Basic Mechanical Maintenance

Bokaro Steel Plant

Workshop

Human Resource Development Department

Aim of the Programme

On completion of the Programme Participants will be able to….

➢ Carry out basic mechanical maintenance work

➢ Find out correct symptoms of mechanical defects

➢ Identify the faulty bearing and their fitment

➢ Examine the coupling and separating them on requirements

➢ Examine and correcting the Key fitting

➢ Assemble and disassemble of small centrifugal pump

➢ Find and correct the mechanical fault of DC brake.

MAINTENANCE

➢ The act of maintaining or the state of being maintained.

➢ The work of keeping something in proper condition; upkeep.

➢ care or upkeep, as of machinery or property: With proper maintenance. The

plant or any system will last for many years.

➢ Any activity – such as tests, measurements, replacements, adjustments and

repairs — intended to retain or restore a functional unit in or to a specified

state in which the unit can perform its required functions.

➢ For material — all action taken to retain material in a serviceable condition or

to restore it to serviceability. It includes inspection, testing, servicing,

classification as to serviceability, repair, rebuilding, and reclamation.

➢ All actions necessary for retaining an item, or restoring to it, a serviceable

condition, include servicing, repair, modification, overhaul, inspection and

condition verification

➢ Increase availability of a system

➢ Keep system’s equipment in working order

➢ Maintenance is a set of organised activities that are carried out in order

to keep an item in its best operational condition with minimum cost

acquired.
PURPOSE OF MAINTENANCE

➢ To keep equipment/system operative.

➢ Attempt to maximize performance of production equipment efficiently and

regularly

➢ Prevent breakdown or failures

➢ Minimize production loss from failures

➢ Increase reliability of the operating systems

➢ To keep operation safe

➢ To prevent leakages/losses

OBJECTIVES IN MAINTENANCE

➢ To achieve product quality and customer satisfaction through adjusted and

serviced equipment

➢ Maximize useful life of equipment

➢ Keep equipment safe and prevent safety hazards

➢ Minimize frequency and severity of interruptions

➢ Maximize production capacity – through high utilization of facility

TYPES OF MAINTENANCE

Generally, maintenance is classified into four categories:

➢ Preventive maintenance

➢ Corrective or Breakdown maintenance

➢ Scheduled maintenance

➢ Predictive (Condition-based) maintenance

There are also some other types of maintenance

➢ Operational Maintenance

➢ Reliability Centered Maintenance

➢ Improvement Maintenance (IM)

PREVENTIVE MAINTENANCE

➢ Principle –“Prevention is better than cure”

➢ Procedure - Stitch-in-time

➢ Preventive maintenance is maintenance performed in an attempt to avoid

failures, unnecessary production loss and safety violations. where equipment

is maintained before break down occurs. This type of maintenance has many

different variations and is subject of various researches to determine best and

most efficient way to maintain equipment. Recent studies have shown that

Preventive maintenance is effective in preventing age related failures of the

equipment.

For random failure patterns which amount to 80% of the failure patterns,

condition monitoring proves to be effective.

 ➢ It Locates weak spots of machinery and equipments

➢ Provides them periodic/scheduled inspections and minor repairs to reduce

the danger of unanticipated breakdowns.

ADVANTAGES OF PREVENTIVE MAINTENANCE

➢ Reduces break down and thereby down time

➢ Less odd-time repair and reduces over time of crews

➢ Greater safety of workers

➢ Lower maintenance and repair costs

➢ Less stand-by equipments and spare parts

➢ Better product quality and fewer reworks and scraps

➢ Increases plant life

➢ Increases chances to get production incentive bonus

CORRECTIVE or BREAKDOWN MAINTENANCE

Corrective or Breakdown maintenance implies that repairs are made after the

equipment is failed and cannot perform its normal function anymore.

➢ Corrective maintenance can be defined as the maintenance which is required

when an item has failed or worn out, to bring it back to working order.

Corrective maintenance is carried out on all items where the consequences of

failure or wearing out are not significant and the cost of this maintenance is

much greater than Preventive maintenance.

DISADVANTAGES OF CORRECTIVE MAINTENANCE

➢ Breakdown generally occurs inappropriate times leading to poor and hurried

maintenance

➢ Excessive delay in production & reduces output

➢ Faster plant deterioration

➢ Increases chances of accidents and less safety for both workers and

machines

➢ More spoilt materials

➢ Direct loss of profit

➢ Cannot be employed for equipments regulated by statutory provisions e.g.,

cranes, lift and hoists etc.

