PMS MSNUAL FINAL07_2

8/3/2019 PMS MSNUAL FINAL07_2

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OBJECTIVE: STUDY DIFFERENT TYPES OF MAITENANCE SYSTEM

LEARNING:

o TYPES AND SCOPE OF MAINTENANCE SYSYTEM

o IMPORTANCE OF MAITENANCE SYSTEM

INTRODUCTION

With the ever growings developing industrial revolution materialized like any

tasking. These have revolutionized the production rate with improved quality

building withing the products. To maintain the quality with economy of production.

The machinery of the plant has to play to with rate.

In ancient times the corrective actions were taken only after the break down of any

machinery with more awareness about Quality of best price concept of thought to

maintain the machinery up to the work every hows every how.

WHY MAINTENANCE IS NESESSARY ?

With the working of any machine over a period of time that frictions were various

parts of machine get deteriorated is charge in the machine resulting into change in

quality of product.

To maintain the quality consistency the part of the machinery are clearly lubricated

refueling over a period of time also the adjustments are made this machine are kept

in good working condition for longer times this consistency of quality is advise.

This modern maintenance concept includes planning details scheduling of

maintenance is repair of the machinery the concept is called maintenanceengineering.

DEFINITIONS

MAINTENANCE

The activities carried out to keep the machine/equipment in working

conditions are known as maintenance of plant.

MAINTENANCE ENGINEERING

PLANT MAINTENANCE & SAFETY

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STUDY OF DIFFERENT TYPES OF MAINTENANCE SYSTEMS.

DATE:-

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Maintenance engineering is concerned with the application of modern latest

technology in keeping the machines equipment of the industries in up to due

to working conditions by solving their day to day maintenance.

TYPES OF MAINTENANCE:

a. CAPITAL REPLACEMENT

An equipment or machine as a whole replaced assists parts with some faults

are replaced instead of repairing when this takes a little time to restart the

machine or equipment the disadvantage is it quite costly sonly economically

bearable maintenance are done through these method.

b. BREAK DOWN MAINTENANCE

The philosophy of this maintenance is allowed machine or equipment to run

without attention fill it break down i.e. stops function as working.

Disadvantages are the longer non productive period of machines equipments

disrupted production this become costly.

It is an out dated philosophy in modern world of technology as it retains

maintenance dept and schedules.

c. PREVENTIVE MAINTENANCE

The main philosophy is to take measure to anticipate break down and to

prevent then before the neutrally occurs.

In this kind of maintenance inspection lubrication adjustments minor or major

is over handling etc are per plan.

Continuous effects for keeping in advance.

d. CORRECTIVE MAINTENANCE

This maintenance is not performed after repented break down engineering

analysis is carried out and cases of break down are identicaland correctedto

the minimize break down.

It needs modification in the design intrinsicexisting hardening etc. are carried

out.

Advantages are reduced no. of breakdown, reduced non productive times.

e. SCHEDULED MAINTENANCE:


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In this philosophy of scheduled maintenance. It is constant direct that break

down are advantages to service life of equipment also after the production.

Therefore the maintenance is scheduled in the day of leave some equipment

which is not in use can be maintained on working days too.

Sometimes the machines are kept in use ever it there is any through may

sometimes leads to high break down maintenance lost.

f. PLANNED MAINTENANCE

Planning is maintenance records are given special emphasized.

Small adjustment repairs replacement are handled regularly periodically. So

as to keep degree of planning is increased compare to scheduling periodic

maintenance by continuously analysis results of simple denotation of planned

maintenance activating improving them for betterment.

Faults are detected regularly repaired also inspection, lubrication and

adjustment are performed as per the plan.

g. PRODUCTIVE MAINTENANCE

Productive maintenance is aims at economy for preventive maintenance are

applied to this equipment.

Disadvantages are produced intensity of maintenance for non vital equipmentleading to the working conditions of machinery kept and ultimate capital

replacement which is quality costly.

h. PREDICTIVE MAINTENANCE

Uses of following are made to predict trouble problem is faults leading to

equipment failure vibration analyzer.

Anodic is pressure gauge.

Femp meter is amplitude meter.

Strain gausses.

Continuous water is kept defect the cause of failure or break down are

removed to reduce the maintenance cost.

Excessive heating or bearing to bush bearing indicates.

i. MODULAR MAINTENANCE

New approach.

This method is most effective.


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Where the penalty cost failure is maximum, this is used in air liner.

Modification machine equipment is made as is then read keeping in mind that

the changes should not.

After the machine considerably. The burning materials when stand up wind of

the fire and should apply the gas in a down wind of the fire and should apply

the gas in a down wind direction as close as possible to the fire on fires in

electrical equipment.

Questions:-

1) State the primary and secondary function of maintenance department.

2) List the responsibilities of maintenance department.3) State the factor effecting maintenance cost.4) Define the Maintenance cost and state the factor effecting it.5) Define the service life of the Equipment.

No Critaria Max. Marks Obtained

Marks

1 Attendances & timely submission 4

2 Presentation & Participation 3

3 Feedback 3

TOTAL MARKS 10


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SIGN OF FACULTY ___________

`

OBJECTIVE : PREPARE A CHECK LIST FOR DIFFERENT LATHE M/C PARTS

LEARNING:

LATHE LATHE M/C

STEPS OF MAINTANACE IN LATHE MACHUNE

MAIN PARTS OF THE LATHE MACHINE

Head stock

Tail stock

Carriage

STEPS IN MAINTENANCE OF TAIL STOCK (LATHE MACHINE)

First of all loosen the clamping bolts and nuts and remove the tailstock from the

guide ways of lathe.

Then open the spindle lock bundle.

Unscrew the nut.

Remove the taper lay inside the flange.

Then remove the hand wheel slowly.

