My new book - any thoughts?
My new book - any thoughts?
(OP)
This is a very general electronic, electricity and automation question.
I have in my fourty+ years as a commissioning engineer, trouble-shooter and designer with ABB, Siemens and own company found that there are a few very common mistakes that account for a vast majority of all problems in automation and drive systems.
I am going to sit down in southern France (Camargue) for a couple of months and compile 30 - 40 dominant causes for unexpected problems and badly functioning systems. It will be about inrush currents that takes out fuses/breakers and cause short contact life, unnecessary high band-width that makes systems unreliable, cooling and why it - contrary to popular belief - is good to have. There will be eternal but forgotten truths about many other things like bearing currents (that will be a long chapter), DC motor operation and thyristor drives and I will mostly use stuff that I have collected during field work. Each subject will get a two - seven pages (A4 - a little less than legal - format) treatment with four or five pages being typical.
I am, however, sure I will miss out a few important topics, I have, after all, not seen all problems (I think).
So, if you have any unusual, interesting or plain stupid things that you think should be included in the book, please add a few sentences here. Or e-mail me. Also, if anyone in southern France would like to have a Pastis with me, just say so. I could use some divertissement... (I do speak French, so language is not a problem. Especially not after a few 51
).
I have in my fourty+ years as a commissioning engineer, trouble-shooter and designer with ABB, Siemens and own company found that there are a few very common mistakes that account for a vast majority of all problems in automation and drive systems.
I am going to sit down in southern France (Camargue) for a couple of months and compile 30 - 40 dominant causes for unexpected problems and badly functioning systems. It will be about inrush currents that takes out fuses/breakers and cause short contact life, unnecessary high band-width that makes systems unreliable, cooling and why it - contrary to popular belief - is good to have. There will be eternal but forgotten truths about many other things like bearing currents (that will be a long chapter), DC motor operation and thyristor drives and I will mostly use stuff that I have collected during field work. Each subject will get a two - seven pages (A4 - a little less than legal - format) treatment with four or five pages being typical.
I am, however, sure I will miss out a few important topics, I have, after all, not seen all problems (I think).
So, if you have any unusual, interesting or plain stupid things that you think should be included in the book, please add a few sentences here. Or e-mail me. Also, if anyone in southern France would like to have a Pastis with me, just say so. I could use some divertissement... (I do speak French, so language is not a problem. Especially not after a few 51
Gunnar Englund
www.gke.org
--------------------------------------
Half full - Half empty? I don't mind. It's what in it that counts.





RE: My new book - any thoughts?
I'll place my order for a signed copy now. Assuming it's not overly expensive.
RE: My new book - any thoughts?
David Simpson, PE
MuleShoe Engineering
"Belief" is the acceptance of an hypotheses in the absence of data.
"Prejudice" is having an opinion not supported by the preponderance of the data.
"Knowledge" is only found through the accumulation and analysis of data.
The plural of anecdote is not "data"
RE: My new book - any thoughts?
Mike McCann
MMC Engineering
RE: My new book - any thoughts?
Mike Halloran
Pembroke Pines, FL, USA
RE: My new book - any thoughts?
I may use that as an introductory remark - it says a lot. And sets the level...
Gunnar Englund
www.gke.org
--------------------------------------
Half full - Half empty? I don't mind. It's what in it that counts.
RE: My new book - any thoughts?
RE: My new book - any thoughts?
RE: My new book - any thoughts?
Gunnar Englund
www.gke.org
--------------------------------------
Half full - Half empty? I don't mind. It's what in it that counts.
RE: My new book - any thoughts?
RE: My new book - any thoughts?
RE: My new book - any thoughts?
Mark me down for a copy!
I think the world is full of "introductory" and "how-to" books, especially in this age of the internet which is miles wide and inches deep.
What we all lack is the benefit of experience and the stories that make us understand WHY.
Just a few of the strange problems I've encountered:
High-resistance terminal connections,
Sneak circuits keeping a circuit on when the switch is off,
Lack of strain relief,
Snow/ice bridging terminals,
Slow RC time constants,
The difference between the junction temperature on a semiconductor's datasheet and the real ambient temperature.
I've been the culprit often enough to stay humble and double-check before hitting the ON switch.
If there's anything you can write that fosters the reader's ability to TROUBLESHOOT anything it could tip the book from being a memoir to required reading in colleges.
Bonne chance
STF
RE: My new book - any thoughts?
I never thought of including the junction temperature and thermal resistance, although I certainly have had that also. Just didn't remember. That's the kind of input I am looking for.
Gunnar Englund
www.gke.org
--------------------------------------
Half full - Half empty? I don't mind. It's what in it that counts.
RE: My new book - any thoughts?
Dan - Owner
http://www.Hi-TecDesigns.com
RE: My new book - any thoughts?
RE: My new book - any thoughts?
Mike Halloran
Pembroke Pines, FL, USA
RE: My new book - any thoughts?
Gunnar Englund
www.gke.org
--------------------------------------
Half full - Half empty? I don't mind. It's what in it that counts.
RE: My new book - any thoughts?
I am constantly amazed by the number of sites and installations that are in need of cleaning, adjusting and testing that doesn't get done because "it can't be taken off line".
On automation, PLC's specifically, maybe why good documentation in the project is important. I get into a lot of programs that the original programmer probably had a very good idea what he was trying to do his head, but after several years and he is no longer available what would be good to leave behind to help the guy that is trying to help his customer and keep the system going? I'm not sure why but it seems to be worse lately.