SCHEDULED MAINTENANCE

➢ Scheduled maintenance is a stitch-in-time procedure and incorporates

❖ inspection

❖ lubrication

❖ repair and overhaul of equipments

➢ If neglected can result in breakdown

➢ Generally followed for:

❖ overhauling of machines

❖ changing of heavy equipment oils

 ❖ cleaning of water and other tanks etc.

PREDICTIVE (CONDITION-BASED) MAINTENANCE

➢ In predictive maintenance, machinery conditions are periodically monitored

and this enables the maintenance crews to take timely actions, such as

machine adjustment, repair or overhaul

➢ It makes use of human sense and other sensitive instruments, such as audio

gauge, vibration analyzer, amplitude meter, pressure, temperature and

resistance strain gauges etc.

➢ Unusual sounds coming out of a rotating equipment predicts a trouble

➢ An excessively hot electric cable predicts a trouble

➢ Simple hand touch can point out many unusual equipment conditions and

thus predicts a trouble.

OPERATIONAL MAINTENANCE

➢ Where equipment is maintained in OPERATING CONDITION.

➢ Operational maintenance is the program focused on the regular task that will

maintain all the critical machinery and the system in optimum operating

conditions.

The major objectives of this maintenance is to

1.Eliminating breakdown

2.Eliminating deviation

3.Eliminating unnecessary repairs

4.Optimize all the critical planned system

TOOLS & EQUIPMENTS W.R.T. MAINTENANCE

➢ Measuring Instruments

❖ Standard Steel Rule

❖ Measuring Tape

❖ Calipers

➢ Instruments w.r.t. removal & installation of components

❖ Hammers

❖ Pliers

❖ Spanners

❖ Screw Drivers

➢ Instruments w.r.t. carry out inspection of components, parts & assembly

❖ Vernier Caliper

❖ Micrometer

❖ Dial Test Indicator

❖ Feeler Gauge

MEASURING INSTRUMENTS

❖ A measuring instrument is a gadget for measuring a physical amount. In the

physical sciences, quality confirmation and engineering, estimation is the

 movement of getting and contrasting physical amounts of certifiable items and

events.

❖ Least Count shows the level of precision of estimation that can be

accomplished by the measuring instrument.

STANDARD STEEL RULE:

❖ Steel Rule is a flat and thin linear measurement instrument. It is the most

commonly used measuring instrument. Steel rule is manufactured from

stainless steel. The edges of the rule are accurately ground to form straight

edges.

❖ Steel rules are available in different sizes like 150 mm, 300 mm and 600 mm.

usually; the reading accuracy is around 0.5 mm.

MEASURING TAPE:

➢ A tape measure or measuring tape is a flexible ruler used to measure size

or distance.

➢ It consists of a ribbon of cloth, plastic, fibre glass, or metal strip with linear-

measurement markings. It is a common measuring tool. Its design allows for a

 measure of great length to be easily carried in pocket or toolkit and permits

one to measure around curves or corners.

➢ Tape measures are often designed for specific uses or trades. Tapes may

have different scales, be made of different materials, and be of different

lengths depending on the use it is intended for.

CALIPERS:

➢ A caliper is a device used to measure the distance between two opposite

sides of an object. A caliper can be as simple as a compass with inward or

outward-facing points. The tips of the caliper are adjusted to fit across the

points to be measured and then the caliper is removed and distance read by

measuring between the tips with a measuring tool, such as a ruler. In general,

there are two types of calipers used in measurement: -

❖ Inside Caliper: It is used for internal measurement of objects

❖ Outside caliper: It is used for external measurement of objects

INSTRUMENTS W.R.T. REMOVAL & INSTALLATION OF COMPONENTS

Hammers:-

A hammer is a tool consisting of a weighted "head" fixed to a long handle that is

swung to deliver an impact to any area of an object. Hammers are used for a wide

range of driving, shaping, taping of components, parts of a assembly for

removal/insertion and breaking applications.

The modern hammer head is typically made of steel which has been heat treated for

hardness, and the handle (also known as a haft or helve) is typically made of wood

or plastic.

TYPES OF HAMMERS: -

Sledge Hammer: A sledge hammer is a tool with a large, flat, often metal head,

attached to a long handle. The long handle combined with a heavy head allows the

sledgehammer to gather momentum during a swing and apply a large force.

Hand Hammer: The hammer which weigh upto 2 Kg known as hand hammer and

used for driving nails, fitting/disassembly of parts and all other general applications.

