Discuss the all repair methods of bearing?

Failure Condition Cause Solution

Rolling fatigue, Avoid installation error

Raceway surface is overload, poor shaft or increasing viscosity of
Flaking flaked and look housing accuracy, lubricant and adequate
very rough installation error, lubrication.
rusting
Occur in roller Controlling surface
Is a cluster of small bearings, if mating roughness and dust,
Peeling
spalls surface is rough and proper selection of
poor lubrication. lubricant
Adopting improved
Scratches in Poor mounting and mounting and
spinning direction removing practice, removing procedures,
Spalling on raceway surface slippage of rolling correction of preload,
and rolling contact elements, oil film proper selection of
surfaces discontinuation lubricant and
lubricating systems
By making sound oil
Smearing Slippage of rolling film, using extreme
Surface is
elements due to poor pressure lubricant,
roughened an tiny
lubricant precautious on radial
particles adhere
characteristics clearance and preload
to avoid slippage
Worn surfaces and Selecting optimum
reduced dimensions Ingress of solid lubricant and
Stepped wear compared to other foreign objects, poor lubrication
. portions, mostly lubrication and system filtering
roughed and skewing of rollers. lubricating oil avoiding
scored misalignment.
Speckles: Improving
sealing efficiency,
Poor lubrication, filtration of oil,
Clusters of tiny dents deposition of effective lubrication
Speckles and
and surface deteriorated oil on system discolouration:
discolouration
colour change surface, ingress of wiping out oil
solid foreign objects deposition by organic
solvents, polishing with
sandpaper
 Partial chipping of Impact of excessive Improved sealing
inner, outer ring load poor handling characteristics, better
Chipping handling, avoiding
and rolling trapping of large solid
elements foreign objects. impact
or excessive loading.
Splits, and cracks Preventing creep.
Excessive load and Correction of fit
Craking in bearing rings and impacts very loose
rolling elements avoiding
fitting large flaking impact and heavy load
Way in for water and Effective sealing,
corrosive materials periodic
Rusting and (acid) condensation of lubrication of
Rust and corrosion corrosion of moisture in air, poor lubricating
bearing surfaces packaging and storing oil, carefully handling
conditions. bearing.

Effective heat
Due to heat, Low heat dissipation, dissipation
disabled spinning, poor lubrication, selecting suitable
discolouration, improper lubricant, lubricant and optimal
Seizing softening and very small clearance, lubricating feed rate,
welding of raceway excessive load and avoiding mis-
surfaces ad rib roller skewing and alignment,
surface. installation error. enhanced operating
conditions.

What are the causes of failures in an electromechanical system like compressor,

pumps and elevators.

Causes of failures in compressors:

 Lack of lubrication due to low oil level
 Overheating of components due to poor air flow/poor heat transfer and poor
ventilation
 Improper mounting of compressor due to incorrect levelling of floor during
installation or loose floor mountings
 Filter damage due to bad atmospheric condition
 Loose pulley, flywheel, belt, belt guard, cooler, clamps or accessories
which may cause excessive noise.
 Water entering in oil reservoir due to compressor operating in high
humidity environment
 Wrong fuse size.
Causes of failures in pump:
 Using low-quality fluids and poor contamination control
 Failure of seals and hence leakage of fluid
 Cracked or bent pulleys due to improper handling or installation
 Shaft breakage due to bearing overload
 Improper mounting of pumps due to incorrect levelling of floor during
installation or loose floor mountings.
 Pump housing or casting breakage due to excessive vibration
 Undersized shaft in an end suction pump
Causes of failures in elevators:
 Sudden stops & abrupt landings
 Poor scheduled maintenance
 High fluctuation in electrical power supply
 Overloading the elevators frequently
 Poor system circuit design
 Malfunctioning of electronic circuits and sensors due to high moisture
 Overheating of the drive and control system
RELIABILITY = SAFETY
 Many accidents occur without any component “failure” – Caused by equipment
operation outside parameters and time limits upon which reliability analyses are
based. – Caused by interactions of components all operating according to
specification. – Highly reliable components are not necessarily safe. For relatively
simple, electro-mechanical systems with primarily component failure accidents,
reliability engineering can increase safety. But this is untrue for complex,
software-intensive or human-intensive systems

Explain the repair methods for crane hydraulic lift and belt conveyor?

