The ability to troubleshoot your own electrical systems can be a real help when there’s a simple fix to the problem. However, industrial electrical troubleshooting can be a complex process that requires extensive knowledge, safety precautions, and specialized equipment. While it’s strongly recommended to trust a professional for this job, in this guide, we’ll cover the most essential things you need to know:
- Common electrical issues in industrial environments
- Necessary tools for electrical troubleshooting
- Safety considerations
- Step-by-step troubleshooting process
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Common Electrical Issues in Industrial Environments
With so many electrical systems and equipment in industrial environments, it’s not a matter of if something goes wrong, it’s a matter of when. All sorts of common electrical issues can arise, including:
- Equipment malfunctions. Sometimes, faulty electrical work leads to equipment malfunctions. Things such as loose wiring or damage from a power surge can quickly start causing issues for your equipment.
- Circuit and wiring problems. An industrial building, especially one that is older, may have outdated or faulty wiring or even circuit breakers that need to be replaced.
- Control system failures. A building’s electrical control system regulates electric currents throughout the facility, so it’s important to keep that system from failing. A simple blown fuse or loose wire can cause this, but more serious issues, like damage from a power surge, can also be the cause.
Necessary Tools for Electrical Troubleshooting
Troubleshooting electrical systems and performing other commercial electrical services requires specialized tools, both to accurately identify potential problems and to keep everyone safe. For this reason, this job is best done by a trained electrician who uses these common tools during the troubleshooting process:
- Multimeters. These tools check the voltage, current, and resistance going through a circuit, enabling technicians to identify live wires.
- Clamp meters. A clamp meter measures the current within a wire. By identifying currents at different points in a circuit, a technician may identify faulty circuits.
- Insulation testers. An insulation tester detects weak points in insulation to identify potential breakdowns in a high-voltage system. It sends a high-voltage signal into the object being tested to measure resistance values.
- Circuit tracers. This tool locates wires and identifies circuits and breakers within walls. It transmits a signal in a wire, which allows it to trace the wire’s path and troubleshoot potential issues.
- Thermal cameras. A thermal camera creates a thermogram, an image that uses color to indicate the heat of what is being pictured.
- Oscilloscope. An oscilloscope displays electrical signals in graph form, which indicates how they change over time.
Safety Considerations
Working with live electrical currents is extremely dangerous and should only be attempted by trained electricians. Additionally, OSHA has strict safety requirements regarding employees who come into contact with electrical systems.
When working on energized equipment, PPE, insulated tools, and other shielding materials are absolutely necessary. The exact equipment needed varies depending on the scenario.
Furthermore, if someone is repairing or performing maintenance on machinery, lockout/tagout practices protect them from unexpected start-ups. This procedure prevents the machinery from being activated as long as it’s being worked on. All lockout/tagout devices must be authorized for the particular machinery being repaired.
Step-by-Step Troubleshooting Process
Several steps comprise the troubleshooting process:
- Perform an initial visual inspection and assessment to identify obvious signs of issues.
- Test the suspected problem areas for more specific details to create a proper diagnosis. This process typically involves isolating each component to determine exactly where the machinery or electrical work is failing. Technicians may repeat this process through several components to ensure there aren’t any other problems.
- Once the problem area is identified, repairs can take place. This may involve replacing a part outright or repairing the faulty part.
- After implementing the fix, it’s time to test that the repair worked. This involves repeating the process from step 1 to ensure the machine now works as intended.
Whenever significant electrical problems are present in an industrial setting, it’s imperative to rely on a trained, licensed electrician. They have experience troubleshooting and repairing electrical equipment safely and efficiently and have access to extensive equipment to help streamline the process.
Schedule your next commercial electrical service with Elliot Services!
If you suspect electrical issues, reach out to Elliot Services today and we’ll take care of that electrical troubleshooting. Our full-service, licensed, and insured contractors are ready to get the job done to your exact needs.