Soft Hammer/Mallet: A soft-faced hammer or mallet is a hammer designed to offer

driving force without damaging surfaces. It is used on finished surface or places

where lighter impact is needed.

SPANNERS

Spanners have jaws or openings which can fit into hexagonal or square nuts and

bolts and used for opening or fixing components/parts of assembly.

The following spanners are typical of those used during maintenance activities.

➢ Open end spanner

➢ Socket spanner

➢ Ring spanner

➢ Adjustable spanners

➢ Torque wrench

➢ Ratchet spanners

OPEN END SPANNERS

These spanners are open at both ends.

These spanners are very helpful when it is

difficult to place the spanner over the bolt

head or due to some obstruction in the way.

SOCKET SPANNERS

These spanners are open at both ends.

These spanners are very helpful when it is

difficult to place the spanner over the bolt

head or due to some obstruction in the way.

RING SPANNERS

Ring spanners are generally accessible with

angled shanks. They come in the form of a

ring and greater force may be applied for

removing difficult or “frozen” nuts.

COMBINATION OPEN END & RING

SPANNERS

In these spanners, ring side opening is used

to loosen the nut and the open end side is

used to tighten the nut.

ADJUSTABLE SPANNERS

Adjustable spanners are like open end

spanners, but they are carrying one

moveable jaw.

TENSION / TORQUE WRENCH

A torque wrench is used where the tightness of bolts and screws is critical. An

operator can also measure the torque applied to the fastener by this tool, so that the

applied torque match to the required specifications for a particular application. This

allows correct tension and loading of all parts.

RATCHET SPANNERS

The ratchet spanner is used in conjunction with sockets and a wide range of socket

accessories. Ratchet spanners are useful because they don’t need to be removed

from the head and relocated every time the limit of the turning arc is reached, like

non-ratcheted spanners. They are turned back and forth repeatedly but the nut is

only turned in one direction. This saves time and Its generally useful at narrow

places.

Finding Spanner Size from Bolt Diameter

PLIERS

Pliers are gripping tools mostly used to hold small components that would otherwise

be difficult to grasp and control. Pliers are also used for shaping and bending light

sheet metal as well as bending, twisting and cutting small diameter wires.

Types of pliers are:

1. Combination Pliers- Standard engineers’

pliers are also called combination pliers

because of their versatility.

2. Slip joint Pliers - Slip joint, multigrips

pliers have a shaped pivot pin which can fit

into two or more openings in the legs. This

gives a range of jaw openings which allows

parallel gripping by the jaws in a number of

positions.

3. Diagonal Cutting Pliers- Another name

for diagonal cutting pliers is ‘side cutters’.

These pliers are made with the jaws

cranked, or offset, that is, they are set at an

angle which allows wire to be cut close to a

surface or in confined spaces.

SCREW DRIVER

The screwdriver is a driving tool with a blade fitted to a handle.

The tip of the blade is shaped to fit in to the head of a screw and, when turned, will

either tighten or loosen the screw.

Standard screwdrivers are made with tips to turn screws with slotted heads. The size

of screwdrivers is specified by the length of the blade and the width of the tip; they

vary from 45mm x 3mm to 300mm x 10mm. The light duty screwdriver is made with

parallel tips and may be used by electricians. The steel blade, as well as the handle,

is insulated with plastic.

Instruments w.r.t. carry out inspection of components, parts & assembly

All such instruments which we need for checking the assemblies, components, parts

or sub parts of any mechanical systems. These are the important tools to confirm the

serviceability of mechanical equipments.

Vernier caliper:-

➢ A Vernier Caliper is a precision measuring instrument used to measure inside

and outside diameter of shafts and thickness of parts having accuracy of

0.02mm.

➢ The vernier calipers measure reading of the distance directly with precision

and high accuracy. These calipers consist of calibrated scale with fixed jaw

and movable jaw with a pointer.

 ➢ The Least Count of a Vernier Caliper can be calculated using the formula LC

= 1 MSD - 1 VSD (Value of one Main Scale Division - Value of one Vernier

Scale Division).