Then takes off the barrel.

Then remove the spindle inside the barrel.

Remove the dead centre.

Clean the all parts by removing dust from it by wire brush.

Now clean them with kerosene and cotton waste.

Measure the wear of all the parts. Repair or replace the parts as per % of wear.


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DISMANTLING & MANTLING OF DIFFERENT LATHE M/C PARTS

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Then alter grassing all the moving parts.

Now assemble them one by one.

Now fit the stock on lathe side ways with the help of clamping nut & bolt.

Now lack of the alignment of tail stock.


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TAIL STOCK

1. Dead Centre 2. Spindle

3. Spindle Clamp 4. Barrel

5. Bush 6. Square threaded

7. Hand wheel 8. Split lug

9. Tailstock clamping bolt 10. Lathe bed ways

11. Clamping plate 12. Set over screw

13. Body 14. Keyway

15. Key


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STEPS IN MAINTENANCE OF TAIL STOCK (LATHE MACHINE)


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CHECK LIST

TAIL STOCK

SR.

NO.PARTS NAME OK DEFECTIVE REMARK

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.


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INSPECTED BY: DATE: NOTE: X INDICATE DEFECTIVE


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CARRIAGE

1. Tool post screw 2. Tool post

3. Rocker 4. Tool

5. Concave ring 6. Compound rest swivel base

7. Cross feed screw 8. Binder screw

9. Cross slide 10. Cross slide nut

11. Saddle 12. Pinion on Cross feed screw for

13. Cross slide hand wheel automatic feed

14. Compound slide hand wheel 15. Compound slide feed screw

16. Compound rest 17. Compound slide nut


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STEPS IN MAINTENANCE OF CARRIAGE (LATHE MACHINE):


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UNIVERSAL CHUCK

1. Bevel pinion 2. Scroll disc

3. Bevel teeth on scroll disc 4. Chuck body


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STEPS IN MAINTENANCE OF 3 JAW CHUCK (LATHE MACHINE):


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CHECK LIST

UNIVERSAL CHUCKSR.


1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.



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FOUR JAW INDEPENDENT CHUCK

1. Concentric circle 2. Chuck body

3. Jaw screw 4. Jaw

5. Gripping surface 6. Recess for back plate


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CHECK LIST

FOUR JAW INDEPENDENT CHUCK

SR.NO.

PARTS NAME OK DEFECTIVE REMARK

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.



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Questions:-

1) What is the main function of lathe? List various types of lathes.2) State the operation which may be performed on a lathe.3) Difference between motion of cross slide and a compound rest.

4) Why chucks are used? List various types of chucks used in lathe.5) What is mandrel? Why they are used in lathe? List various types of

mandrels.6) What is a thread chaser?

7) What steps required for installtion and maintain the proper working of the

lathe?


Marks



3 Feedback 3

TOTAL MARKS 10



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OBJECTIVE: DIASASSEMBLY AND ASSEMBLY OF VERTICAL HEAD OF

MILLING MACHINE , CHECK LIST

LEARNING:

o TYPES OF MILLING M/C

o VERTICAL MILLING M/C

o STEPS FOR MAINTENANACE IN VERTICAL MILLING M/C.

INTRODUCTION

A Milling Machine is machine tool that removes metals as the work is fed against a

rotating multipoint cutter.The cutter rotates at high speed and beacuse of the

multiple cutting edges it removes metal at very fast rest.This is superior to other

machines as regards accuracy and better surface finish,and is designed for achining

a variety of tool room work.

TYPES OF MILLING MACHINE COLOUMN AND KNEE TYPE

Hand milling machine

Plain milling machine

Universal milling machine

Omniversal milling machine

Vertical milling machine

MANUFACTURING MILLING MACHINE

Simplex milling machine

Duplex milling machine

Triplex milling machine

PLAINER TYPE


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STUDY OF DISASSEMBLY & ASSEMBLY OF VERTICAL HEAD OF

MILLING MACHINE AND ALSO PREPARE A CHECK LIST FOR IT.

Assembly of VERTICAL HEAD of Milling Machine and also prepare a

check list for it.

MAINTENANCE SYSTEMS.

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SPECIAL TYPE

Rotary table milling machine

Drum milling machine

Planetary milling machine

Pantograph ,Profiling & tracer controlles milling machine.

VERTICAL MILLING MACHINE :

A vertical mllling machine can be dstinguished from a horizonatal milling machine

milling by the position of its spondle which is vertical or perpendicular to the work

table.the machine may be or plain or universal type and has all the movements of

the table for proper setting and feeding the work. The spindle head which is


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clamped to the vertical coloum may be swovelled at any angle,permitting the

milling cutter mounted on the spindle to work on angular surfaces.In some

machine ,the spindle is adapted for machining grooves,slots and flat surfaces .the

end face milling cutter are the real tools mounted on the spindle .

MILLLING MACHINE ATTCHEMENTS

The attchments are standard or special auxiliary devices inteded to be fastened to

or joined with one or more components of the milling machine for the purpose of

augmenting the range,versatility,productivity or accuracy or operation.Some classes

of milling machine attchements are used for positioning and driving the cutter by

altering the cutter axis and speed,whereas other classes are used

positioning,holding and feeding the work along a specified geometric path.The

following are the different attchements used on standard column and knee type

milling machine.

VERTICAL MILLING ATTTCHEMENT

A verticle milling attchement can convert a horizontal milling machine into a

vertical machine by orienting th cutting spindle axis from horizontal to vertical for

performing specific operations .The attchement consists of a right angle gear boxwhich is atteched to the nose of the horizontal milling machine spindle by bolting it

on the column face.The speed of the vertical spindle is same as that of the machine

spindle.The attchment with the spindle can also be swivelled at any angle other than

at right angles to the table for mahining angular surfaces.


