PART I Rotating Equipment - Booklet

Troubleshooting, Rotating & Stationary Equipment
Troubleshooting Methods
Techniques
PART I
Rotating Equipment
Booklet
Issued by: MSTC
PREPARED BY: Mohammed M. Hamdy
Mechanical consultant Engineer
Booklet Code. MH-MSTC-010

Page 1 of 36
INDEX
1 INTRODUCTION 3
1.1 General 3
1.2 Troubleshooting guidelines 3
1.3 Equipment troubleshooting 4
1.4 Different Causes of a Failure 5
1.4.1 Mechanical faults 5
1.4.2 Electrical faults 8
1.4.3 Electronic faults 10
2 EXAMPLES OF TROUBLESHOOTING 12
2.1 Centrifugal Pump Troubleshooting 12
2.2 Centrifugal Compressor Troubleshooting 19
2.3 Typical Blower Troubleshooting 22
2.3.1 Troubleshooting Check List 22
2.4 Air Cooler Troubleshooting 26
2.5 Electric Motors Troubleshooting 27
2.6 Gas Turbine Troubleshooting 31

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1. INTRODUCTION
1.1 General
Troubleshooting of any kind of defective functioning is a logical thought process.

The technician won’t do anything with all the fancy tools and test equipment in the
world unless he has thought through the nature of the problem, and determined
where the cause of the problem most likely is located. This document will provide
some general rules of troubleshooting and describe the troubleshooting of some
rotating equipment.
1.2 Troubleshooting guidelines
Because troubleshooting is a logical process, it makes sense to consistently follow

a set of guidelines to insure both safety and efficiency of the process.
Here's the set of guidelines to follow:
1. Safety first - know the hazards associated with the unit/equipment you are
troubleshooting. Take all safety precautions. Expect the unexpected.
2. Always think "what if?" This applies both to the analytic procedures as well
as to precautions with respect to type of fluid, pressures, temperatures existing
in the unit/equipment.
3. Learn from your mistakes. We all make mistakes. Some of them can be quite
costly. A simple problem can turn into an expensive one.
4. Don't start right in with the test equipment, start with some analytical
thinking. Many problems associated with equipment do not require a
schematic diagram (though one may be useful). Your built in senses and that
stuff between your ears represents the most important test equipment you have.
5. If you get stuck, sleep on it. Sometimes, just letting the problem bounce
around in your head will lead to a different, more successful approach or
solution. Don't work when you are really tired - it is both dangerous and mostly
non-productive (or possibly destructive).
6. Many problems have simple solutions. Don't immediately assume that your
problem is some combination of esoteric complex convoluted failures. Try to
remember that the problems with the most catastrophic impact on operation
usually have the simplest solutions. The kinds of problems we would like to
avoid at all costs are the ones that are intermittent or difficult to reproduce.
7. Whenever possible, try to substitute a working unit. This is usually safe to do

and will quickly identify which unit needs work. Note that there is the possibility
of damaging the known good part by putting it into a non-working device or vice
versa. With appropriate precautions the risk can be minimized.

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8. Don't blindly trust your instruments. If you get readings that don't make
sense, you may be using your equipment in a way that is confusing it.
9. Realize that coincidences do happen but are relatively rare. Usually, there
is a common cause. In other words, first look for a common root cause rather
than trying to locate bad parts.
10. Confirm the problem before diving into the repair. It is amazing how many
complaints turn out to be impossible to reproduce or are simple cockpit error. It
also makes sense to identify exactly what is and is not working so that you will
know whether some fault that just appeared was actually an existing problem
or one that was caused by your poking. Try to get as much information as
possible about the problem from the operating personnel. If you are the
operating personnel, try to reconstruct the exact sequence of events that led to
the failure.
11. Get used to the idea of working without service literature in some cases.
While a service manual may be available from the manufacturer of your
equipment, or an operating manual is available of the plant, they may not
include the information you really need. With a basic understanding of how the
equipment works, many problems can be dealt with without a schematic. Not
everyone, but quite a few.
12. Select a work area which is wide open, well lighted, and where dropped parts
can be located. The best location will also be relatively dust free and allow you
to suspend your troubleshooting to eat or think without having to pile everything
away for storage.
1.3 Equipment troubleshooting
Troubleshooting is a technique utilized in identifying the possible causes of plant or

equipment malfunctioning.
The equipment manufacturer’s manual generally includes a troubleshooting section,

where for each malfunction are listed the different possible causes and the
suggested remedies. This information is of great interest in approaching equipment
maintenance, because it can guide the maintenance operator to find the cause of
the malfunction and in applying the corrective remedies.
The equipment manufacturer troubleshooting table may also be useful in order to

establish the types of inspections and controls to be performed as preventive
maintenance.
The equipment manufacturers troubleshooting guide, is generally supplied in a table

format where in the first column is listed the different possible problems, in the
second column the probable causes and in the third column, the remedies.

