Question Bank Prof.

Maharshi Bhatt
MAINTENANCE ENGINEERING Mechanical Engineering Dept.
DME409

1. Explain what is maintenance?

“Maintenance is combination of all technical and associated administrative action intended
to retain an item in or restore it to a state in which it can perform its required function.”

“Maintenance is defined as all actions which have an objective to retain an item, or restore
it to, a state in which it can perform the required function. The action include the
combination of all technical and corresponding administrative, managerial, and supervision
actions.”

2. Enlist Various Maintenance strategies.

3. Sectors where Maintenance is required?

4. Who are Maintenance Engineers?

 Maintenance engineers are at the forefront of engineering; they deal with all
equipment maintenance and are responsible for the continuous running of
equipment and machinery.
 They also use specialized computer systems to oversee routine maintenance and
organize any repairs that are needed.

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 Question Bank Prof. Maharshi Bhatt
MAINTENANCE ENGINEERING Mechanical Engineering Dept.
DME409

 As a maintenance engineer, you will be involved in controlling and monitoring

devices, as well as occasionally helping to manufacture items.
 By working alongside other engineering professionals you will have the chance to
improve production facilities, reduce costly breakdowns and develop your own
strategies to help progress reliability and safety within the workplace.

5. What are the Tasks of a Maintenance Engineer?

1. Designing maintenance strategies, procedures and methods
2. Carrying out maintenance work
3. Responding to faults with equipment
4. Diagnosing issues with equipment
5. Fitting new parts and ensuring equipment is working as it should be
6. Carrying out inspections
7. Monitoring maintenance costs
8. Dealing with unplanned issues or repairs, including emergencies

6. What is the need of Maintenance Engineering?

1) To plan and set some quality and usage standards for the staff internally, that too
based upon your asset type. This way the asset will be operated in the appropriate
manner with reduces chances of its misuse and downtime.
2) To conduct careful repairing, when proper consultation is done from the side of
the concerned department. This way your maintenance projects will be properly
scheduled and will determine the need for subcontracting whenever needed.
3) To document all the activities thoroughly. It will make it easier for you to track the
repair history and calculate depreciation for timely disposal. The centralized
system will automatically update the asset records; therefore, you should look for an
online system provider.
4) To complete all the daily tasks and more, within their deadlines in order to stick to
the maintenance plan. This completion of tasks on time will minimize your waste of
repair resources.

7. What is the Importance of Maintenance explain in brief.

• Operator and Machine Safety
By performing regular preventive maintenance, you will always be assured that your
equipment will operate under safe conditions, both for the machine and the operators.
Possible issues can be cut off before it tends to cause any harm, without taking any chance.
• Machine Efficiency
With normal wear and tear, machines can cause lower efficiency. Proper preventive
maintenance management will assure you of the optimal working conditions of the
equipment and moreover, conserves its life span.
• Time Savings
Planned preventive maintenance management will reduce the actual downtime caused by
the breakdown and further enhance the products that too in less time, thereby, saving a lot
of time. Preventative maintenance will consume less time than the time taken in emergency
repairs and replacements.

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 Question Bank Prof. Maharshi Bhatt
MAINTENANCE ENGINEERING Mechanical Engineering Dept.
DME409

8. Enlist the types of Maintenance. Or Write a short note on types of Maintenance. Or

explain in brief different types of Maintenance.
1) Preventive Maintenance
2) Condition-based Maintenance
3) Predictive Maintenance
4) Corrective Maintenance
5) Breakdown Maintenance
6) Reliability-based Maintenance

9. What are the three Ps for maintenance?

10. Difference between PM & BM(Preventive Maintenance and Breakdown Maintenance)

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 Question Bank Prof. Maharshi Bhatt
MAINTENANCE ENGINEERING Mechanical Engineering Dept.
DME409

11. Explain different Maintenance Cost. Or What are the various Maintenance Cost explain.

✔ Repetitive repair or replacement of specific items, such as belts, bearings, motors, filters
etc.
✔ Scheduled routine work, such as oiling, cleaning, housekeeping, and inspection.
✔ Spare-parts production and overhaul.
✔ Planned equipment overhaul.
✔ Building and facility repairs.
✔ Assigned area service.
✔ Planned non-repetitive replacements and repairs
✔ Relocations
✔ Modifications
✔ Equipment improvements

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 Question Bank Prof. Maharshi Bhatt
MAINTENANCE ENGINEERING Mechanical Engineering Dept.
DME409