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STEPS IN MAINTENANCE OF VERTICAL HEAD (MILLING MACHINE):


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CHECK LIST

VERTICAL HEADSR.


1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.



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Questions:-

1) Describe the steps for installing milling machine.

2) Classify milling machines and list them accordingly how milling differs from

turning in lathe.

3) Write the safety measures in milling.

4) Compare between plain and universal milling machine.


Marks



3 Feedback 3

TOTAL MARKS 10



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OBJECTIVE: MEASURE WEAR IN GIVEN SURFACES

LEARNING:

o TYPES OF WEARS

o METHODS FOR MEASURING WEAR.

o BEAM COMPARATOR

o MEASURING WEAR OF GEAR TOOTH,

o MEASURING THREAD WEAR

INTRODUCTION

Wear is a process of a gradual change in the dimensions of machine parts which

are in motion during the operation.

TYPES OF WEAR

MECHANICAL WEAR

The main cause of mechanical wear is friction occurs between two mating

surface. They may be same hard particles due to them wears take place.

MOLECULAR WEAR

This type of wear is due to sticking of conjugate surfaces. It is caused by

insufficient lubrication and high unit pressure when two surfaces fit together so

tight that forces of molecular cohesion come in to play.

CORROSIVE WEAR

When the open surface reacts with oxygen, oxidation of metal takes place, it is

called corrosion. This corrosion eats away the metal and the part acquires

spongy surface and looses mechanical strength.

EFFECTS OF WEAR

Effects of wear on performance of machinability are as follows:

I. Overheating of machine and its mechanism.II. Faulty alignment of machine and its parts.

III. Vibration in machine.


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TO MEASURE AMOUNT OF WEAR IN GIVEN SURFACE

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IV. Noisy operation.

V. Loss of quality of machine and production.

VI. Lower efficiency.

METHODS OF MEASURING WEAR

According to the surface on which the wear occurs there are main five occurs

of wear.

I. Wear on flat surface.

II. Wear cylindrical surface.

III. Faulty alignment of shaft due to wear.

IV. Wear on threads.

V. Wear on gear tooth.

METHODS OF MEASURING WEAR ON FLAT SURFACE

Wear on flat surface can be measured by the following methods.

a) STRAIGHT EDGE AND THICKNESS GAUGE (FELLER GAUGE)

Amount of wear on narrow and short guide surfaces is measured by this

method. The Straight edge placed along the guide surface and the gap(wear)

if any is measured with a feeler gauge. The length of the straight edge must

be at least 2/3 of the length of the surface to be checked.

BRIDGE AND SENSITIVE SPIRIT LEVEL

This method is used for determining the wear on longer guide surfaces.

Bridge is placed on the surface at regular intervals and each time wear is

measured by sensitive spirit level placed over the bridge. Divide the plane in

it equal to corresponding to width of bridge and distance between two

supports on this equal parts wear is measured by spirit level.

c) MICROSCOPE AND STEEL STRING

Guide surfaces over 2500 mm in length are checked for straightness by use

of steel string and microscope with a high accuracy scale.

In this method a steel string is stretched parallel to the surface by adjusting

the centre of cross hairs with the string at both ends. The wear is measured

on microscopic scale at different places by the amount of deviation of the

centre of the cross hair from the wire stretched.


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Where Mw = Micrometer reading on wire.

N = No. of thread in unit length.

W = Diameter of wire.

Pd = Pitch circle diameter of thread.

METHOD OF MEASURING WEAR OF GEAR TOOTH

To measure wear on gear tooth Vernier Caliper with height gauge is used

with the help of fair measurement we can measured tooth thickness m in

P.C.P we can also set height h with height gauge thickness of m is called

chordal thickness of tooth.

M ZAB

AB = (d/2) sin (dt/t)

Where T = No. of tooth of wear.

d = Pitch diameter.

MAXIMUM PERMISSIBLE ERROR

The maximum permissible error for guide ways of precession machine is 0.02 to

0.03 mm per 100 mm for standard accuracy of machine is 0.01 to 0.02 mm and

for shaft operating in plan gearing is with in 0.0001 to 0.01 mm the shaft and

spindle from 0.01 to 0.15 mm.

Questions:-

1)State different types of wear. Explain the effect of different types ofwear on Performance.

2) Write causes for mechanical wear.

3) State the causes for corrosive wear.4) State defferent methods used to detect wear on parts.

5) List the different method of wear measurement


Marks

1 Attendances & timely submission 42 Presentation & Participation 3

3 Feedback 3


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TOTAL MARKS 10


OBJECTIVE: TO STUDY RECOVERY METHOD FOR WORN OUT PARTS.

LEARNING:

o METHODS OF RECOVERY

o

EFFECT OF THE FACTORS ON RECOVERY METHODS

INTRODUCTION

Repairing means to make the things serviceable in another works we can

say that to recover the things from unsuitable condition. We can not

replace all the worn out parts by recover as it becomes costly. Hence to

reduce the maintenance cost the parts are repaired it they are worm out

withing the limit. The parts which are worm out taken or become unsuitable are made

suitable by means of some kind of repairs known as recovery to the parts.

The cost incurred in recovering the parts shown not be more than the

40% cost of the service as if it is new one also reliability of parts retains

for expanded duration. All these process are known as recovery.

MATHODS OF RECOVERY

The following are the main methods of recovery.

I. Welding & surfacing.

II. Metal spraying.

III. Chromium plating.

IV. Adhesive Bonding.

V. Plastic deformation

VI. Winding

VII. Scraping

VIII. Electrolyte Bonding.


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TO STUDY AND SELECT APPROPRIATE RECOVERY METHOD FORWORNOUT PARTS.