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Such type of format is not a standard. Different types of formats are:
• Trouble – Action – Correction;
• Causes – Effects – Prevention/Remedies;
• Causes – Trouble Symptom.
In this document some examples of troubleshooting are included.
The troubleshooting tables shown in the following examples have been taken from
literature available on the subject for a specific equipment family and therefore are
quite general. For more specific troubleshooting tables you have to refer to the
specific vendors’ manuals.
1.4 Different Causes of a Failure
In this chapter, some examples of troubleshooting of instrumentation will be given to

make you understand that a failure can be due to different causes such as
mechanical faults, electric faults and electronic faults. During the troubleshooting
process all these possible causes should be considered.
In the following paragraphs 1.4.1÷1.4.3, control valves are taken as example but the
logic behind the troubleshooting process is the same for the rotating equipment that
can be present in an Oil and Gas Plant.
1.4.1 Mechanical faults
Generally speaking, all equipment can have faults due to the normal wear of
materials, improper use or particularly severe operating conditions for which the
equipment is used.
The wear is a normal and inevitable phenomenon that causes deformation in the
profile of the apparatus in respect to initial conditions, thus modifying the shape of
some parts so to make them incompatible for their scope.
Improper use and severe operating conditions are instead phenomena that can
generally be avoided by using the equipment in its working range, not tampering with
it and inserting suitable protections. Generally speaking, the first important thing to
do is to avoid situations that can bring faults; this can be done by using the
instrument in a proper manner: for example, every valve is built to work in a precise
range of pressures and temperatures, so it must not be exposed to conditions out of
specifications.

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Mechanical faults are generally due to all the above mentioned causes
and are presented under form of deformations and breakages of
moving and under load fixed parts; in those cases a repair or the
substitution of the faulted element are recommended.
A correct maintenance allows avoiding faults too; always checking equipment

conditions and adopting measures so to maintain it in the best conditions as
possible: in some apparatus the parts must be lubricated, other ones must be
replaced after a specific period and so on. In case of damage, usually the broken
item must be replaced; in few cases it can be repaired.
A further cause of faults is the presence of faulty items: these elements can break
in unforeseeable ways and must usually be replaced.
Here below we take in consideration the mechanical faults of various rotating

equipment.
Example: Control valves
Table 1.1 – Mechanical faults - Control valves
Fault Cause Remedy

The valve doesn’t The air supply is missing. Restore the air supply
open (Fail-close –
The diaphragm is broken Replace the diaphragm
pneumatic)
due to an air
overpressure
The stem is broken after Replace the stem
the plug was in closed
position (in rotary-type
valves and in some
linear-type ones)
The valve doesn’t The air supply is missing. Restore the air supply
close (Fail-open –
The diaphragm is broken Replace the diaphragm
pneumatic)
due to an air
overpressure.

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Fault Cause Remedy

The stem is broken after Replace the stem
the plug was in open
position (in rotary-type
valves and in some
linear-type ones)
The valve doesn’t The electrical power Restore the power supply
open/close (Fail supply is missing
close/open – electric)
The motor is broken due Replace the motor
to collisions or wear
The valve is blocked The stem is broken (in Replace the stem
in a random position rotary-type valves and in
some linear-type ones)
The valve doesn’t The springs of the fail- Replace the springs
return in its fail-safe safe mode are broken
position after having
close the air supply
The valve is closed The plug is broken due to Replace the plug
but the fluid wear or an overpressure
continues flowing
The seats are damaged Replace the seats
through it
Dirt or other foreign Clean plug and seats
particles lodged between
the valve seat and valve
plug
There is a leakage of The packing gland is Replace the packing
the fluid towards the damaged due to wear or gland
environment an overpressure

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1.4.2 Electrical faults
The majority of instruments in an oil and gas plant are electrically fed; this implies
that all these instruments can have faults of electrical type. Also signals flow through
electrical wires, so they can present this kind of fault.
• The main cause of electrical faults is the short circuit due to a lack in the
insulation: it allows the flowing of a too high current that can irreparably damage
the equipment.
• Also the accidental contact between two uncovered under voltage wires can
provoke the flowing of such high current, unless appropriate systems are installed
such as fuses and switches.
• An insufficient ventilation of power circuits can overheat all nearby components

of the instrument, producing deterioration in the insulation or deformations in
these components.
• Another cause of faults is the connection of the DC input in a wrong way

(inversion of the wires) or the feeding with a voltage higher than specified voltage.
• Moreover, lightning can strike power lines and destroy the instruments connected
to it.
• In the case of fuses, the interruption of the electric circuit by the fuse rupture, due
to an overcurrent, is its correct task. In this way it can prevent such current to flow
to the load it protects. When the fuse has blown it can only be replaced.
The maintenance of electrical parts allows avoiding a great part of faults.

