Mechanical Systems and Maintenance Quiz
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Questions and Answers

What document is needed to verify that an item is delivered at the work site?

  • Work order receipt
  • Bill of sale
  • Shipping bill
  • Invoice (correct)

At what speed will the Turbine Trip valve activate to protect the turbine?

  • 45%
  • 60% (correct)
  • 30%
  • 90%

If a gearbox shaft seal is leaking oil, what should be done?

  • Change the seal of shaft (correct)
  • Use grease instead of oil
  • Add more oil in gear
  • Increase temperature of oil

What is the first step to be taken when planning an alignment for rotating machinery?

<p>Clean the part (B)</p> Signup and view all the answers

How should excessive clearance between two coupled shafts be addressed if alignment is not required?

<p>Change coupling (C)</p> Signup and view all the answers

What action should be taken if a V belt is jumping off the sheave?

<p>Adjust the alignment or tension on the belt (D)</p> Signup and view all the answers

Which procedure is correct to start the oxy-acetylene gas cutting?

<p>Turn on oxygen valve full, turn on 1-1/2 turn of Acetylene valve, Ignite and Adjust (C)</p> Signup and view all the answers

Which pressure gauge shows zero psi at sea level?

<p>PSIG (B)</p> Signup and view all the answers

What is a method to convert a hydraulic system from non-laminar to laminar flow?

<p>Change fittings (A)</p> Signup and view all the answers

How can air starvation downstream in a pneumatic grid piping system be addressed?

<p>Increase pipe diameter (A)</p> Signup and view all the answers

What is one way a Journey person can confirm that an apprentice understands a task?

<p>Prepare a checklist for the apprentice (A)</p> Signup and view all the answers

Which program utilizes past and present data to predict mechanical issues?

<p>Predictive (A)</p> Signup and view all the answers

What type of bearing is typically used in a 5Hp electric motor?

<p>Sealed bearing (D)</p> Signup and view all the answers

What should be done to protect the key slot when installing a bearing on a shaft without a step key?

<p>Fill with oil or silica-gel (D)</p> Signup and view all the answers

What best describes the cavitation process?

<p>Implosion of vapor bubble (C)</p> Signup and view all the answers

If the volume in a cylinder at the beginning of the stroke is 6 cubic inches and at the end it is 75 cubic inches, what is the compression ratio?

<p>1:12.5 (C)</p> Signup and view all the answers

Which of the following seals is a contactless seal?

<p>Labyrinth seal (A)</p> Signup and view all the answers

What is the next step after confirming zero energy during the unloading valve change?

<p>Verify isolation, Prepare the workspace, Remove the old unloading valve, Inspect and clean, Install the new unloading valve, Re-energize and test (B)</p> Signup and view all the answers

What is the first step to be taken while performing laser alignment?

<p>Rough alignment (C)</p> Signup and view all the answers

Which method is considered a Sensory NDT method?

<p>Vibration, Visual, Noise (D)</p> Signup and view all the answers

What is the correct process for setting up economical equipment outdoors?

<p>Clean area, Prepare base, Put equipment, Add barricade to protect people (A)</p> Signup and view all the answers

Which action increases the flow rate in a hydraulic system?

<p>Increase pipe diameter (B)</p> Signup and view all the answers

How should bolts be tightened on a piston head with a torque requirement of 350 lb/ft?

<p>In star pattern up to 350 lb/ft torque (C)</p> Signup and view all the answers

What is the procedure for removing a conveyor belt for reuse?

<p>Loose tension, cut, store at safe place, mark in logbook (B)</p> Signup and view all the answers

What is the minimum rating of a steel chain used in rigging?

<p>80% (A)</p> Signup and view all the answers

Which of the following is used to minimize the lifting angle in a hitch?

<p>Double basket hitch (C)</p> Signup and view all the answers

What is the first aspect to check during regular maintenance of a gearbox?

<p>Visual inspection (C)</p> Signup and view all the answers

What is used to check the surface of the teeth in a gear?

<p>Ultrasonic testing (B)</p> Signup and view all the answers

What steps are involved in the air clutch decommissioning procedure?

<p>Lockout, depressurize the system, remove cover, clean, replace (C)</p> Signup and view all the answers

If a centrifugal fan motor is overheating, which action should be taken first?

<p>Check fan built up (B)</p> Signup and view all the answers

What is the recommended practice to ensure the life longevity of a sling?

<p>Clean with solvent (B)</p> Signup and view all the answers

What should be done first if a leakage occurs?

<p>Secure the area and stop the leakage (D)</p> Signup and view all the answers

What is indicated by the '70' in a welding electrode 7018 label?