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IX. Machining

WORKING PRINCIPLE OF RECOVERY METHODS

I ) WELDING AND SURFACING

Welding & surfacing are employed in repair jobs, worm and broken m/c parts

including critical parts such as m/c tools crank shaft etc. are restored

economically by welding. Welding such as gas/electric arc welding can weld

only around the periphery, whereas friction welding welds the whole surface of

contact.The parts of be recovered are first dipped in hot solution of caustic soda and

washed with warm water sometimes the parts are dipped in organic solvent or

by welding. The worm out portion of the parts is filled with weld deposition

metal and finally the part is machined to req. size.

II) METAL SPRAYING OR METALLIZATION PROCESS

Metal spraying is the process of deposition a layer of metal in which the metal in

melted by an electric arc or by oxy-acetylene gas flame & forced under

compressed air pressure against the surface to the sprayed.

The surface to be machined is first prepared either by knurling or by sand

blasting or by cutting rough threads. Then it is cleaned from oil. It is advisable to

preheated the surface about 200c for better deposition.

The welding wires from the coil are fed by the rollers through the guiding pipes

and the receiving pipes. The arc is generated at the meeting ends of the wires,

which melts the metal. The molten metal is forced against the surface by means

of the compressed air (6 kg/cm2 ) entering though the pipe & the nozzle.

III) CHROMIUM PLATING

Chromium plating is widely used for the restoration of the working surfaces of the

shafts, spindles & similar parts, where wear is up to 0.24 mm. Chromium coating

can withstand a high temperature (8000 C) & is very hard and anti-corrosive in

nature.

IV) ADHESIVE BONDING


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This method is employed to close cracks in casing type parts and to apply

patches, eliminate nicks and dents on the guide surfaces, mount wear

compensating parts for journals, shafts and spindles and tailstock quills, recover

worn holes in pulleys and flywheels etc. A glue joint is water impermeable and is

not destroyed by the action of air oxygen, water, mineral oil and temperature up

to 1000C.

V) PLASTIC DEFORMATION

It is one type of forging work. In this method the part is heated up to its

recrystallization temp. & then defects like cranks, change of shape etc. can be

removed by applying pressure. This method is simple and less costly. This

method is applicable to those parts which do not retain dimensional fit.

VI) WINDING

Joint of electric wires leakage prevention of fluid from the pipes can be

recovered by this method.

VII) SCRAPPING

In this method rough uneven surface is scraped means of scrapping tool & made

flat horizontal. The upper surface of m/c is made flat by this method. The shape

of the scraping tool is similar to chisel used in wood work.

VIII) ELECTROLYTIC BONDING UP

This process is conducted either in bath of foliate ceramic ceramics & acid

resistant concrete or in metal baths with an acid resistant lining. The electrolyte

is eated by an electric current. The electrolyte used may be chlorous acid. A coat

deposited by this method adheres strongly to the base metal.

IX) MACHINING

In these methods uneven wear surface of the part is removed by machining,

then the surface is filled by welding and again it is machined to accurate size.

EFFECTS OF THE FACTORS ON THE CHOISE OF RECOVERY METHODS

I) OPERATION

Before repairing the part what is the function of the part, how much it is

assembled, what is the nature of wear; all these things should be selected

so that satisfactory result can be obtained.


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II) PRODUCTION

The type of production is one of the vital factors for the selection of

recovery methods. The elements of machines are subjected to less wear

in one shift production as compared to those three shift production.

From this it is clear that the elements of machines which are to berecovered for three shifts production should have three time service life as

compared to elements of same machine used in one shift production.

Hence wear rate of elements of these machines will be different.

Depending upon this wear rate of particular element, recovery method is

selected.

III) TYPE OF FIT

Depending upon the type of fit, how much thick metal layer is to be laid

on the surface of the part is decided and then the method of recovery is

selected.

IV) ECONOMY

Under this factor cost of material used, labour cost and other overhead

charges are considered for the recovery method. The economical method

with best result is selected.

V) RELIABILITY

The recovery method should be reliable and acceptable when it is

selected for particular repair. Any recovery method is basically viewed in

terms of accuracy, strength imparted to part and long service life. To

achieve these things reliability plays an important role.

Questions:-

1) Describe the factors effecting the choice of different recovery method.2) How will you repair broken tooth of large gear.3) Describe the recovery method to recover the machine bed.


Marks


2 Presentation & Participation 33 Feedback 3

TOTAL MARKS 10


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OBJECTIVE: STUDY DECISION TREE AND FAULT TRACING

LEARNING:

o MEANING OF DECISION TREE

o STEPS INVOLVE IN MAKING DECISION TREE

INTRODUCTION

Friends, in a last topic you have studied fault finding procedure for the

equipment. The second side of the coin is a decision tree diagram for detecting

maintenance with the help of logical sequence. With the help of logical

sequence, it is very easy to reach to the problem in a right time. Decision tree

diagram shows the right path to maintenance engineer to solve the problem in

very systematic way, small example like develop maintainability of a freshtechnician in the industry.

MEANING OF DECISION TREE

It is a systematic representation of sequential activities in form of blocks, which

helps in eliminating different variable, believed to have causing the defects in a

system.

There are two types of decision which we come across while locating a faults.

I. Natural controlled decision which is represented by a circle.

Assumption

II. Man controlled decision which is represented by a square or rectangle.

Or Assumption.


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TO STUDY DECISION TREE AND FAULT TRACING6

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It should be perfectly understood that inspector is an inherent part of

decision making and student shall use their back ground of inspection

from metrology.

Making a decision tree is putting down logical and sequential activities in a

tree form. It takes account of all the possibilities which could causes of the

fault in various situations. It is the system representation in totally.