The proper maintenance of material handling equipment is extremely essential for

preventing the occurrence of bottle neck or points of congestions production line
flow can be maintained only if the material handling equipments is in proper
working order.
 Out of money maintenance techniques available preventive maintenance is one of
the best maintenance techniques suggested in case of material handling
equipments.
 Preventive maintenance helps to keep the material handling equipments always
running conditions there by minimizing the interruption during operation. A
periodic inspection and minor alignments may be adequate to prevent the
equipment breakdown.
 Preventive maintenance also includes lubrication adjustment and repair. There are
three stages of preventive maintenance and they are
Inspection
Repair and
Overhaul Maintenance strategies for hoists and cranes.
1. Portable cranes:
The major issues covered in maintenance of portable cranes and cranes are,
 It is necessary to keep loads within design limits on portable cranes
that are mounted on wheels or wheeled platforms
 Frequent inspection of brakes, load hoisting and lowering
mechanism.
 Inspection of boom, base and platform for any sign of stress e.g.,
cracks, bends, breaks.
2. Overhead cranes:
The major issues covered in maintenance of overhead cranes are,
 Keep the attachments in overhead cranes loaded within the rating
capacity.
 Maintain safety factors for replacement parts according to
manufacturer’s specification.
 Keep rail level grounded, properly aligned, properly spaced, and
securely attached to the supporting structure, free of beading and
bends.
 Examine over speed sensing mechanisms, brakes and clutch,
sheaves, pins, gears, cables, hooks, rails, etc,. For wear and
maladjustment
 Check welded connections for cracks, bends, abrasion and corrosion.

Discuss about how to maximize friction clutch and brakes?

“How long will it last?” It’s often the first question we’re asked when helping our customers specify a
friction clutch or brake. And the answer is always, “It depends.” We’ve seen severe applications where
clutches and brakes require replacement wear parts after a few weeks and other applications where they
last decades with no maintenance at all.

If you want to maximize the service life of friction clutches and brakes in your industrial machines,
here’s an overview of the design, installation and maintenance factors you should keep in mind:

Start with the application details. The most important factor in assuring the maximum service life of a
clutch or brake is choosing the right unit for the job based on application details such as cycle rates,
revolutions per minute and the torque needed to drive or stop the load. For selection assistance, it’s a
good idea to ask for a review by an application engineer at your clutch or brake manufacturer.

Factor in safety. When sizing a friction clutch or brake, add torque service factor to ensure the clutch or
brake will have the required torque to drive or stop the load. A service factor of 1.5 to 2 — or 50 to 100
percent more torque than required — is recommended by most clutch and brake manufacturers.

Follow the speed limits. Adhere to the manufacturer’s maximum RPM rating, because excessively high
RPM can significantly reduce the life of clutch and brake components such as bearings and linings. The
wear effects of rotational speed are particularly pronounced in high-cycle applications. Larger clutches
may need precision balancing.

Get some clean air. The quality of compressed air affects the service life of clutches and brakes. It’s
important to use only filtered air to eliminate particulate contamination, which can result in worn sealing
components and hinder proper cycling of cylinder-piston assemblies. And air needs to be regulated to
match supply and demand. If a clutch or brake does its job at 50 psi, don’t operate it at 80 psi. Using the
lowest workable pressure will maximize bearing life. Also, if a clutch is transmitting more torque than
necessary, the unit may overdrive the system further down the drive train, leading to the breakage or
wear of other machine components.

Install it right. Following installation instructions is a critical factor in assuring maximum wear life.
Common mistakes include mounting the clutch or brake in the wrong orientation and incorrectly
installing anti-rotational restraints so that they apply axial force to a clutch, inducing bearing or lining
wear.  Misalignment in shaft-to-shaft applications can impair clutch or brake function and cause
premature wear. If both angular and offset alignment of the shafts cannot be achieved, a flexible
coupling is recommended.

Keep chains and belts in order. Chains and belts that are poorly aligned or tensioned are another source
of wear and service-life reduction. Chain misalignment, for example, can cause bearing and bushing
wear in the pilot of a clutch or clutch-brake. It can also cause sprocket wear. And some misalignment
scenarios can result in the clutch moving axially, potentially allowing it to walk off the shaft. Excessive
chain or belt tension likewise causes pilot-bearing and sprocket wear — and can allow clutches to
continue to be driven when disengaged.