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Table 1.2 – Electrical faults - Control valves
Fault Cause Remedy

There’s no power input Restore the power input
Signal wires are not
The positioner Connect signal wires
connected
doesn’t work
Signal wires are Rebuild electrical link or
interrupted replace signal wires
Connect signal wires
The solenoid valve connected
doesn’t work Signal wires are Rebuild electrical link or
interrupted replace signal wires
Connect signal wires
connected
The position
transducer doesn’t Signal wires are Rebuild electrical link or
give any signal interrupted replace signal wires
The transducer is broken Replace the transducer
There’s no power input Restore the power input
External wires are Rebuild electrical link or
The electric motor interrupted replace wires
doesn’t work Internal wires are If possible, rebuild
interrupted electrical link
Motor winding are broken Replace the motor

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1.4.3 Electronic faults
The majority of instruments and control devices in an oil and gas plant include simple
or complex electronic circuits; this implies that all these instruments and devices can
have faults of electronic type.
Typical causes of intermittent electronic equipment faults are: vibration, shock,

changes in temperature and electromagnetic interference.
One of the most common causes of electronic equipment failure, when the continued
existence of fault is confirmed, is electrical power disturbances. It is estimated that
95 percent of electronic equipment failure is caused by electrical surge damage that
has taken place over a period of time. Damage caused by electrical surges, also
known as transient voltage, renders electronic circuits of instruments and control
devices useless by burning sensitive circuits.
Some electronic equipment can be functionally tested, in accordance with the

maintenance manual, for troubleshooting of fault or malfunction. The fault is
progressively isolated to specific modules or components of equipment using
selected testing procedures.
When the cause of the fault is clearly identified, it is recorded in the maintenance
documentation. Where required, repair or replacement of the equipment is
determined.
Before replacing faulty electronic control equipment or component, make sure the
system is in a safe state and remove power source before proceeding.

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Table 1.3 – Electronic faults - Control valves
Fault Cause Remedy

The positioner (in
pneumatic actuated
Replace the electronic
valves) doesn’t work, There is a fault in the
module or the
even if there is power electronic module
complete positioner
input and signal wires
result properly connected
The position transducer
Replace the electronic
doesn’t work, even if
There is a fault in the module or the
there is power input and
electronic module complete position
signal wires result
transducer
properly connected
The actuator (in

electrically actuated
valves) doesn’t work, There is a fault in the Replace the electronic
even if there is power electronic module module of the actuator
input and signal wires
result properly connected
Examples of typical manufacturers troubleshooting tables for rotating equipment are

included in the following paragraphs.

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2. EXAMPLES OF TROUBLESHOOTING
2.1 Centrifugal Pump Troubleshooting
Centrifugal pumps are of different types (horizontal, vertical) and with different
accessories (mechanical seals, couplings, etc.). Maintenance requirements and
troubleshooting are strictly linked to the pump design and the manufacturer manual
is detailing:
• Causes
• Effects
• Remedies.
The following figure shows the sectional drawing of a horizontal type centrifugal
pump.
Figure 2.1 - Centrifugal Pump Horizontal Type
Item Description Item Description
1 Bearing frame 77 Lantern ring
4 Bearing cover frame 83 Stuffing box

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Item Description Item Description
5 Bearing cover frame 92 Bearing lock nut
9 Deflector 109 Bearing frame support
10 Bush ring 192 Oiler
23 Deflector 192A Oiler level
30 Venting plug 252 Packing ring
51 Pump casing R1 Ball bearing
55 Impeller R2 Ball bearing
58 Impeller lock nut R3 Ball bearing
59 Shaft Re2 Safety washer
60 Shaft sleeve T1 O ring
62 Gland T2 O ring
67 Casing wear ring J1 Spiralled wound gasket
68 Box wear ring J2 Gasket
70 Impeller wear ring J3 Gasket
71 Impeller wear ring J12 Gasket
In the following pages are reported two different troubleshooting tables for a
centrifugal pump. Pay attention to the information, some coincident and some other
different, contained therein and to the different forms they have.