<p>Tensile strength in KPA (D)</p> Signup and view all the answers

What is the weight of a 3x3x3 feet steel block with a 6-inch diameter hole in the middle if 1 cubic feet of steel weighs 480 lb?

<p>12677 lb (D)</p> Signup and view all the answers

If too much chromium is found in oil analysis of equipment, what is the likely cause?

<p>Bearing failure (A)</p> Signup and view all the answers

What is the correct sequence of steps for performing a laser alignment outside?

<p>Take wooden tripod, level tripod, mount laser level, clean, do rough alignment (A)</p> Signup and view all the answers

Which correction should be made to fix a conveyor that moves off-center?

<p>Correction at idler pulley (C)</p> Signup and view all the answers

What is a likely cause for a three-phase electric motor to overheat while running?

<p>Low voltage (D)</p> Signup and view all the answers

What does the number '2' represent in EP2 type grease?

<p>Penetration number (C)</p> Signup and view all the answers

Which unit is commonly used to express velocity?

<p>Inch/ sec or mm/ sec (A)</p> Signup and view all the answers

What is the most probable reason for air starvation in an air compressor?

<p>Clogged air filter (C)</p> Signup and view all the answers

What could be a reason for material falling off at the unloading point of a conveyor belt?

<p>Skirt board angle is not proper (A)</p> Signup and view all the answers

What is the drill bit angle for a twist drill bit?

<p>118 degrees (D)</p> Signup and view all the answers

What is the correct procedure to change the pyrometer in a steam turbine?

<p>Lock out, release steam, replace pyrometer, test, inform supervisor (A)</p> Signup and view all the answers

If Gear 'A' is the drive gear driving 'B', which is an idler gear connected to 'C', what direction will gear 'C' rotate?

<p>Against the drive gear (D)</p> Signup and view all the answers

Which type of oil is specifically used in Hypoid gear applications?

<p>EP type oil (D)</p> Signup and view all the answers

What is the appropriate method to support scaffolding on uneven surfaces from the bottom?

<p>Use wood block shim or wedge (D)</p> Signup and view all the answers

Flashcards

What is the reason for material falling off at the unloading point of a conveyor belt?

The angle of the skirt board is incorrect, causing material to fall off at the unloading point.

What does the '70' signify in a '7018' welding electrode label?

The '70' in a welding electrode label indicates the tensile strength of the weld in pounds per square inch (PSI).

What type of bearing is a 'K' type bearing?

A 'K' type bearing is a needle roller bearing, known for its high radial load capacity.

What is the reading of the 2-3 inch depth micrometer in Fig 8?

The reading on the 2-3 inch depth micrometer in Fig 8 is 2.182 inches.

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What does it mean if too much Chromium is found during oil analysis of equipment?

When excessive Chromium is found during oil analysis, it usually indicates bearing failure. The metal particles from the worn bearing contaminate the oil.

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If a conveyor is moving sideways with no load, where should you adjust to fix it?

If a conveyor is moving sideways despite no load, the problem most likely lies in the alignment of the head pulley. Adjust the head pulley to correct the off-center movement.

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What is the drill bit angle for a twist drill bit?

The standard angle for a twist drill bit is 118 degrees. This specific angle helps create a strong and consistent cutting action.

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What is the angle of a prick punch?

A prick punch typically has an angle of 30-60 degrees. This angle allows for a precise marking of the metal surface before drilling.

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Non-Laminar Flow in Hydraulic Systems

The process of a liquid flow becoming turbulent due to excessive fittings, leading to increased energy loss and potential damage to the hydraulic system.

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Reducing Fittings in Hydraulic Systems

Reducing the number of fittings in a hydraulic system can help minimize turbulence and promote smoother, more laminar flow.

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Throttled Valves in Hydraulic Systems

A throttled valve can control the flow rate of a fluid, helping to reduce turbulence and create more laminar flow.

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Air Starvation in Pneumatic Systems

Air starvation in a pneumatic system occurs when there is insufficient air supply to the downstream components, resulting in reduced performance or malfunction.

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Increasing Pipe Diameter in Pneumatic Systems

Increasing the diameter of pipes in a pneumatic system can enhance airflow and reduce the risk of air starvation by lowering pressure drops.

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Predictive Maintenance Programs

Using predictive maintenance programs involves analyzing historical data and current sensor readings to anticipate potential mechanical problems before they occur.

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Sealed Bearings in Electric Motors

Sealed bearings are commonly used in electric motors, particularly those with enclosed housings, to prevent contamination and ensure proper lubrication.