12. What are the Methods for deciding the Replacement?

1) Total Life average Method
2) Annual Cost Method
3) Present Worth method
4) Rate of return method of replacement
5) MAPI method

• Total Life average Method

• Add the initial cost of machine and its operating expenses.
• Divide figure by the estimated life of the machine to arrive a the average annual
cost.
• Annual Cost Method
• Annual cost method of evaluating alternatives, compares annual costs of obtaining
services from different equipment.
• Annual Cost = Capital Recovery + Operating Cost
• Present Worth Method:
• This method of comparing alternatives, consists of reducing all receipts and
expenditures for each alternative equipment is a present worth basis.
• While using this method, one should make sure that equal services are being
compared.
• Rate of Return Method
• Rate of return method calculates a rate of return which is then examined for
adequacy.
• Interest costs are not accounted and therefore the resulting figure is known as
unadjusted of return.

• MAPI Method:

• Research done by Machinery and Allied Products Institute of Washington, D.C. has
done a lot of thinking and the subject of equipment replacement.

• MAPI formula might characterized best as an adjusted after tax rate of return
criterion.

• Critical requirement of MAPI method is costs should be based on the process and
system performance. In other words, costs of individual facility should not be
measured in isolation from the system.

• Comparison is based on one year, ten year, twenty year etc.

13. Explain Replacement Theory.

Or Write a short note on Replacement Theory.
Or Define replacement.
 “The Replacement Theory is concerned with the prediction of replacement costs,
and the determination of the most economical replacement policy. “
 It is concerned with equipment and machinery that deteriorate with the passage of
time.

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 Question Bank Prof. Maharshi Bhatt
MAINTENANCE ENGINEERING Mechanical Engineering Dept.
DME409

 It is decided to replace an equipment when maintenance and capital costs of

defender equipment is more than average operating costs of replacement.
 Replacement Situations can be categorized into the following four categories:
a. Deterioration
b. Obsolescence
c. Inadequacy
d. Working Condition

 Replacement Theory – Deterioration:

 It is the decline of performance of an equipment as compared to a new equipment
identical to present one.
 Deterioration may be due to wear & tear, misalignment etc.
 It has following effects:
o Increases maintenance cost
o Reduce product quality
o Decrease rate of production
o Causes losses in operating time
o Increase labor costs
o Reduce efficiency of the equipment
 Replacement Theory – Obsolescence

• Newer and better equipment's are being developed and turned out every year.
• If management of concern does not go for change in the equipment or machinery,
the unwarranted costs arising from obsolete equipment will
• Reduce Profits
• Impair The Concern’s Competitive Position In Market
• Obsolescence causes loss In value of machinery.

 Replacement Theory – Working Condition

• It may be thought of replacing an old equipment's and machinery which create unpleasant
i.e. smoky, noisy and hazardous conditions causing worker unsafety and leading to
accidents.

 Replacement Theory – Inadequacy

• When an existing machine becomes inadequate to meet challenge of making new products
or existing product in large quantity, replacement can be considered.
• An existing pit furnace can be replace by cupola to increase the production rate.
• Normal milling machine is not able to produce gears in large scale

14. Define and Explain Corrosion.

Definition:
Corrosion is the destruction of solid metallic materials through unwanted chemical attack by
environment.
Example :
1. Formation of reddish scale (Ferrous Oxide-Fe3O4) when iron is exposed to atmospheric
condition.

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 Question Bank Prof. Maharshi Bhatt
MAINTENANCE ENGINEERING Mechanical Engineering Dept.
DME409

2. Formation of green film of basic carbonate (CUCO3+CU(OH)2) on the surface of the copper
when exposed to moist-air condition.

15. What are the FACTOR AFFECTING CORROSION. Or Enlist the FACTOR AFFECTING
CORROSION. Or Explain in brief FACTOR AFFECTING CORROSION. Or Write a short note
on FACTOR AFFECTING CORROSION.
• Following factors affect the corrosion.
(i) Position in galvanic series
(ii) Relative area of cathode and anode.
(iii) Purity of metal.
(iv) Physical state of metal.
(v) Temperature.
(vi) Humidity of air
(vii) Influence of PH
(viii) Polarization of electrodes
(Note: As per marks contain explain each factors briefly.)