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Table 2.1 – Centrifugal Pumps Troubleshooting - A
TROUBLE CAUSE REMEDY

Suction or speed too Open suction valve wide.
low. Check power supply for
correct voltage
Incorrect direction or Check driver instruction

rotation book
Excessive amount Check suction system for air

of air or vapours in leakage and correct. Vent
the liquid air, tighten flange bolts
Insufficient
Foreign material in Dismantle pump and remove
capacity and/or
impeller any foreign material
pressure
Foreign material in Dismantle suction line and

suction line remove foreign material
Mechanical causes: Dismantle pump and correct

Impeller damaged
by foreign material
Broken or damage
coupling
Insufficient liquid Ensure that section valve is

supply wide open.
Check for appropriate liquid
level.
Blocked section strainer.
Excessive amount Check suction system for air

Pump loses after of air or vapour in leakage and correct.
starting the liquid
Clogged impeller Dismantle pump and correct.
Suction pipe Remove foreign material

clogged

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Loose mounting or Tighten bolts.
coupling bolts.
Coupling. Check alignment and

correct.
Air or gas in the Vent air and check suction

liquid. for leaks. Tighten flange
bolts.
Pump vibration Incorrect installation. Base-plate not correctly

supported along rails.
Foreign material in Dismantle pump and remove

impeller causing any foreign material.
unbalance.
Mechanical causes: Dismantle pump and replace

Shaft bent. part or parts causing
vibration.
False overload Check starter controls.

signal.
Wire/connections Check for hot spot in lines.

faulty.
Speed too high. Check driver instruction

Pump overloads section.
driver
Specific gravity too Check rated conditions.
high.
Pump bearings Dismantle pump and realign

seized or rotating rotor in casing.
element binding.
Pump binding at Dismantle pump and realign

Pump stops
running fits. rotor in casing.
abruptly.
Incorrect lubrication, Replenish oil with correct
including inadequate grade lubricant and assure
cooling. cooling capacity.
High pump thrust
bearing Insufficient oil. Add oil.
temperature rise.
Contaminated oil. Drain and refill with clean oil,
change filter.

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Excessive seal Dirt across seal Replace seal.
leakage. faces.
Cavitation Check that pump is primed.
Check for high suction
temperature, increase static
head. Check for obstruction
in suction line.
Pump is noisy.
Loose parts. Tighten or replace defective
Noise in driver. parts
Check driver with
stethoscope.
Table 2.2 – Centrifugal Pumps Troubleshooting - B
OPERATING POSSIBLE
CORRECTIVE ACTIONS
TROUBLES CAUSES
Suction line not full. Check suction line up.
Check the pump is not

Pump loses Vapour in the liquid. overheating. Stop the pump,
suction. reprime and restart.
Suction strainer Stop the pump, clean strainer,

plugged. prime and restart.
Check product feed system.

Insufficient feed. Stop the pump, prime and
restart.
Cavitation
(fluctuating Product too hot
Inform foreman. Check suction
discharge (causing
line up.
pressure). vaporization).
Suction strainer Stop the pump, check suction

plugged. strainer and prime again.
Overheating of Insufficient cooling. Check cooling system.

bearings. Backflush lines.

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OPERATING POSSIBLE
CORRECTIVE ACTIONS
TROUBLES CAUSES
Low lubricating oil Refill and check for leaks.

level
Contaminated oil. Stop the pump and contact

Wrong grade of oil. foreman / maintenance.
Overfilling of bearing Inform foreman.

housing.
Pump misaligned. Inform foreman and stop the

pump.
Cavitation. Refer to cavitation corrective

action.
Misalignment. Inform foreman and stop the

Excessive
(Bent/unbalanced pump.
vibration and
shaft, worn
unusual noise.
bearings, damaged
impeller or foreign
bodies in pump
casing).
Leaking Worn seal. Inform foreman and stop the

mechanical seal. pump.
Loss of power Inform foreman

(electric driver).
Pump stops
Loss of steam to Inform foreman.
(trips).
turbine.
Mechanical failure. Inform foreman.
Wrong rotation. Inform foreman.

Pump discharge
pressure low. Suction valve Stop pump, open suction
closed. valve, prime and restart.

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OPERATING POSSIBLE
CORRECTIVE ACTIONS
TROUBLES CAUSES
Suction strainer Stop pump, clean strainer,

plugged prime and restart.
If electric driver: no Inform foreman.

power.
If steam turbine *) Open block valve slowly.

driver:
**) Close inlet/outlet block
valves, clean strainer and
Pump will not
*) Steam supply restart.
rotate.
block valve close.
**) Strainer on
steam supply line
plugged.
Pump seized. Inform foreman.
Low discharge The standby pump should

Pump automatic pressure. start.
switch system
operates (if Check the other pump to find
fitted). out why it had low discharge
pressure.