STEPS INVOLVED IN PREPARING DECISION TREE DIAGRAM

Remember to choose the first line of action which is going to consume the

least check on time as a matter of policy since there are number courses of

action and they are to be prim established from QUEUING THEORY, to

minimum the loss of a number of units waiting idle, it preferable to choose

first choose units whose services time is the least as compared to the other.

DECISION TREE

Ex : 1 Draw the decision tree for repair the petrol engine which does not start.


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EX: 2 Prepare a decision tree to locate fault when centrifugal pumpdoes not deliver water.


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EX : 3 Draw a decision tree for the fault lathe chuck stops revolving.


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Ex : 4 Draw a decision tree for low air pressure in a compressor


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Ex : 5 A scooter engine fails to start. Draw a decision tree for theSequence of activities involved in fault tracing.


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Questions:-

1) Explain meaning the term Planing and Scheduling in maintenance work.

2) Define fault tracing and state fault tracing activities.3) What is fault tracing? List the activities of fault tracing


Marks



3 Feedback 3

TOTAL MARKS 10



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OBJECTIVE: PREPARE ACCEPTANCE TEST FOR GIVEN M/C TOOLLEARNING:

Acceptance test for given m/c tool

INTRODUCTION

Machine tools are the means by which different products and their components

are shaped to make them within specific dimensions. The finish and geometric

accuracies of the part depend upon the accuracy of the machine itself on which it

is made. Machine must produce the work within specified accuracy consistency

and without requiring any extra skill by the operator. This quality of machine

depends on rigidity of machine, fitment of part of machine and their alignment

with each other and accuracy and quality of control and other devices.

Thus on purchases of new machine and its installation the above checking must

be done prior to start of actual working on the machine and also the one running

machines the checking must be done after certain intervals.

Alignment tests are especially useful because they establish the relationship

between various moving parts of machine on which accuracy of component is

directly dependent. e.g. a component on a lathe machine will not be round if the

chuck and spindle on which it is held has run out and it will not be straight along

its length if the movement of tool parallel to axis of work (i.e. spindle) is not

parallel.

ACCEPTANCE TESTS FOR MACHINE TOOLS

These tests help to specify the grades and accuracy of the machine tools. The

acceptance tests for the machine tools can be divided in to two types of tests.

(A) Performance test.

(B) Alignment test.

These tests can be applied to new machine tools. The test charts for themachine tools are supplied along with the machine tools by the manufacturer,

which specifies permissible alignment and working accuracy.PLANT MAINTENANCE & SAFETY

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TO CARRY OUT ACCEPTANCE TEST FOR A GIVEN MACHINE TOOL ASPER I.S.

DATE:-

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Instruments are used in alignment test.

1) Dial gauge.

2) Test mandrel.

3) Spirit level.

4) Straight edge and squares.


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ACCEPTANCE TEST FOR GEOMETRICAL TESTS LATHE M/C

SR.NO

FIGURE Nature of testPermissibleDevitation

ActualEtrror

1. Straightness ofcarriege

movement in ahorizontal planeor possibly ,in aplane defined by

the axis of thecentres and the

tool point.

DCDC1000 : Foreach spplementrylength of 1000 forDC beyond 1000add 0.005 w/oexceeding themaximumdevitation 0.03

0.01

2. Parallelism ortaper bore oftail stock sleeveto the carriegemovement.a) in horizontal

planeb) in vertical

planeL=Da/2 or Max300

a)

A ) 0.03/300.freeend of mandrelinlclined to ward thetool only.

B) 0.03/300,freeend of mendrelinlined up wardsonly.

0.03

0.03

3. Difference inheight betweenhead stock and

tail tail stockcentre.

0.04Tail stock centre

hiegher thanheadstock centre.

0.03


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SR.NO


ActualEtrror

4.

Parallelisn of thelongitudinal

movement of thetool slide to the

spindle axis.

0.04/300 freeend of mandrel

inclined upwardsonly.

0.02

5.

Run out ofspindle nose

centeringsleeve or cone.

0.01 0.005

6.Turn running ofthe taper bore of

the spindle.A) near to thespindle nose.

B) at a distancewhere L=Da/2

Or Max 300

a) 0.01

b) 0.02 for 300

0.005

0.015


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SR.NO


ActualEtrror

7.

Squarness ofthe transeverse

movement of thecross to thespindle axis.

0.02/300,Directon of error

c>=900.01

8.

Axial slip 0.015 0.005

9.

Accuracy of thepitch generated

by the lead screw.

A) 0.04 for anylength of 300 forDC


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No Critaria Max. Marks Obtained Marks

1Attendances & timelysubmission

4


3 Feedback 3

TOTAL MARKS 10



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OBJECTIVE: prepare palnt maintenance schedule for m/c

LEARNING:

o Plant maintenance schedule

INTRODUCTION

There is not single method or procedure for plant maintenance which could be

applied for all plants or units like wise P.M programme depends upon the plant.

It differs from plant to plant. If P.M programme is prepared by maintenance

dept. location which many element and production department P.M scheduled

pousponed on the basic angle of the past records.

Site plants and location of building and equipment.

Plant indicating pipe lines, power lines etc.

Details of all major equipment.

Operation and maintenance instruction for equipment.

Record of inspection repair and mechanical work.

Defect Register.

The above regards help to prepare plant maintenance schedule consisting

below.

List of item required P.M schedule.

Inspection.

Lubrication.

Over drilling.

Time required for the job.

It should be done when it has get low effect on the production.

B= Bench

B.B = Black board

C = cupboard

C.V = Carpentry vice

F.V = Fitting vice


49

TO PREPARE PLANT MAINTENANCE SCHEDULE FOR MACHINE IN

YOUR WORKSHOP LABORATORY

.

