Practical Troubleshooting of Electrical Equipment and Control Circuits


There is a chasm between the theory of electron flow, magnetic fields and troubleshooting electrical equipment and control circuits in the plant. This workshop shows delegates how to troubleshoot electrical equipment and control circuits.

The workshop helps individuals and employers. It does this by increasing all delegates knowledge and skills in improving equipment productivity whilst reducing maintenance costs.

Attendance on this workshop will help all delegates identify, prevent and fix common electrical equipment and control circuits. The focus is “outside the box”. The emphasis is on practical issues that go beyond typical electrical theory and focus on providing those that attend with the necessary tool-kit of skills in solving electrical problems, ranging from control circuits to motors and variable speed drives.'

This workshop focuses on the main issues of troubleshooting electrical equipment and control circuits of today to enable you to walk onto your plant or facility to troubleshoot and fix problems as quickly as possible

This is not an advanced workshop but one aimed at the fundamentals of troubleshooting systems. The workshop is very practical in its approach to troubleshooting and the examples you will be shown are applicable to any facility.


  • Receive a certificate of attendance in support of your continuing professional commitment
  • All workshops include the associated hardcopy technical manual
  • Printed workshop handouts
  • Lunch and refreshments
  • Interact and network with workshop attendees and experienced instructors
  • Practical, industry driven content to assist you in your continuing professional development (CPD)
  • Attendees automatically become IDC subscribers and receive exclusive deals and technical content every month


This workshop is designed for personnel who want to understand the design and engineering principles involved in process plant layout and piping design. Those who will benefit the most from this workshop include the following:

  • Consulting engineers
  • Electrical and electronics engineers
  • Electricians
  • Maintenance engineers
  • Plant maintenance personnel
  • Production managers
  • Project engineers


MODULE 1 - Types of problems

  • Introduction
  • Problems and their genesis
  • Problem categories

MODULE 2 - Troubleshooting fundamentals

  • Basics of troubleshooting
  • Drawings
  • Documentation and historical records
  • Skill sets for troubleshooting
  • Relationships between early resolution of problems and plant productivity

MODULE 3 - Use of appropriate instruments

  • Instruments for troubleshooting
  • Insulation tester (Megger)
  • Continuity testers
  • Voltage indicator
  • Multimeter
  • Clamp-on meters
  • Ohm-meter and ducter
  • Special instruments

MODULE 4 - Troubleshooting rotating electrical machines

  • Basic principles of electrical machines
  • Rotating machines - AC
  • Rotating machines - DC

MODULE 5 - Troubleshooting transformers

  • Basic principles
  • Transformer failures
  • Monitoring of transformer parameters and oil properties
  • Early warning of internal failures
  • Use of dissolved gas analysis for problem detection
  • Use of partial discharge detection/measurements
  • Use of furan analysis/degree of polymerisation tests for residual life prediction
  • Failures in auxillary systems and tap changers
  • Case studies of typical transformer failures, analysis and remedial measures

MODULE  6 - Troubleshooting cable problems

  • Construction of HV and LV cables (overview)
  • Joints and terminations
  • Types of cable failures and reasons
  • Detecting cable failures
  • Prevention of failures by proper jointing/termination quality and by periodic testing
  • Use of thermo-graph for hot spot detection
  • Case studies of typical failures and detection

MODULE 7 - Troubleshooting of switchgear and circuit breakers

  • Overview of HV, MV and LV switchgear
  • Basics of circuit breakers
  • Problems faced in power circuits of panels, remedies and prevention
  • Problems faced in circuit breakers
  • Problems caused by bad contacts
  • Internal short circuits due to rodents
  • Problems due to dust accumulation
  • Useful role of thermo-graphic examination in pre-empting problems
  • Case studies of failures/malfunctions and remedial measures

MODULE 8 - Problems caused by poor power quality

  • Overview of power quality
  • Effects of poor power quality on equipment
  • Voltage limits and equipment tolerance
  • Power factor and its effects
  • Problems due to frequency drifts
  • Voltage unbalance (negative sequence)
  • Harmonics (waveform distortion) and its effects on equipment

MODULE 9 - Problems associated with electrical control circuits

  • Devices and symbols
  • Language of control circuits
  • Reading and understanding electrical drawings
  • Reading and understanding ladder logic
  • Wire and terminal numbering
  • Motor control circuits
  • Motor control strategies
  • Problems due to incorrect wiring
  • Problems due to poor terminal connections and contacts
  • Problems in power and control (auxillary) contactors
  • Tracking problems using drawings and continuity/voltage tester
  • Precautions while performing insulation tests on control circuits

MODULE 10 - Troubleshooting PLCS

  • Principles of programmable control
  • Programming tools
  • Typical controls using PLC
  • Problems experienced in PLC controls
  • Use of status lamps in I/O cards to troubleshoot
  • Rectification approach
  • Internal failures and diagnostics

MODULE 11 - Troubleshooting power electronic equipment

  • Power electronic devices
  • Power electronic applications in industry
  • AC variable speed drive fundamentals
  • Controllers used for power electronic equipment
  • Device failures and checking of devices using simple instruments
  • Common problems faced in power electronic equipment, reasons and remedial measures
  • Examples/case studies

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