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2.2 Centrifugal Compressor Troubleshooting
A centrifugal compressor is a dynamic compressor and thus depends on motion to

transfer energy from the compressor rotor to the process gas. Compression of the
gas is implemented by means of blades on a rotating impeller. The resulting rotary
motion of the gas results in an outward velocity due to centrifugal forces. The
tangential component of this outward velocity is then transformed to pressure by
means of the diffuser.
In the following table is reported an example of troubleshooting for a typical

centrifugal compressor.
Table 2.3 – Troubleshooting of centrifugal compressors
Trouble Possible cause Remedy
Carry out a vibration

frequency analysis.
Misalignment To check alignment,

refer to proper section
of the instruction
manual.
Check condition of
Coupling failure
coupling.
Check to see if
Vibrations or Compressor rotor particle adherence is
abnormal unbalance the cause, and if
necessary, rebalance.
compressor
noise
Gas pipes should be
properly anchored
Stresses transmitted by down to prevent
gas pipe to casing excessive stresses on
resulting in compressor casing
misalignment and possess sufficient
elasticity to allow for
heat expansion.
Disassemble coupling
Unbalanced coupling and check for
unbalance.

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See that compressor

operating conditions
Surge
are kept far from
surge point.
Isolate their
Machines working in
foundations and
the vicinity of
increase elasticity of
compressor
any connecting pipes.
Make sure
recommended oil is
used.
Improper lubrication
Periodically check that
no water or dirt has
contaminated the oil.
Journal
bearing
Check alignment and,
failure Misalignment
if necessary, correct.
Bearing clearance Check clearance and,

incorrect if necessary, replace.
Compressor or Refer to section

coupling unbalance "Vibrations".
Make sure coupling is

clean and assembled
so that excessive
Excessive axial thrust thrust is not
transmitted from the
coupled driver to the
Thrust
bearing compressor.
failure
Refer to section
Improper lubrication "Journal Bearing
Failure".
Refer to sections
Vibrations
"Vibrations"

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Check filter condition

and replace dirty
Dirty gas cartridges.
Check piping
cleanliness.
Check gas piping and

Presence of liquid in
piping/compressor
the gas system
drains.
Check that differential

Insufficient buffer gas
pressure does not
pressure
drop below minimum.
Check that pressure

Insufficient flushing gas
does not drop below
pressure
minimum.
Check the drains of

Presence of oil in the chambers between
seals external rings of gas
seals and bearings.
Check values in
differential pressure
Insufficient differential gauges and adjust
pressure at primary orifices to obtain 0.2
vents to 0.3 Bar g (20 to 30
Mechanical kPa g) at primary
gas seal vents.
failure
Check shaft rotation
manually.
Assembling
Check static
pressurization of
compressor.
Counter-rotation (for Check possible

seals with unidirectional abnormal operating
operation) conditions.

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2.3 Typical Blower Troubleshooting
The following figure shows a schematic of a typical Blower.
Figure 2.2 - Blower
2.3.1 Troubleshooting Check List

Here below is reported a list of possible problems and the related “checks for” for a
typical blower.
Problem: Vibration
Check for:
1. Loose bolts in bearings and pedestals, or improper mounting.
2. Defective bearings.
3. Improper alignment of bearings and coupling.

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4. Out of balance fan wheel
5. Loose setscrews holding wheel to shaft.
6. Weld cracking.
7. Improper fan wheel clearance to inlet piece(s).
8. Material build-up and/or wear on wheel.
9. Insure expansion joints in ductwork are not fully compressed.
10. Improper wheel rotation.
11. Operation near system critical speed.
12. Shaft bent or distorted during high-temperature shutdown.
13. Defective motor
14. Resonant frequencies of structural steel mounting.
15. Beat frequency with other fans on common base
16. Loose hub to shaft fit.
Problem: Duct pulsation
This often occurs when a centrifugal fan is operated on a system with high
resistance.
The fan is forced to operate far below the normal or design volume.
If the operating volume is lower than the value corresponding to the fan’s peak static
pressure, instability (surge) can occur.
Possible solutions include:
1. Increase operating volume (reduce system resistance).
2. Control volume with a radial inlet damper.
3. Add a “blow-down” valve on fan discharge to allow discharge of part of the gas
stream to atmosphere.
4. Re-circulate a portion of the gas stream back to the fan inlet.