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W.C = Wood cutter

P = Pillar

L = Lathe Machine

F = Furnace

M = Milling M/C

D = Drilling M/C

S = Shaper M/C

G = Grinder M/C

A typical symbol used in plant maintenance schedule is given below.

- General Cleaning

- Inspection

- Lubrication

- Over hauling

Questions:-

1) Define preventive maintenance & list its advantages.

2) Enlist steps involved in preventive maintenance programme.3) Explain repair complexity & write the work involved in different

stages of repair cycle.4) State the aids to a good preventive maintenance.

5) Draw typical two forms used in plant maintenance programme.


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3 Feedback 3

TOTAL MARKS 10



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OBJECTIVE: Study of fire hazards and preventive measures

LEARNING:

o FIRE AND CAUSE OF FIRE

o FIRE EXTINGUISHERS

INRODUCTION

The subject of fire protection in variably finds the lost the any human behavior

unless the nature of operation situation or environment wants cover for the riskdue to high potential hazards. It has been prevent beyond about in case of

reported fires which has been investigated that in as much as 90% of the

situation and the hazards and damage have been caused due to the fire at

insufficient stages not being controlled which in develop in to a below perhaps

adiabatic names of first oil fire protection which comparability little cost could

have saved the situation in these instance.

It will be an appropriate at this stage to understand that a fire pressure stage

incipient flame stage fuel intense heat engines. A fire develops from a smoke to

an uncountable place through these stages. A fire develops from a smoke to a

uncountable place through these stages.

The first aid fire protection prevent fire from developing into a blast it used

properly at the appropriate stage those equipment it properly installs maintained

and use can put off these little spark that source of again.

ELEMENTS OF FIRE

Fire loss in India is estimated as more than and day dead and injour figures

which thousands every year the best over to fight fires is to prevent than

Understand the nature of fire.

Know hot it starts.

Know what to do in case of fire.

HOW FIRE STARTS IN FACTORY

Some of the causes of fire as follow:


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TO STUDY THE FIRE HAZARDS AND PREVENTIVE MEASURES.

DATE:-

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Overheating of motors.

Uncontrolled welding sparker.

Hot soldering iron left unwedded.

Sparker from the grinding wheel.

THE NATURE OF FIRE

Fire is a chemical reaction that gives out heat light and smoke. To start fire

three things more come together they are:

Fuel

Heat

Oxygen

a) FUEL

Fuel is something that can bush as with fire (e.g. petrol, kerosene, cooking

gas, rubber, etc.) bush at different soft and given out different dangerous

gases while bushing.

b) HEAT

Fuel by itself can not catch fire for to start burning. We need to supply heat

once a fuel in it can generate additional heat on its own to keep fire growing.

c) OXYGEN

The requirement for a fire is air or oxygen which is usually always available.

These when fuel is heat and oxygen comes together into right amounts have

a fire in a simple way there ingredient of fire can be dissipated by there sides

of triangle properly known as the fire triangle.

COOLING

The most common way to remove heat is by the use of ratio absorbs a lot of

heat specially while be coming steam & coils the fire.

STARVATION

Another method of extinguishing a fire is to remove the fuel for example the

flame pf gas supply.

SMOOTHEZING


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It is the method of putting out fire by removing the supply of oxygen for example

from applied to liquid on fire puts out fire for the liquid on fire for the liquid will no

longer being contact with fire.

CLASSIFICATION OF FIRES

Paper clothes woods etc. when material like paper clothing as wood catch fire it

is heat to use water cutting off oxygen supply from the surface of burning liquids

will usually parts out such fires.

COMPRESSED GAS

Fires involving compressed gas like L.P.G and acetylene are class - c fires

there are usually extinguish by starvation as closing the leakage of gas from the

enter to prevent overheating or the cylinder wants can be prayed on the cylinder.

METALS

Fire involving metals like magnesium, zirconium etc. from a special category the

fire. There are not so common and need to be hand load with great case usually

sand or power called be applied to output metal fires.

ELECTRICAL EQUIPMENTS

Fire involving electrical equipment ratio than that controls electricity should not

be applied on equipment of fire to avoid out electrical fires.

FIRST AID FIRE FIGHTING EQUIPMENT

The first aid fire protection appliance can be classified as under.

Fire buckets.

Strip pumps.

Small bare hose reels.

Fire extinguisher.

(A) FIRE BUCKETS

The simplest among the fire application is the fire buckets made of C.I. sheets

there or sound bottler design with bottom handle fire buckets are either filled

with sand or ratio depending on nature of to be protected a fire respectively.

(B) STRIP PUMPS


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The next appliance strip pump while is having a manual plunger type pump

used to such argue it under pressure through a nozzle fitted at the other end of

which and connected to the pump. The disadvantages or these pump is that

throw and continuous end the pressure be not of much consequence the pump

can be used continuously where a surface of ratio exist and suitable for class it

fires only near continuous 3 charge can be achieved by double barrel strip

pump. So that B charge B in both the down ward and upward strokes.

(C) HOSE REELS

One of best means of first aid fire protection for class and fires are of hose

reels. These are normally connected to permanent surface of ratio generally on

overhead tank ratio flower into here seals by the gravitational force and their

system B more useful in multistoried construction when B fairly good pressure.

(D) FIRE EXTINGUISHERS

Different types of extinguishers are use to compact different classes of fires.

There are four types of exiting is here in our organization.

Soda acid type extinguisher

Foam type fire extinguisher

Dry powder type extinguisher

CO2 type fire extinguisher

I. SODA ACID TYPE EXTINGUISHER

Soda acid can extinguisher are used momentum is class A fires involving

combustion material like wood, paper, textile, etc. which are put cut by

coupling action of ratio besides when applied to burning material be invented

to stain which excludes oxygen an langsediant of fire.