Environment matters. Friction clutches and brakes run best when free from contamination — whose
sources include lubricants, brake cleaners, solid particulate and moisture. All of these contaminants can
contribute to premature wear or even reduced functionality. For example, contaminants on a clutch drive
surface may prevent the unit from full engagement, which can lead to wear and inconsistent torque
output. Contact your clutch or brake manufacturer for advice on units that must run in particulate or
moisture rich environments. Covered and sealed units that will shield against these contaminants are
often available.
Discuss about different types of pipe fittings?

Pipe fittings are used to attach pipes together, and the type of fitting is determined by its function. Since
every system is different, the fittings and accessories you need may vary in material, size or usage
requirements. Consider your needs to help select the correct fitting. Are you extending a pipe, changing
directions or trying to reduce water flow?
Explore the most common pipe fittings and their uses:
Type Use Example

Extends or changes connection

Adapter
type at the end of a pipe

Bushing Joins pipes of various sizes

Cap Covers the end of a pipe

Straight fitting used to make

Coupling
permanent pipe connection

Elbow Changes direction of flow

 Fits inside pipes to extend the
Extender
length

Plug Fits inside to seal pipes

Reducer Changes pipe size 

Combines fluid flow from

Tee
multiple branches

Helps easily connect and

Union
disconnect pipes

Valve Stops or regulates the flow 

What are the steps for installation of a machine of equipment?

PLANNING AND PREPARATION

The first step to equipment installation is planning and preparation.

This stage includes site evaluation, assessment of equipment needs, and obtaining necessary permits
and approvals.

During site evaluation, millwrights should thoroughly assess the job site to ensure it is suitable for the
equipment to be installed. This includes looking at the foundation where the equipment will be placed.

They also assess the client's equipment needs to ensure that the right equipment is selected and will
function properly in the intended environment.

After the site evaluation and assessment of equipment needs, the millwright will create a detailed
installation plan outlining the steps to take during the installation process.

This plan includes a schedule of when the equipment will be delivered and installed, who will be
responsible for each task, and how long the installation will take.

Finally, the necessary permits and approvals must be secured to ensure the installation complies with
all local regulations and safety standards.

By thoroughly planning and preparing for the installation process, millwrights can ensure the
installation is completed safely, efficiently, and to the highest standards.

EQUIPMENT ARRIVAL AND UNLOADING

The second step is the equipment arrival and unloading.

This process includes coordinating equipment delivery, unloading, and inspecting equipment for
damage or defects.

Millwrights will work with clients and equipment suppliers to coordinate the delivery of the equipment
to the job site.

This helps ensure that the equipment arrives on time.

After the equipment is unloaded, it is thoroughly inspected for signs of damage like dents, scratches, or
other issues that may have occurred during transportation.

If any issues are found, the millwright will work with the supplier to resolve them before proceeding
with the installation process. 
  

EQUIPMENT ASSEMBLY AND TESTING

The next phase is the equipment assembly and testing phase.

This step includes assembling equipment according to the installation plan, testing it to ensure proper
function, and identifying and resolving issues that arise during testing.

Once the assembly is complete, millwrights will run tests to check the equipment's performance,
including electrical, mechanical, and pneumatic systems.

They will also make sure the equipment is properly aligned and calibrated. 

Any issues that arise during testing are identified and resolved.

EQUIPMENT INSTALLATION AND COMMISSIONING

The installation and commissioning step is the final phase in the equipment installation process.

This phase includes physically installing equipment at the job site, commissioning equipment to ensure
proper operation, and training personnel on the appropriate use and maintenance of the equipment.

They also ensure that the heavy machinery is aligned correctly and calibrated for optimal performance.

After installing the equipment, the millwrights commission it to ensure it operates correctly.

A series of tests are done to check for proper alignment and calibration of equipment. 

Finally, the personnel is trained on the proper use and maintenance of the equipment. 

FOLLOW-UP AND MAINTENANCE

After successfully installing equipment, ensuring it continues functioning properly in the long term is
essential.

The follow-up and maintenance step includes the following:

 ongoing maintenance and support of the equipment

 scheduled check-ins to ensure equipment is functioning properly
 identification and resolution of any issues that arise in the future
Completing regular check-ups, cleaning, and replacing worn or damaged parts is important to make
sure your equipment runs optimally for as long as possible.