➢ Parts of a vernier caliper:

1. Outside Jaw - To measure outer dia. and width of an object.

2. Inside Jaw - To measure inner dia.

3. Depth Probe - To measure depth of an object.

4. Main Scale - Scale set apart in millimeter (mm)

5. Main Scale - Scale set apart in inches

6. Vernier Scale - Interpolated estimations in millimeter

7. Vernier Scale - Interpolated estimations in inch

8. Retainer - Used to lock movable parts

Steps: Using Vernier caliper

STEP 1: First loose the locking screw of caliper and check the vernier scale for its

proper working by moving the slider and ensure that caliper is reading 0 when closed

fully. If you find caliper is not showing 0 reading, then adjust the jaws of caliper till

that you get a 0 reading. If it is not adjusting at 0 reading, then add or subtract the

correct offset in final reading for getting 0 reading.

STEP 2: Close the jaws delicately on the object which need to be quantify (For

instance a round steel ball).

STEP 3: The primary metric scale is perused first and for instance says this

demonstrates there are 13 entire divisions before the 0 on the hundredths scale.

Thusly, the main number is 13.

STEP 4: The ‘hundredths of mm’ scale is then perused. The most ideal approach to

do this is to tally the quantity of divisions. This is 21 divisions on the hundredths

scale.

STEP 5: Then 21 is multiplied by 0.02 giving 0.42 as the appropriate response

(every division on the hundredths scale is comparable to 0.02mm).

STEP 6: The 13 and the 0.42 are included to give the last estimation of 13.42mm

(the diameter across of the bit of round area steel).

Micrometer

A micrometer is a gadget assimilating an aligned screw broadly utilized for exact

estimation of segment in mechanical trades and machining.

 ➢ Micrometers utilize the rule of a screw to expand little separations (that are

too little to measure normally) into big rotation of the screw that are sufficiently

enormous to read from a scale.

➢ A micrometer is used to measure very small distances.

➢ L/c-0.01mm

Reading the Measurement

The user needs to look at the lines on the spindle and finds which markings are

aligned with the datum line. This line, highlighted with the red arrow in Figure, is the

measurement.

To interpret the measurement requires some mental math:

➢ + Read the largest number shown on the datum line. In Figure, the 6 is still

visible. This corresponds to 06mm

 ➢ + Count the number of dashes on the datum line between the last large

number and the spindle. In Figure, 1 line is visible and represents .5 mm

➢ + Read the number on the spindle that is aligned with the datum line. This is

the line highlighted with the red arrow. As each line is equal to .01mm the

highlighted line in the picture is read as .16

➢ + Lastly add these three numbers together to get the final measurement:

Example: 06 + 0.5 + 0.16 = 6.66mm

Dial Test Indicator (Dial Gauge)

The dial test indicator is a comparative measuring instrument.

It is used in the following functions: -

1 To check the flatness of the surface of a job

2 Checking the parallelism of a job

3 Checking the tapering of a job

4 Checking ovality of cylindrical job or shaft

5 Checking the straightness of the job or shaft

6 Head stock and tailstock alignment checking

7 Checking Concentricity of Shaft

8 coupling alignment check

Feeler Gauge

A feeler gauge is a tool used to measure gap widths. Feeler gauges are mostly used

in engineering to measure the clearance between two parts. In engine the throttle

gap or spark plug gap are checked by Feeler gauge mostly.

➢ Feeler gauge available in no. of the blade like 10,13,20 and 28. With a step of

0.05 and 0.10 mm.

➢ The thickness of the blades are in fractions of mm and inches, usually ranging

from 0.03 mm to 1mm.

Coupling and key

Coupling:- Shafts are usually available up to 7 meters length due to inconvenience

in transport. In order to have a greater length, it becomes necessary to join two or

more pieces of the shaft by means of a coupling.

Key:- A key is a piece of mild steel inserted between the shaft and hub or boss of

the pulley to connect these together in order to prevent relative motion between

them. It is always inserted parallel to the axis of the shaft. Keys are used as

temporary fastenings and are subjected to consider-able crushing and shearing

stresses.
Coupling

Shaft couplings are used in machinery for several purposes, the most common of

which are the following:

1. To provide for the connection of shafts of units that are manufactured separately
such as a motor and generator and to provide for disconnection for repairs or
alternations.

2. To provide for misalignment of the shafts or to introduce mechanical flexibility.

3. To reduce the transmission of shock loads from one shaft to another.

4. To introduce protection against overloads.

5. It should have no projecting parts.

Types of Couplings

Shaft couplings are divided into two main groups as follows:

1. Rigid coupling. It is used to connect two shafts which are perfectly aligned.

Following types of rigid coupling are important from the subject point of view:

(a) Sleeve or muff coupling.

(b) Clamp or split-muff or compression coupling, and

(c) Flange coupling.