16. Write a short note on TYEPS OF CORROSION. Or write down TYEPS OF CORROSION.
1) Uniform corrosion
2) Pitting corrosion
3) Transgranular and Intergranular (Intercrystalline ) corrosion
4) Exfoliation corrosion
5) Stress corrosion
6) Crevice corrosion
7) Galvanic corrosion
8) Erosion
(Note: As per marks contain explain each factors briefly.)

17. What is Corrosion Control explain in brief. Or Write a short note on Corrosion Control.
 Use of high purity metals
• Impurities causes heterogeneity which decrease the corrosion resistances.
• High purity metals will have homogeneous grain structures which will prevent corrosion.
• High purity metals have a improved protective oxide film which will prevent penetration of
the corrosion.

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 Question Bank Prof. Maharshi Bhatt
MAINTENANCE ENGINEERING Mechanical Engineering Dept.
DME409

 Protective Coating
• A coated surfaces isolates underlying metal surfaces from the exposed corrosive
environment.
 Anodic Coating:
• Produced from the coating-metals which are “anodic” to the base metal.
• Example : Coating of zinc, al etc. on iron surface.
• As Zinc, Aluminum etc. are more anodic than iron (base metal), coating metal becomes
anode and base metals become cathode so corrosion of the base metal can be avoided.
 Cathode Coating
• Cathodic coatings are obtained by coating a more noble metals than base metals.
• They protect base metal as they have higher corrosion resistance than base metal.
• It provides continuous protection when it is free from cracks/breaks.
• Example : Tin coating on iron.
• If tin coating is punctured tin will become cathode and iron will become anode and severe
corrosion occurs.
 Cathode Coating
• Cathodic coatings are obtained by coating a more noble metals than base metals.
• They protect base metal as they have higher corrosion resistance than base metal.
• It provides continuous protection when it is free from cracks/breaks.
• Example : Tin coating on iron.
• If tin coating is punctured tin will become cathode and iron will become anode and severe
corrosion occurs.
 Inhibitors
• It is a substance which when added to the corrosive environment , effectively decreases the
corrosion of the metals.
• Anodic Inhibitors : Example chromates, phosphates, tungstate's forming a protective film on
metal surface and hence reduces corrosion.
• Cathodic Inhibitors : Example amines, mercaptans slowing cathodic reactions.
• Natural Inhibitors : Example Zn, Ni etc.
 Use of Special Alloys:
• Metals which are alloyed with cobalt, nickel, copper, chromium etc. are having higher
corrosion resistance.
• Example : Steel containing 13% chromium is best alloys for medical surgical instruments.
 Proper designing:
• Avoid contact of two different material in corrosive environment.
• When two dissimilar metals are in contact large anodic and small cathodic are combination
is preferred.
• For dissimilar materials in contact, they should be close in electrochemical series.
• Crevices to be avoided.
• Sharp corners should be avoided to reduce residual stresses.

18. What is Breakdown Maintenance?

19. What are the common challenges in Breakdown Maintenance?

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 Question Bank Prof. Maharshi Bhatt
MAINTENANCE ENGINEERING Mechanical Engineering Dept.
DME409

20. Write down the advantages of Breakdown Maintenance.

21. What are the types Of Faults In Machine Tools?
• Wear or breakage of the parts.
• Overheating of the parts and units.
• Poor running condition of the machine.
• Vibration and noise produced during operation.
• Poor condition of the prime-mover.

22. What is Periodic Inspection?

23. What are the factors considered in Periodic Inspection?
• Age of the machine tools
• Nature of production
• Skill of the operator
• Number of production cycles
• The type of machine tool
• Repair complexity of machine tool
• Repair scheme applicable
• Total time duration of a repair cycle
• Different stages in adopted repair cycle
• Work involved in each stage

24. Define /Explain (1) Degreasing & (2) Cleaning.

25. Mention the need Of Cleaning the Parts.
26. Write down the Procedure of Periodic Inspection.
27. Explain various Repair Schemes. Or Explain Repair cycle.
28. Explain / Define: Repair Complexity.
29. Explain Overhauling - Dismantling Sub Assemblies.
30. Explain Maintenance of pumps.
31. Explain Maintenance Of Compressor.
32. Explain Maintenance Of D.G. Sets.
33. What is Tribology?
• Derived From the Greek word ‘tribos’ means rubbing or sliding.English equivalent
name is friction and wear or lubrication science.
• It focuses on friction, wear and lubrication of interacting surfaces in relative motion.
It is applied to an operational analysis to problems of great economic significance.
34. Explain the Need of Tribological study.
• To minimize and eliminate losses.
• Greater efficiency, performance, fewer breakdowns & savings.
• Study various losses and analysis of losses.
• Reduce losses by introducing a layer of lubrication.
• Atomic and molecular observations on sliding surfaces.
35. Enlist various terms in Tribology.
• Wear & Various types of wear
• Friction
• Lubrication & Various types of lubrication