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Key Slot Lubrication for Stepped Shafts

The key slot in a stepped shaft is a critical feature for aligning components, and filling it with grease ensures proper lubrication and prevents damage during bearing installation.

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What document verifies item delivery?

A document confirming the delivery of goods to a specific work site.

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What does a Turbine Trip valve do?

A safety mechanism that shuts down a steam turbine when its speed exceeds a predetermined limit, protecting the turbine from damage.

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How to fix a gearbox shaft oil leak?

The process of replacing a leaking shaft seal in a gearbox, typically involving removing the old seal and installing a new one.

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First step in rotating machinery alignment?

The first step in aligning rotating machinery is to gather the necessary tools, ensuring that all equipment and materials are available for the alignment process.

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What to do if a coupling has excessive clearance?

A solution for excessive clearance in a coupling connecting two shafts, involving replacing the entire coupling or specific components to restore the desired fit.

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How to fix a V-belt jumping off the sheave?

Adjustments to a V-belt's alignment and tension can resolve the issue of the belt jumping off the sheave, ensuring proper function and preventing wear.

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How to start oxy-acetylene gas cutting?

The correct procedure for starting gas cutting with an oxy-acetylene torch involves opening the oxygen valve first, followed by partially opening the acetylene valve, igniting the torch, and then adjusting the flame.

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Procedure to open oxygen valve in oxy-acetylene torch?

When opening an oxygen valve for an oxyacetylene torch, the main cylinder valve should be fully opened first, followed by adjusting the oxygen regulator and finally opening the torch oxygen valve.

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What type of seal is considered "contactless"?

A contactless seal prevents direct physical contact between the rotating shaft and the stationary housing, reducing friction and wear. This type of seal relies on barriers like labyrinth paths or magnetic fields to create a seal.

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What is the correct sequence for replacing an unloading valve?

The steps involved in replacing an unloading valve typically include isolation, workspace preparation, removal of the old valve, inspection and cleaning, installation of the new valve, re-energizing the system, and finally verification of proper operation.

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What is the first step in a laser alignment process?

Rough alignment is the initial step in laser alignment, aimed at bringing the two shafts roughly in line before proceeding with precise adjustments.

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Which NDT methods are considered "Sensatory"?

Sensatory NDT (Non-Destructive Testing) methods utilize various sensing techniques, such as vibration, visual inspection, and ultrasonic sound, to examine components without causing damage.

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What is the process of setting up equipment outdoors?

Setting up equipment outdoors requires a systematic approach, including preparing the base, cleaning the surrounding area, putting the equipment in place, and adding barricades for safety.

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How do you increase the flow rate in a hydraulic system?

Increasing the diameter of the pipe will increase the flow rate in a hydraulic system, allowing more fluid to pass through.

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What PSI is needed to move a 500lb load with a 4-inch cylinder?

To move a 500 lb load with a 4-inch cylinder, the required PSI (pounds per square inch) is calculated by dividing the load by the cylinder's area. In this case, the needed PSI would be 50 psi.

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How should you tighten bolts on an 8-bolt piston head?

Tightening bolts in a star pattern ensures even distribution of force, preventing warping or stress concentration on the component. Tighten each bolt incrementally to the specified torque, rotating in a star pattern until the desired torque is reached.

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Lockout

A safety procedure used to isolate equipment from power sources before maintenance or repair.

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Purge

The process of removing air or other gases from a system or equipment.

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Double Basket Hitch

A hitch that uses two legs of a sling wrapped around a load, forming a basket shape.

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Chain Drive Slack

The minimum and maximum slack allowed in horizontal chain drives to prevent chain wear and damage.

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Operator Logbook

A document used to record the operating history of a machine, including maintenance and repairs.

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Predictive Maintenance

A maintenance approach that aims to identify potential failures before they occur.

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Air Clutch Decommissioning

A maintenance procedure that involves shutting down equipment and removing its cover for cleaning and inspection.

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Gear Teeth Inspection

A method used to check the condition of gear teeth for irregularities or damage.

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Pressure Reducing Valve

A pressure reducing valve regulates the pressure of a fluid flowing through it. It lowers high pressure to a desired lower pressure.

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Pressure Relief Valve

A pressure relief valve is a safety device that prevents excessive pressure build-up in a system. It opens automatically when the pressure exceeds a defined limit, releasing excess fluid to protect components.

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Cushion Adjustment

Cushion adjustment refers to controlling the rate at which a valve opens or closes. This helps prevent abrupt pressure changes and damage to the system.

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Free Check Valve

A free check valve allows fluid to flow in only one direction. It prevents backflow and ensures unidirectional movement.