Soda acid extinguishers should not be used on Class - E fires involving

electrical equipment

CONSTRUCTION

The various parts and contents of a soda acid extinguisher are shown in

fig. the total liquid capacity of body requires to be lost an internal hydraulic

pressure of 25 kg/cm2 for5 minutes.

METHODS OF OPERATION


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Before the generating extinguishers the operational instruction given on

the body of the extinguishers should be seas carefully at these stage it

would be available to know whether soda acid extinguishers use of the up

sight type turnover type depending on their method working one must

know the type of the extinguisher provided at a given place.

PRICIPLE OF WORKING

Which the plunger is shut it breakers the acid bottle. The sulphuric acid

and sodium bicarbonate solving seat together to release carbon dioxide

the CO2 generated creates pressure which forces the ratio out of the

extinguishers.

CASE & MAITENANCE

a) For efficient performance of extinguisher to following maintenance

should to at least once a week, polish pointed parcels which a little

colors maximum polish check that the plunger B in the fully extended

portion and that it B clean & fire.

b) Once a quarter dismantle the components check for damage clean

than as required sharp the solution in the extinguisher body and top

up with lever mark.

c) Carry out pressure test once every and year on each extinguisher by

means of hydraulic test pump. The test pressure be 179 kg/cm2& be

applied to 2(1/2) minutes.

II. FOAM TYPE EXTINGUISHER

Portable extinguisher expelling foams are best suited to put out close. Brief

involving flammable liquids like oils solvents. Petroleum product etc. the foam

expelled by the liquids with air thus extinguisher there containers when filled

to the specified fuel contain a liquid.

The outer container holes solution sodium which form stabilizer intermixed

produces from that is expelled from the extinguisher.

METHOD OF OPERATION

I. Remove the extinguisher from a socket.

II. Remove the knob & turn the extinguisher over to ensure the mixing

of two liquids.


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III. Where a liquid on fire is in a contains direct the jet at for inside the

edge container as shown in sketch adjoining vertical surfaces above the

land or immersing liquid.

We not direct the jet directly into the liquid because this will drive the room

the surface and ineffective on addition it may splash the fire in to the

surroundings foam solution are electrically conductive and therefore are not

recommended for use on electrical fires.

CARE & MAITENANCE

At least once week polished the painted sections with a little colorless

over polish and the braes parts with brass polish & the brass the nozzle

outlet event hole on the threaded portion of the cap for slogging.

One can quarter dismantle the components check for any damage the

solution in the owner and auto containers with supported clean and dry

sticks.

Recharge the extinguisher compositely carry out pressure test once every

four years on each extinguisher by means of a hydraulic test pump least

test pressure is 175 kg/cm2 and be applied 2(1/2) minutes.

III. DRY POWDER TYPE FIRE EXTINGUISHER

Dry powder type extinguishers are recommended mainly checking problem

fires. They are also suitable for gas fires in textiles fibers. These

extinguishers are noted the speed with which they put fires.

CONSTRUCTION

The construction of this type is fire extinguisher is shown in the fig. the

chemical power contained in the main shell of the extinguisher and CO 2

gases held under high pressure in a arrange when the extinguisher is

operated the carriage is known allowing the CO2 gas to example to the

main shell and push out the power in the four of fig.

METHOD OF OPERATION

Carry the extinguisher has to the place of the fire and feed it up right

remove to supply clip and strike and knob located in the cap to actual the

pining mechanisms which in term breaker the selling disc of cartridge for


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effective results stand about 5 to 8 feet away direct the stream hearer the

sent of the fire.

CARE AND MAITENANCE

Following maintenance schedules are recommended for effective

performance of extinguisher once a week.

I. Clean the exoteric of the extinguisher polish the painted person with

a colorless week polish and polish the brass parts.

II. Check the piercing mechanism for its proper function.

III. Remove the inner shell and clean part it necessary.

IV. Check to powder for granulation and checking it. Checking

granulation is observed remove and replace with fresh charge.

ONCE IN A YEAR

20% the total number of extinguisher of these types should be put into

operation for calculating their satisfactory performance in the event of

poor performance or any one of them the balance will also have to be

total.

ONCE IN 5 YEAR

Every extinguisher should be discharge at least once in 5 year. It should

be hydrostatically pressure tested at 3/5 kg/cm2. However in the main

while it there is any indication of mechanical injury of corrosion to the

extinguisher is her shell it should be pressure tested immediately before

recharging to extinguisher is shell be banded.

V. CARBON DIOXIDE TYPE FIRE EXTINGUISHER

CO2 is effective as an extinguisher agent primarily because it reduce to CO2

contents is of air to a point where combustion can not continuous being a gas it

can prevent and to all the parts of fire area.

CONSTRUCTION

The principle parts of the extinguisher are shown in fig. CO2 air retained in

the cylinder is filled with the charge to about to threads by weight of its

total ratio capacity.

METHOD OF OPERATION

Carry the extinguisher so the place of fire remove the safety pin and

operate the discharge device of over screw the valve depending on thePLANT MAINTENANCE & SAFETY

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design carbon dioxide is delivered be means of discharge have through a

high pressure hexible hearer.

Direct the jet at the base of fire starting at one edge and sweeping occurs.

QUESTIONS :-

1) Classify types of accident.

2) List various types of hazards in an industry.

3) State the principle of safe guarding.

4) Explain in brief the safety color code.

5) List the common causes of fire in an industry.


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Marks



3 Feedback 3

TOTAL MARKS 10


OBJECTIVE: FOUNDATION AND ERECTION OF INDUSTRIAL EQUIPMENT:

LEARNIG:

o Need of foundation

o Function of foundation

o Design criteria for foundation

o Material requirement for foundation

INTRODUCTION

You are familiar with the word foundation normally the building portion below

the soil or the structure which supports machine/equipment is called

foundation. Generally machine foundation prepared between soil and

machine/equipments.