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 Question Bank Prof. Maharshi Bhatt
MAINTENANCE ENGINEERING Mechanical Engineering Dept.
DME409

36. Explain types of wear.

37. What are the types of lubrications?

38. TRIBOLOGICAL INSTRUMENTS

TRIBOMETER
 Measures tribological quantities, such as
 coefficient of friction,
 friction force,
 wear volume.
 Invented By- Dutch scientist Musschenbroek.

39. What are the advantages of reducing friction and wear?

40. Explain Maintenance of pumps.
41. What are the technologies applied for condition monitoring.
42. Explain the failure modes for fault detection.
43. Explain the general rule-of-thumb for testing of insulation of the equipment.
44. Write down the benefits of Condition Monitoring? Why it is needed?
45. Explain the Ultrasonic analysis technique for condition monitoring.
46. Write a short note on Motor Current Signature Analysis.
47. Draw a periodic maintenance chart for CNC turning machine.

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 Question Bank Prof. Maharshi Bhatt
MAINTENANCE ENGINEERING Mechanical Engineering Dept.
DME409

48. Explain Maintenance of D.G. Sets.

49. Explain Control of Defeat in brief.
50. What are the types Of Faults In Machine Tools?
51. What are the technologies applied for condition monitoring.
52. Explain the failure modes for fault detection.
53. Which is the main type of Unplanned maintenance? Explain.
54. Explain in your word: what do you mean by winding insulation resistance.
55. Explain the Vibration analysis technique for condition monitoring.
56. Write a short note on Thermo graphic Analysis.
57. Draw a periodic maintenance chart for TIG welding machine.
58. Define:
Fault: The partial or total failure of a device.
Detection: The ability to recognize the functional ability of a device.
Consequence: Something produced by a cause or following from a set of conditions.
Prevention: The ability to overcome an undesirable outcome from a given set of
conditions or circumstances.
59. Explain fault detection Methods.
60. What are the six key steps to approach electrical fault finding?
 Here are six key points to consider:

Collect the Evidence

All the evidence collected must be relevant to the problem at hand. If one is in doubt
as to whether anything is relevant, then include it. Reject it afterwards at the first
opportunity if it clearly is not relevant. The quantity of information collected is
unimportant, what matters is that all information collected is relevant. Observe the
system running, if you consider it safe to do so. Use all your senses: smell (burning),
hearing (vibration), touch (temperature), sight (for unusual conditions). Refer to any
relevant documentation.

Analyse the Evidence

Consider all the evidence collected and, if possible, reject any which after further
careful consideration is not relevant. Study the hardcore of relevant evidence and –
through the process of careful, logical thinking –diagnose the likely fault or at least
the area or region of the fault.

Locate the Fault

In a sense, this is a continuation of the process of ‘analysis’. The areas or regions are
systematically reduced in size until a specific part can be identified as being faulty.
For example, if a doorbell does not ring when it should, it is only by means of a
systematic approach that one determines that the bell itself is faulty.

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 Question Bank Prof. Maharshi Bhatt
MAINTENANCE ENGINEERING Mechanical Engineering Dept.
DME409

Determination and Removal of the Cause

If the cause of a fault is not removed, the fault will recur even though the fault has
been rectified. For instance, a flat bicycle tyre might be the result of a puncture (the
fault) in the inner tube. If the puncture is repaired (i.e. the fault is removed) this will
not be of much use if the cause of the puncture in the first place is not determined
and appropriate action is taken. The cause of the puncture may be a nail that has
penetrated the outer cover. This must be removed.

Rectification of the Fault

This may be a simple task, as in the case referred to above, or it may be a much
bigger one. Whatever is the case, it is a specific task based on earlier findings.

Check the System

It is important to ensure that the machine, equipment or system is functioning

normally after the cause of the fault and the fault itself has been dealt with. In the
case of the puncture, it is easy to confirm that the cause of the fault – and the fault
itself – has indeed been dealt with satisfactorily, assuming that the tyre remains
inflated. With more sophisticated equipment or systems, it may necessary to ‘fine-
tune’ the system in order to return it to optimum working conditions.

61. Explain the visual analysis for condition monitoring.

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