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Problem: High motor temperature
Check for:
1. Improper ventilation of cooling air to motor (may be blocked by dirt).
2. Input power problems, (especially low voltage).
3. High amperage.
4. High ambient temperature.
5. Motor cooling fan is incorrect rotation for full cooling.
Problem: Noise
Check for:
1. Defective bearings or bearing seal rubbing.
2. Misaligned bearing seal.
3. Misaligned housing shaft seal.
4. Foreign material in fan housing.
5. Scouring of shaft seal, wheel to inlet piece, housing.
6. Heat flinger is contacting guard.
7. Coupling failure.
8. Untreated expansion joints.
9. Ductwork is thinner than housing.
Problem: Poor performance
Check for:
1. Incorrect fan rotation.
2. Wheel is off-center; poor Inlet piece fit-up allows recirculation of air.
3. Fan drive sheaves selected for too low or too high RPM.
4. Poor duct design. Installation of elbow splitters or turning vanes could remedy
problem.
5. Pre-spin condition at fan outlet, add splitter plate to inlet box.

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6. Inlet damper installed backwards (counter-rotation).
7. System resistance is excessive compared to design requirements, (partially

closed damper may be the cause).
8. Fan speed too low/high.
9. Density may be different than design density.
Problem: High bearing temperature
Check for:
1. Defective bearings.
2. Over lubrication.
3. Improper lubrication or contaminated lubricant.
4. Lack of lubrication, cooling fluid, or circulation.
5. High ambient temperatures or direct exposure to sunlight.
6. Improper location not enough room for free axial movement of floating bearing
in its housing at elevated temperatures.
Problem: Excessive starting time
Check for:
1. Motor improperly sized for fan wheel.
2. Properly selected time-delay starter/fusing required, (many industrial fans take

up to 20-25 seconds to reach operating speed).
3. Temperature at Inlet is excessively low (high density).
4. Low voltage at motor terminals.
5. Inadequate system resistance.

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2.4 Air Cooler Troubleshooting
Air coolers find wide application in a large variety of applications inside an Oil and
Gas Plant. A typical troubleshooting table for an air cooler is reported here below.
Table 2.4 – Air Coolers Troubleshooting (Typical)
OPERATING
POSSIBLE CAUSES CORRECTIVE ACTIONS
TROUBLES
Insufficient Fan(s) tripped Report to electrical
cooling department. Restart
Loose drive belts Shut-down, adjust belts.
Cooler fins plugged, Clean by air blowing or
dirty condensate washing.
Insufficient fan blade Adjust pitch
pitch
High approach Reduce approach
temperature. temperature.
Louvers incorrectly set. Adjust louvers.
Bent tubes Insufficient cooling Adjust approach
capacity temperature.
Adjust fan blade pitch.
Abnormal noise Broken fan blade. Shut-down and repair.
or vibration Fan blade fouling the Shut-down and adjust.
stationary part.
Drive belts slipping or Shut-down and tighten or
broken. renew belts
Driver mechanical Report to maintenance
problems. department

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2.5 Electric Motors Troubleshooting
The following figure shows a typical structure of a three-phase asynchronous

electric motor.
Figure 2.3 - Asynchronous Motor
An example of a typical electric motor troubleshooting is shown in the table here

below.

Page 27 of 36
Table 2.5 – Electric Motor Troubleshooting
Misalignment with the Verify and provide to align

coupled machine. the machine
Unbalanced or settled Verify and provide as

Motor vibrations foundation, loose hold- required.
down bolts, uneven air
gap alignment.
Worn bearings. Replace the bearings.
Two phases or the Verify and restore the

Motor at no-load power supply line interrupted phases.
does not start up interrupted.
(without noise) Power supply line Verify and provide to cut-on
without voltage power supply line.
One phase interrupted. Verify and restore the

Motor at no-load
The motor can turn in interrupted phase.
does not start up
no-load in both
(with magnetic
directions, in single
noise)
phase.
Supply line voltage too Check that the supply voltage

low. is in compliance with the
tolerance values indicated in
Motor under load the motor plate.
does not start up
(normal magnetic Resistant torque too Disconnect the motor from
noise). high, as consequence the driven machine, check
of locking of the and remove the lock.
coupled machine or of
the rotor.
Motor starts at A phase down after Verify and restore the

no-load, but it start up. interrupted phase.
produces low
One or more rotor bars Verify, repair or replace the
torque when
are broken. rotor.
under load

Page 28 of 36
The welding between Restore welding or replace

cage bars and cage the rotor
rings are interrupted
(an amperometer,
inserted on the stator
supply line, swings
periodically).
Wrong connections Verify the correspondence

between stator winding with the connection data
and supply line (i.e. detailed on the data plate and
delta instead of star on the cover of main terminal
connection). box and carry out the correct
connection.
Motor, at no-load,
heats Supply line voltage too Verify that supply line voltage
much high. is in compliance with the
tolerance values listed in the
motor plate.
Improper or restricted Check air passages grids for

ventilation, obstructed obstruction. Remove
air passages. obstructions.
Motor under load Motor is overloaded Verify that operating

heats too much. conditions of the coupled
machine are in compliance
with the specifications.
Motor runs only in Check the supply and provide

single phase (supply to restore the interrupted
line interrupted). phases.
Supply line voltage to Verify that supply line values

high or low. are in compliance with
specifications of the motor
plate.
Local heat on the Short circuit in the Verify and replace the stator.
motor with: noise, stator winding.
smoke, sparks, or
flames. The rotor rubs on the Check the air gap and
stator during running, eventually replace the
causing sparks in the bearings.
air gap.