Installation of machine/equipment assumed increased important in the wake of

vast programme of industrial development in the country foundation for the

machine/equipment are required to be carefully designed to take care of theunbalanced forces and vibration and the properties of soil under dynamic

condition.

MEANING OF THE TERM FOUNDATION

We know that all the machines/equipments when at work have balanced forces

which tend to give them either vertical or horizontal movement. To restrain this

movement foundation are necessary. Foundation is a part of the structure is

direct contact with and transmitting load to the supporting ground.


59

TO STUDY FOUNDATION AND ERECTION OF INDUSTRIAL EQUIPMENT.

.

DATE:-

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Foundation is a one type of structure which can support the machine /

equipment, transmit the load of the machine/equipment and absorbed the

vibration without affecting balanced position of the machine/equipment.

FUNCTION OF FOUNDATION

Functions of foundation are as under, To support the weight of the machine/equipment.

To held the m/c or equipment firmly into leveled and aligned

position.

To absorb the vibration produced by unaligned form.

CLASSIFICATION OF FOUNDATION

I) BLOCK TYPE FOUNDATION

This type of foundation consisting of concrete on which the machines rests.

II) BOX TYPE FOUNDATION

Box type foundation consisting of hollow concrete block supporting the

machine on the top.


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FOUNDATION BOLT

FLOOR LINE

SOLID CONCRETE FOUNDATION FOR VERTICAL ENGINE

ENGINE HOLDING BOLTLOCATION

FLOOR

SOLID CONCRETE FOUNDATION FOR HORIZONTAL ENGINE

ROUGH TOP

GROUTING BONDS

CONCRETE

BLOCK

CONCRETE RAFT

ABOUT 2m

THICK

BANDS BETWEEN PILES & RAFTFOUN

FOUNDATION FOR TURBO GENERATOR SET


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III) WALL TYPE FOUNDATION

Wall type foundations consisting of a pair of walls which supports the

machinery on their top.

IV) FRAMED TYPE FOUNDATION

Framed type foundations consisting of vertical columns supporting on their

top a horizontal frame work which forms the seat of essential machinery.

EFFECTS OF THE PROPER FOUNDATION

Let us study the effects of the proper foundation upon.

Accuracy of product

Equipment

Safety of the operator

The effects of the proper foundation are

I. The accuracy and finish of work piece depends upon the accuracy of

machines tool. If the machine is fixed upon suitable foundation its accuracy is

mineralized and hence accuracy and finish product is produced.

II. Machine leveling and alignment is maintained hence wear on parts is

less.

III. Increase machine life and improve efficiency.

IV. Unliterary stirrers are not produced.

V. Prevent accidents.

VI. Property constructed foundation will absorb vibration ad shock and

hence joint will not become loose. Prevent the adjoining structure from

damage.

VII. It provides the better working condition to the operator.

CRITERIA FOR DESIGN OF FOUNDATION

I. Weight of machine/equipment.

II. Type of soil.

III. Possibility of vibration.

IV. Impact load.

V. Depth of foundation.

VI. Base of area.

VII. Out of balance force.


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VIII. Type of toothing.

IX. Other data such as anchorboltr its provision for pits tanner and ducts.

X. Speed and power of equipment.

XI. Space and flexibility requirements.


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MATERIAL FOR FOUNDATION

I. Bricks or stones.

II. Plain or rain forced concrete.

III. Structural steel.

IV. Timber.V. Cork sheet.

VI. Steel springs.

VII. Rubber sheet.

VIII. Felt and lead sheets.

TYPES OF FOUNDATION BOLTS

I. Split foundation bolt.

II. L Shaped foundation bolt.

III. Square head foundation bolt.

IV. Eye foundation bolt.

V. Bent foundation bolt.

VI. Rag foundation bolt.

VII. Lewiss foundation bolt.

INSTALLATION PROCEDURE OF AN ENGINE OR MACHINE

The installation procedure of an angle or a machine involves a series of

activities like:

I. Location and layout

II. Positioning of a machine

III. Foundation

IV. Leveling and alignment

V. Grouting

VI. Fitting of other parts, accessories, pippins etc.

VII. Find leveling and fast runs.


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VIII.


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ERECTION

We know that for the satisfactory working of machine equipment it must

be fitted on the proper foundation. After the foundation has been made the

machine is then carefully lifted with the help of crane or chain pulley block

and put on the foundation bots in the flaw. The machine must be properly

horizontal position spirit levels are used to check position.

THE EQUIPMENT USED IN ERECTION WORK

I. Chain and pulley black

II. Ropes and chains

III. Gantry and denied crane

IV. SlingsV. Rollers pinch bars or levers

GROUTING

Grouting is a procedure of the connecting the machine with foundation by a

mixture of one part of port land carnet and two parts of clean, sharp sand

mixed to a mossiest consistency sufficient to facilitate the grout be carefully

worked under all seating. It is externalizes used in installing most of the

machine.

GROUTING PROCEDURE

The top of the foundation block is made roughened made moistened with

water & wooden partisan are placed all around the machine. The right of the

gap between the top foundation and bottom of the machine. The grout is than

poured within the boundary with care to eliminate air gap within. Once stared

the pouring should be completed continuously and the machine must be left

undisturbed. For a few days and grouting to pruned in time to set.


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Questions :-

1) Define following terms:-

a. Foundation

b. Groutingc. Alignment

2) List the criteria for design of foundation .State need for foundation.3) Define the term erection & lest the equipment used in erection work.4) Explain foundation plan for I.C engine. (Mercy-land)5) Write at least eight names of tools used for machine tool alignment


Marks


Documents

PMS MSNUAL FINAL07_2