How to Troubleshoot Obscure Electrical Issues in Industrial Buildings

Introduction

Troubleshooting electrical issues in industrial buildings can be challenging, especially when the problems are obscure and difficult to diagnose. As an electrician working in industrial settings, I often encounter complex electrical systems and equipment that can develop faults that are not obvious at first glance. However, there are strategies and best practices I've learned over my career that help me methodically track down even the most elusive electrical gremlins.

In this guide, I will share my step-by-step process for troubleshooting obscure electrical issues in warehouses, factories, processing plants and other industrial facilities. Whether the problems involve power distribution, equipment malfunctions or flickering lights, these tips will help you pinpoint the root cause efficiently.

Preparation and Safety

Before troubleshooting any electrical issue, safety should always be the top priority. Dealing with industrial-scale electrical systems requires caution and preparation:

• Use proper personal protective equipment (PPE) such as insulated gloves, boots, helmets and eye protection. Arc flash hazards are a serious risk.
• De-energize and lock out the affected circuit or equipment before performing any diagnostic work.
• Have your electrical safety tools on hand like multimeters, clamp meters and voltage testers.
• Refer to system schematics and wiring diagrams to gain an understanding before digging in.
• Have the contact information for the facility manager to request diagrams and ask questions.
• Bring along a notebook to record detailed notes about your troubleshooting process, findings and theories. These notes can be invaluable for pinpointing the root cause of a problem.

Conducting a Methodical Systematic Investigation

With the prep work and safety steps completed, you can now begin your detective work to track down the issue. I recommend following these best practices during your investigation:

1. Clearly Define the Problem

• Interview facility staff and maintenance technicians to understand when and how often the issue occurs. Knowing whether the problem is intermittent or recurring will guide your troubleshooting.
• Ask witnesses to describe in detail what they are experiencing. Get them to be as specific as possible about the problem.
• Recreate the issue yourself if possible to get first-hand knowledge of the malfunction.

2. List Potential Causes

• Based on your understanding of the symptoms and system, brainstorm a list of possible causes like:
• Faulty wiring connections
• Failed components like breakers, transformers or relays
• Overloaded circuits
• Improper installation
• Damage from electrical events like lightning strikes or power surges
• Malfunctioning equipment connected to the circuit

3. Divide the System into Sections

• The electrical system may be vast, so divide it into sections like:
• Individual branch circuits
• Different areas of the facility
• Upstream vs downstream equipment
• Components like transformers, panelboards, disconnects

This allows you to narrow the focus of your investigation one section at a time.

4. Perform Targeted Testing

• Use your electrical tools and diagnostic skills to test each section methodically:
• Check voltage, current and resistance readings
• Inspect connections for defects
• Listen and feel for abnormalities like buzzing or excessive heat
• Check for loose wiring or corroded terminals
• Monitor the circuit under normal and simulated fault conditions

5. Record and Analyze Results

• Keep detailed notes about the readings and observations from each test.
• Pay attention to findings that deviate from normal baselines or system specifications.
• Correlate data points from different tests to identify patterns pointing to the defective component.

6. Isolate the Faulty Section

• Use process of elimination to narrow down the problem:
• Repeat tests on individual components within a suspect section
• Disconnect sections one-by-one to pinpoint the source
• The faulty section will display distinct symptoms revealing the problem

This troubleshooting methodology allows you to systematically hunt down the root cause by gathering data, analyzing evidence and isolating the issue through deduction.

Common Obscure Electrical Faults in Industrial Facilities

In addition to general defects like loose connections or overloaded circuits, here are some of the more obscure electrical faults I frequently encounter in industrial buildings along with tips for identifying them:

Intermittent Ground Faults

Faulty grounding connections that only act up under certain conditions can be incredibly difficult to capture. Telltale signs include:

• Nuisance tripping of ground fault circuit interrupters (GFCIs) or breakers.
• Intermittent power losses confined to specific equipment.
• Tingling sensations indicating current leakage if you touch the affected equipment.

Tip: Use a clamp meter to detect intermittent current imbalances between hot and neutral indicating ground faults. Monitor over an extended period if necessary to catch it.

Contactor Chatter or Rapid Cycling

When a magnetic contactor or relay chatters on/off rapidly, it indicates:

• Weak contacts not closing properly due to wear or contamination.
• Low voltage reaching the coil.
• Wrong coil voltage being applied.

Tip: Measure voltage across the coil terminals and contact resistance to determine if they are within specifications.

Variable Frequency Drive Issues

VFDs can display faulty symptoms like irregular speeds, overheating, tripping and error codes. Potential causes include:

• Poor wiring connections on drive I/O terminals.
• Noise interference from adjacent equipment affecting drive signals.
• Parameter settings incorrectly programmed into the drive.

Tip: Check wiring, add line reactors or filters to mitigate noise, and verify parameter settings using manufacturer guidelines.

Unbalanced Voltages

One phase measuring significantly higher or lower than others often indicates:

• Loose connections in a multi-phase system.
• Overloaded neutral conductor.
• Blown fuse.

Tip: Check connections at panel and equipment for defects. Verify neutral is properly sized for load.

By understanding common obscure electrical gremlins like these examples, you gain familiarity with the distinct signatures of each issue to recognize during your troubleshooting.

When to Call for External Support

For the most complex obscure problems that persist even after methodical troubleshooting, it may be appropriate to call in specialized external resources like:

• Manufacturers of installed equipment, who can provide detailed diagnostic and repair expertise for their products.
• Engineering firms to conduct advanced testing like thermographic surveys to identify faults.
• Electrical inspectors to check for code compliance issues.

Don't hesitate to seek outside help when needed - just be sure to first follow a structured troubleshooting methodology yourself to provide the external experts with the best data to pinpoint the root cause efficiently.

Conclusion

Troubleshooting electrical issues in an industrial environment requires skill, experience and a systematic investigative approach. By understanding the equipment, dividing the system into testable sections, methodically gathering data and isolating the problem through process of elimination, even obscure intermittent faults can be uncovered. Ensuring safety, seeking outside expertise when needed and continuing to grow your diagnostic expertise will serve you well in tracking down the trickiest electrical gremlins.