Page 29 of 36
Rotor cage bars Verify, repair or replace the

broken. rotor.
Motor with Worn damaged Replace the bearings

abnormal noise bearings
Incorrect coupling Check the coupling of the

driven machine and provide
as consequence.
Abnormal bearing Axial thrust much too Verify operations of the

temperature high driven machine and provide
as consequence.
External shocks Verify and eliminate the

external cause
Poor bearing lubrication Verify lubricating oil circuit (if

or damaged bearing present), lubricate or replace
the bearing.
Incorrect lubricating oil Verify that lubricating oil

viscosity (in sleeve characteristics are according
bearings). with the ones shown on the
plates. Change the oil if
required.
Generation of shaft Measure the bearing

currents (in the sleeve insulation resistance and
bearings). correct if required.
Periodical swing Rotor cage interrupted Verify, repair or replace the

of the ammeter in one or more places. rotor.
pointer, inserted
on the feeding
line (i.e. until 6
times per
second).

Page 30 of 36
2.6 Gas Turbine Troubleshooting
A gas turbine, also called a combustion turbine, is a type of internal combustion

engine. It has an upstream rotating compressor coupled to a downstream turbine,
and a combustion chamber in-between.
Figure 2.4 shows the key engine parameters and their symbols used in controlling,
monitoring and analyzing gas turbine operation. For the meaning of the symbols,
Figure 2.5 can be useful.
Figure 2.4 – Key engine parameters.

Page 31 of 36
Figure 2.5 – Inspection detail of a Gas Turbine.
The following is an example of troubleshooting of a small Gas Turbine.
Prop Overspeed:
• Defective prop governor - check setting. Replace unit if not adjustable.
• Defective pneumatic section of prop or fuel topping governors - replace units.
• Defective overspeed governor - replace unit.
• Defective RPM indicator - replace unit.
Compressor Overspeed (N1):
• Sheared FCU (Fuel Control Unit) drive coupling - replace FCU and coupling.
• Defective FCU bypass diaphragm - replace FCU.
• FCU bypass valve stuck closed - replace unit.

Page 32 of 36
Vibration:
• Prop out of balance - check prop for damage and balance. If unable to balance
out vibration, check blade angle and twist.
• Compressor out of balance - cause steady hum. Check bleed valve for being
stuck shut.
• Compressor out of balance - cause intermittent hoot. This condition is okay if hoot
goes away by 60% N1 RPM. Check turbine balance.
• Power turbine out of balance - check turbine for balance and failure.
High N1 RPM:
• Check indicating system - replace indicator as necessary.
• Compressor dirty - perform compressor wash.
• Compressor bleed valve(s) open. Have bleed valve(s) bench checked.
Flameout:
• Fuel pump drive failure - preceded by slight increase in N1 RPM.
• Air in fuel system - Bleed fuel system. Check reason for air entering fuel system.
Has a part of the system been apart?
• Minimum fuel stop setting too low - flameout during deceleration. Perform normal
start and check N1 RPM.
• Contaminated FCU - check all fuel filters. Clean fuel system and replace filters
as necessary.
Overtemp (Above Maximum):
• Instruments out of calibration - have all instruments calibrated.
• Faulty T5 system - check T5 system per the maintenance manual.
• Torque indication low - have instrument calibrated.

Page 33 of 36
Temperature Limited:
• Instruments out of calibration - have all instruments calibrated.
• Dirty compressor - perform compressor wash. Open inlet screen and check
compressor.
• Excessive accessory load - place generator off line. Check accessories for extra
loading.
• Hot section distress - N1 speed down, T5 up.
Low Oil Pressure:
• Low oil level - check the tank oil level. Check oil consumption.
• Defective oil pressure indication - check with direct reading gauge.
• Pressure relief valve malfunctioning - probably stuck open. Replace unit.
• Failed heat shield in power section - causes excessive heating of oil. Oil cooler
may not be able to handle the added temperature.
• No oil pressure. Can happen after normal filter check. Oil filter is installed
backwards.
High Oil Pressure:
• Defective oil pressure indication - check with direct pressure gauge.
• Pressure relief valve malfunctioning - stuck closed. Oil pressure will follow N1
RPM.
High Oil Temperature:
• Insufficient supply - check tank level. Replenish supply, check consumption.
• Defective cooling system - check oil cooler thermostat.
• Failed heat shield in power section - causes excessive heating of oil. Remove
and repair power section.