Good Luck on your book, real world experience compiled into something others can use and learn from sounds like a neat project.
Thanks, Mike L.
RE: My new book - any thoughts?
Dominant causes for badly functioning systems? Not getting somebody to do an independent check of all your switch positions before deciding your equipment is broken - especially when picking and choosing sections from a longer set-to-work procedure. Catching this one by telephone today just saved us a 16,000 mile wasted round trip (I hope).
A.
RE: My new book - any thoughts?
If I may share a bad experience that I once had about connecting 2 DC motors (900 hp each). Since the connection box was not so big, all power cables where pushed very close to eachother inside the connection box. To prevent friction damage between two cables or bewteen cables and ground, my boss (senior electrician) recommended to add some thick rubber pads between cables and between cables and ground.
One day, both motors had been revised by an external company and when we reconnected the motors, as usual we used thick rubber sheets to avoid ground contacts or short circuits.
As a final check we tested the insulation resistance and found that the value was somewhere arround 0,1 Megohm of both motors. When disconnecting the cables again, now the resistance of both motors and cables where ok. So reconnected both motors and again bad insulation resistance.
It turned out that the rubber pads where not the same as usual, although they seemed identical. The rubber sheets that where used contained graphite and were in fact excellent electrical conductors.
Since then I no longer thrust any kind of rubber as insulator
Kind regards,
WTRVS
RE: My new book - any thoughts?
Also, some recommended troubleshooting techniques and methods - no one learns this in school.
RE: My new book - any thoughts?
I thought that was a wonderful trick...
Best to you,
Goober Dave
Haven't see the forum policies? Do so now: Forum Policies
RE: My new book - any thoughts?
I have thought about some type of structured "tree" to help in systematic trouble-shooting. And there are inputs that help me doing that.
And, I think that I shall include little factoids/ancedotes like Dave's falling buckets. That will make for lighter and more interesting reading. More such stuff!
Gunnar Englund
www.gke.org
--------------------------------------
Half full - Half empty? I don't mind. It's what in it that counts.
RE: My new book - any thoughts?
RE: My new book - any thoughts?
Some stats:
Mass; about 7000 tons
Power: 12,000 HP. 4 MG sets. Each set comprised of a 3000 HP motor driving three 1050 HP DC generators and two 1300 HP generators. Weight of each MG set, about 80 tons.
Working radius: 360 feet.
Height of boom above grade: 214 feet.
Length of boom 400 feet.
Drag bucket: about 75 or 80 cubic yards.
Power supply: 12,000 Volt trailing cable.
Watching the meters when this was working, the draw would be about 7 MW when the bucket was being lifted. Dropping the empty bucket would regenerate about 2 MW.
We had ample power to start the machine. We had an adviser from Bucyrus-Erie on-site. While sharing a coffee break, he told us of the technique that was used in strip mines with a soft power supply of using the regenerated power from the dropping buckets of several machines to ease the starting surge of an incoming machine.
This machine is now out of service and on display beside highway 63 near The Syncrude base plant.
http://far
http://me
Bill
--------------------
"Why not the best?"
Jimmy Carter
RE: My new book - any thoughts?
That is a wonderful story! The 'puter paralyzed need to hear such things! I guess there is even som math they can do on this. The pictures, the way out and the math. That is something the youngsters will love.
Gunnar Englund
www.gke.org
--------------------------------------
Half full - Half empty? I don't mind. It's what in it that counts.
RE: My new book - any thoughts?
The operating cycle was such that the generators were never simultaneously loaded to their maximum capacity.
The generators had Babbitt bearings lubricated with oil rings. There was no turning gear. Once running these machines typically run 24/7 indefinitely. During test and commissioning, each night, we had to manually "roll" each set until the oil rings had brought enough oil up so that the set turned freely. We started them with two men on a seven foot hook wrench on a coupling and two more to reposition the wrench each time it was lifted for another bite. We usually had four to six men working together to roll each of the four sets. When four men could keep the set turning easily by pushing on the ends of the armature windings we were ready to go DOL and then move on to the next set.
Bill
--------------------
"Why not the best?"
Jimmy Carter
RE: My new book - any thoughts?
RE: My new book - any thoughts?
http://www.google.se/url?sa=t&rct=j&q=&...
Gunnar Englund
www.gke.org
--------------------------------------
Half full - Half empty? I don't mind. It's what in it that counts.
RE: My new book - any thoughts?
Remember, it will not be a text-book on automation. There are many good ones already. The book will cover things that never get mentioned in text-books, but still will meet the engineer once he is 'on the loose'.
Gunnar Englund
www.gke.org
--------------------------------------
Half full - Half empty? I don't mind. It's what in it that counts.
RE: My new book - any thoughts?
RE: My new book - any thoughts?
Gunnar Englund
www.gke.org
--------------------------------------
Half full - Half empty? I don't mind. It's what in it that counts.
RE: My new book - any thoughts?
The brake coil was controlled by a relay similar (but not identical) to this:
http://www.cesco.com/b2c/product/224599
The machine had been in service for several years but for some reason the relay did not interrupt the current. The brake coil was a fairly high resistance and the current was quite low but it set up an arc across each break of the double break contacts. The heat was just enough to melt the silver alloy contact material. The molten material then flowed together in such a way as to bridge the contacts. Once there was a metallic path and no arc the metal cooled and left the contacts welded together by two miniature hour glasses of silver alloy.
Bill
--------------------
"Why not the best?"
Jimmy Carter