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Hot Electric Motor

A motor running hot can be caused by low voltage. Insufficient voltage can overload the motor, causing it to overheat.

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Unit of Velocity

The unit of velocity is distance traveled per unit time. Common units include inches per second (in/sec) or millimeters per second (mm/sec).

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Air Starvation

Air starvation in an air compressor happens when there's insufficient air intake. This can be caused by a clogged air filter restricting airflow.

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Pyrometer Replacement

Replacing a pyrometer in a steam turbine requires following safety procedures: lock out the system, isolate the steam, replace the pyrometer, test its performance, and then inform the supervisor.

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Study Notes

MILL 30

  • DOV in figure: 3 Position, 4 Way, Float centre, Manual return.
  • PPE not used with bench grinder: High visibility vest.
  • Correcting horizontal-offset misalignment (fig 2): Move motor from A to B.
  • Steel E rod weight (6 feet length, 4-inch diameter): 514 lb.
  • Overhead structure crane movement: Chain.

Crane Material Movement

  • Material movement by crane: Boom position and hoist position during material movement (load).
  • Crane boom and hoist position during material movement: Boom up and hoist up.
  • Weight on each sling (fig 3): 9205 lb

Crane Signals

  • Crane signal (fig 4): Use main hoist.
  • Crane signal (fig 5): Boom up, load down.

Milling Machine Procedure

  • Milling head squaring procedure: Clean the square mill head, Set the Dial Indicator, Adjust the height of Milling Head, and Tighten the Head Bolts
  • Chemical drum leak procedure: Secure area, stop leakage, transfer material to new drum, refer to SDS, and inform safety panel.
  • Conveyor Belt Length (fig 6): 58 feet.

Equipment Measurements and Readings

  • Depth micrometre reading (fig 8): 2.182.
  • Oil analysis and chromium reasons: Low oil in the reservoir, bearing failure, worm wear, high oil temp.

Conveyor Belt Issues

  • Conveyor issues – uneven movement: Correction at tail pully.
  • Drill bit angle: 118 Deg.
  • Prick punch angle: 20-40 Deg.
  • Part width (fig 9): 15-5/8

Grease Type

  • EP2 grease number 2: Strength number

Oil Types for Equipment

  • Hypoid gear application oil: Mineral oil.

Single Choker Hitch Load

  • 3,000 lb basket hitch capacity, damaged, single choker hitch load: 2,100 lb.

Sling Safety

  • Synthetic web sling usage caution: Water on sling, identification of sling specifications is important
  • Multiple sling safe working load: 720 lb.
  • Oxy-fuel torch cutting procedure: Hold torch tip perpendicular to the cutting piece, then move slowly.

Vessel Pressure Law

  • Vessel pressure law: Pascal's law.

Eye Bolt Lift Angle

  • Shouldered type eye bolt minimum lift angle: 25 deg.

Micrometre calibration

  • Calibration of outside micrometre: Transfer callipers.

Equipment Maintenance

  • Fluid overheating in the tank: Vent blocked
  • Next step after blueing the worm gear: Check the number of teeth.
  • Shaft Keyway enlargement procedure: Refill (weld), machine and use a woodruff key.

Equipment Issues and Procedures

  • Air compressor air starvation reasons: Low voltage, Clogged Air Filter, Low Amp.
  • Steam turbine pyrometer change procedure: Inform supervisor, Lock out, Release steam, replace pyrometer, test

Gear and Material Cutting

  • Gear tooth surface checking method: Dye penetration.
  • Cutting thin gauge materials: Hold torch tip perpendicular to the cutting piece and move slowly
  • Procedure when a shaft keyway is enlarged: Refill, machine and insert a woodruff key

Various Equipment Aspects

  • Welding electrode label meaning: Tensile strength in PSI.
  • Hydraulic system flow rate increase method: Increase pipe diameter.
  • Steel chain minimum rating: 80%.
  • Bridle hitch sling load calculation: 1,1250 lb.
  • Horizontal chain drive slack: 4% minimum and 5% maximum.
  • Conveyor belt maintenance: Cut, loose tension, store, mark in logbook.
  • Reason for 3000 lb basket capacity change to single choker hitch capacity: 2100-2200 lb single choker hitch capacity.
  • Oil color checking method: UV or optical method

Equipment Issues

  • Equipment issues due to high fluid temperature: Fluid overheating, improper fluid type.

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Mill 30 PDF

Description

Test your knowledge on mechanical systems, maintenance procedures, and troubleshooting techniques. This quiz covers topics such as turbine safety, gearbox maintenance, and alignment planning for rotating machinery. Perfect for students and professionals in mechanical engineering or maintenance fields.

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