. Improper brush
tension on commutator or on the
slip-rings. Shape less brushes
Commutator creating gap between brush and
darkening, commutator surface / slip-ring Clean the commutator. Adjust and check brush
4 burning. surface. tension. Replace shape less brushes.
 Troubleshooting Chart - D.C. Machines:

A) Symptom: Failure to build up of voltage (dc generator)

Possible Cause of Trouble:

 Faulty Voltmeter, test output voltage with separate voltmeter. Open field resistor.
 Open field circuit. Test coils for open circuit or loose connections.
 Nonexistence of residual magnetism in self excited generator.
 Dirty commutator, high mica, brushes not comprising good contact with commutator.
 New brushes seated but not contacting enough area.
 Armature shorted internally to ground.

Remedy:

 Change voltmeter. Replace or repair resistor

 Change defective coils, tighten or solder loose connections.
 Flash the field. Connect battery to field with correct polarity permit current momentarily and cut
off. Field will resume residual magnetism.
 Within cut mica, clean or dress commutator.
 Change or reseat brushes, free if binding in holders.
 Brush bedding and reseat brushes. Eliminate, test and repair or replace.

B) Symptom: Output voltage too low (dc generator)

Possible Cause of Trouble:

 Grounded or shorted field coil. Shorted filtering capacitor; open filter choke, open ammeter shunt,
broken brush shunts.
 Prime mover speed low (test speed)
 Brushes not seated properly. Commutator dirty, or film very heavy

Remedy:

 Test, repair or replace. Adjust governor on prime Mover. Reseat brushes.

 Clean commutator with fine sand paper. Change brushes with appropriate grade set or Use
complete new set of brushes
 Adjust correctly. Connect properly

C) Symptom: Output voltage too high (dc generator)

Possible causes of trouble:

 Field resistor not appropriately adjusted

 Reversed field coil or armature coil connections
 Prime mover speed too high.
 Faulty voltage regulator
 Overloaded.
Remedy:

 Adjust governing device.

 Adjust or change faulty voltage regulator.
 Test speed.

D) Symptom: Armature too hot

Possible causes of trouble:

 Test meter readings against name plate rating.

 Excessive brush pressure.
 Belt very tight or coupling not aligned.
 End plate out of position. Bent shaft.
 Armature coil shorted Armature striking poles. Test bearing for play and air gap for correct
spacing, shaft for bent condition.
 Poor ventilation. Clogged air passages.
 Repeated changes in load In bulk. Examine meter readings.

Remedy:

 Decrease load.
 Adjust pressure or replace tension springs.
 Adjust belt. Align units properly.
 Assemble accurately.
 Straighten on lathe or replace.
 Repair or replace armature. Replace bearings.
 Straighten shaft or replace Armature.
 Clean clogged air passages. Give clearance. For circulation of air around equipment. Clean
equipment.
 Faulty design. Generator should be employed in steady load application.

Troubleshooting Chart – Three Phase induction motor :-

Three phase induction motors are one of the most popular electric motors commonly found in processing
plants or any manufacturing concern. They are used in situations where large power is required. The
squirrel cage brand is the most popular and they perform various tasks wherever they are applied.

Because of the critical roles these motors play in any plant, a failure of the motor, inability to start, noisy
operation and sundry other problems need to be remedied as soon as possible to avoid costly production
downtime. The table below gives the commonly encountered problems in 3 phase squirrel cage induction
motors, cause of problems and what remedy to apply to bring the motor back to production. This
troubleshooting guide can also be applied to other types of three phase induction motors:
Motor Problem Cause Remedy
Blown fuses Replace fuse with proper type and rating
Overload Trips Check and reset overload in starter
Check to see that power supplied agrees
Improper power supply with nameplate specifications and load
factor
Check connections with wiring diagram
Improper line connections
supplied with motor
This is normally indicated by a humming
Open circuit in winding or control sound when switch is closed. Check for
Motor fails to start switch loose wiring connections. Confirm that
all control contacts are closing.
Check to see that motor and drive turns
Mechanical failure
freely. Check bearings and lubrication
Indicated by blown fuses. Motor must be
Short circuited stator
rewound
Remove end belts. Locate poor
Poor stator coil connections
connections with test lamp.
Rotor defective Check for broken bars or end rings
Motor may be overloaded Reduce motor load
One phase may be open Check supply lines for open phase
Change type or size. Consult motor
Wrong application
manufacturer
Overload Reduce load
Motor stalls
Check that nameplate voltage is
Low voltage
maintained. Check connection.
Fuses blown. Check overload relay,
Open circuit
stator and push buttons
Motor runs and Check for loose connections to line, to
Power failure
then dies down fuses and to control
Motor is applied for the wrong Consult manufacturer for right
application application of motor
Use higher voltage on transformer
Voltage too low at motor terminals terminals or reduce load. Check
because of line drop connections. Check conductors for proper
Motor does not size.
come up to speed Check load motor is supposed to carry at
Starting load too high
start.
Look for cracks near the rings. A new
Broken rotor bars or loose rotor rotor may be required as repairs are
usually temporary not permanent
Open primary circuit Locate fault with testing device and
 repair.
Excessive load Reduce load
Motor takes too Check for high resistance. Adequate wire
Low voltage during start up
long to accelerate size.
and/or draws high Defective squirrel cage rotor Replace with new rotor
current (Amps)
Improve voltage at terminals of
Applied voltage too low
transformer by tap changing.
Reverse connections at motor or at
Wrong rotation Wrong sequence of phases
switchboard.
Overload Reduce load
Frame or bracket vents may be clogged
Open vent holes and check for a
with dirt and prevent proper ventilation
continuous stream of air from the motor.
Motor overheats of motor.
while running Check to make sure that all leads are well
Motor may have one phase open
under load connected.
Grounded coil Locate and repair
Check for faulty leads, connections and
Unbalanced terminal voltage
transformers.
Motor misaligned Realign
Weak support Strengthen base
Coupling out of balance Balance coupling
Driven equipment unbalanced Re-balance driven equipment
Motor vibrates Defective bearings Replace bearing
Bearings not in line Line bearings up properly
Balancing weights shifted Re-balance motor
Poly-phase motor running single phase Check for open circuit
Excessive end play Adjust bearing
Unbalanced line Unequal terminal volts Check leads and connections
current on poly- Single phase operation Check for open contacts
phase motors
during normal Unbalanced voltage Correct unbalanced power supply
operation
Airgap not uniform Check and correct bracket fits or bearing.
Noisy Operation
Rotor unbalance Rebalance
Bent or sprung shaft Straighten or replace shaft
Excessive belt pull Decrease belt tension
Hot bearings
Pulley too far away Move pulley closer to motor bearing
general
Pulley diameter too small Use larger pulleys
Misalignment Correct by realignment of drive
 Maintain proper quantity of grease in
Insufficient grease
bearing
Remove old grease, wash bearings
Deterioration of grease or lubricant
thoroughly in kerosene and replace with
contaminated
new grease.
Hot bearings ball
Reduce quantity of grease, bearing
Excessive lubricant
should not be more than 1/2 filled
Overloaded bearing Check alignment, side and end thrust.
Replace bearing, first clean housing
Broken ball or rough races
thoroughly