Page 34 of 36
Excessive Oil Consumption:
• Extended leakage - repair oil leak.
• Restriction in scavenge tubes. Unable to scavenge oil - will cause bearing area
flooding.
• Defective packing on oil filter housing - check packings.
• Clogged scavenge screen in rear case - check main oil filter for carbon. If
excessive carbon is found, pull engine to clean scavenge screen.
• Oil from breather excessive - cocked or defective carbon seal.
• Defective filter check valve - will allow oil to migrate to pressure system
overflowing bearing areas.
• Seal on pressure pump backwards - will cause excessive oil in scavenge system
overloading oil separator.
• System over serviced - keep level at one quart to maximum level. Check oil
immediately after shutdown.
High Breather Discharge:
• Overfilled system
• Breather carbon seal defective
• Excessive backpressure in scavenge system - check scavenge tubes, oil lines

and oil cooler for restriction.
Oil Leaking from Compressor Inlet:
• Defective packings oil tank tubes - replace.
• Defective packings on oil filter housing - replace packings.

Page 35 of 36
Prop Overspeed (N2)
• Defective prop governor - check setting. Replace unit if not adjustable.
• Defective pneumatic section of prop or fuel topping governors - replace units.
• Defective overspeed governor - replace unit.
• Binding or disconnected rigging - repair or replace as necessary.
• Defective RPM indicator - replace unit.

Page 36 of 36

PART I Rotating Equipment - Booklet

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PART I Rotating Equipment - Booklet

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Troubleshooting, Rotating & Stationary Equipment

Issued by: MSTC

PREPARED BY: Mohammed M. Hamdy

Mechanical consultant Engineer

Booklet Code. MH-MSTC-010

Booklet Code. MH-MSTC-010

Troubleshooting of any kind of defective functioning is a logical thought process.

1.2 Troubleshooting guidelines

Because troubleshooting is a logical process, it makes sense to consistently follow

Here's the set of guidelines to follow:

7. Whenever possible, try to substitute a working unit. This is usually safe to do

Booklet Code. MH-MSTC-010

1.3 Equipment troubleshooting

Troubleshooting is a technique utilized in identifying the possible causes of plant or

The equipment manufacturer’s manual generally includes a troubleshooting section,

The equipment manufacturer troubleshooting table may also be useful in order to

The equipment manufacturers troubleshooting guide, is generally supplied in a table

Booklet Code. MH-MSTC-010

Such type of format is not a standard. Different types of formats are:

• Trouble – Action – Correction;

• Causes – Effects – Prevention/Remedies;

• Causes – Trouble Symptom.

In this document some examples of troubleshooting are included.

1.4 Different Causes of a Failure

In this chapter, some examples of troubleshooting of instrumentation will be given to

1.4.1 Mechanical faults

Booklet Code. MH-MSTC-010

A correct maintenance allows avoiding faults too; always checking equipment

Here below we take in consideration the mechanical faults of various rotating

Example: Control valves

Table 1.1 – Mechanical faults - Control valves

Fault Cause Remedy

Booklet Code. MH-MSTC-010

Fault Cause Remedy

Booklet Code. MH-MSTC-010

1.4.2 Electrical faults

• An insufficient ventilation of power circuits can overheat all nearby components

• Another cause of faults is the connection of the DC input in a wrong way

The maintenance of electrical parts allows avoiding a great part of faults.

Booklet Code. MH-MSTC-010

Example: Control valves

Table 1.2 – Electrical faults - Control valves

Fault Cause Remedy

Booklet Code. MH-MSTC-010

1.4.3 Electronic faults

Typical causes of intermittent electronic equipment faults are: vibration, shock,

Some electronic equipment can be functionally tested, in accordance with the

Booklet Code. MH-MSTC-010

Example: Control valves

Table 1.3 – Electronic faults - Control valves

Fault Cause Remedy

The actuator (in

Examples of typical manufacturers troubleshooting tables for rotating equipment are

Booklet Code. MH-MSTC-010

2.1 Centrifugal Pump Troubleshooting

Figure 2.1 - Centrifugal Pump Horizontal Type

Item Description Item Description

1 Bearing frame 77 Lantern ring

4 Bearing cover frame 83 Stuffing box

Booklet Code. MH-MSTC-010