2. Flexible coupling. It is used to connect two shafts having both lateral and angular
misalignment.

Following types of flexible coupling are important from the subject point of view:

(a) Bushed pin type coupling,

(b) Universal coupling, and

(c) Oldham coupling.

(d) Disc Coupling

(e) Spring Coupling

(f) Gear Coupling

Rigid Couplings

A Sleeve coupling is a basic type of coupling. This

consists of a pipe whose bore is finished to the required

tolerance based on the shaft size. Based on the usage of

the coupling a keyway is made in the bore in order to

transmit the torque by means of the key.

Muff coupling, a rigid coupling that is simple split in

horizontal rather than vertical plane. The halves are

clamped together to grip the ends of both the driver and

driven shafts.

Flange Couplings are connectors between rotating chutes

that have two arrangements of flanges. One of these chutes

or flanges is fixed toward the finish of each shaft. To finish

the process of transferring power, both the flanges are

attached together with numerous nuts and screws.

Flexible Couplings

Spring couplings are flexible couplings in a number of

design variations which will accommodate minor
misalignment and have the common element of a
continuous steel strip that weaves through serrations in
each half of the coupling. It is also known as Bibby
coupling.

A chain coupling is a flexible coupling which will

accommodate misalignment up to 5 degrees. It consists of
a chain wheel sprocket cut onto each half coupling flange
end which are then joined together by a double roller chain
which just encircles the cut teeth. The chain must be grease
lubricated.
 Gear couplings are also flexible couplings which are
capable of transmitting very high torques. Gear engineering
plays a major role and utilizes the advantages of gear
coupling. There is no sleeve in this and its also required
lubrication.

In Tire coupling the half couplings are joined together by a

specially made rubber tire which transmits the drive and
allows a degree of flexibility in alignment.

Universal joint couplings are used for very large angular

or offset misalignment between two shafts. The most
familiar example is the universal joints on a car
transmission shaft. When this type of coupling is fitted with
needle roller bearings in spider, it is known as HOOKE’S
Joint.

Types of Keys

The following are the types of keys:

1. Sunk keys

(a) Rectangular Sunk Key (b) Square Sunk Key

(c) Parallel Sunk Key (d) Gib-head Key

(e) Feather Key (f) Woodruff Key

2. Saddle keys

(a) Flat Saddle Key (b) Hollow Saddle Key

3. Tangent keys

4. Round keys, and

5. Splines.
Sunk Keys

The sunk keys are provided half in the keyway of the shaft
and half in the keyway of the hub or boss of the pulley.

The different types of sunk keys are as follows:

1. Rectangular sunk key called rectangular because the

cross section of the key in rectangular shape. there is a
taper in key from upper side and the ratio is 1:100. It is also
known as tapper key.

2. Square key The cross section of the square key is in

square shape that's why it’s called square key and there is
only difference of cross section between square and
rectangular key.

3. Parallel key There is no taper in this key and also the

upper and lower surfaces are parallel in to each other that's
why it’s called Parallel key. Cross section of the parallel in
rectangular and also in square shape both.

4. Gib-head key It is a rectangular sunk key with a head at

one end known as gib head. It is usually provided to
facilitate the removal of key.

5. Feather key A key attached to one member of a pair and

which permits relative axial movement is known as feather
key. It is a special type of parallel key which transmits a
turning moment and also permits axial movement.

6. Wood ruff key is that kind of key which mounts easily.

Wood ruff key is a part of round disk which is looking like a
segment as we see from front. For mounting wood ruff key,
a key is made in part and mount key in it.
Coupling Maintenance

Shaft couplings are critical parts of any power transmission system, providing the
smooth transfer of power from one component to another. As with any other part of
the system, maintenance maximizes coupling life and ensures reliable system
operations.

Coupling maintenance is generally a simple matter, requiring a regularly scheduled

inspection of each coupling. It consists of:

➢ Performing visual inspections, checking for signs of wear or fatigue, and

cleaning couplings regularly.

➢ Checking and changing lubricant regularly if the coupling is lubricated. This

maintenance is required annually for most couplings and more frequently for
couplings in adverse environments or in demanding operating conditions.

➢ Documenting the maintenance performed on each coupling, along with the

date.

In most cases, these maintenance steps should be sufficient to keep couplings

working smoothly and to enable them to reach their full-service life. Even with proper
maintenance, however, couplings can fail. Underlying reasons for failure, other than
maintenance, include:

➢ Improper installation (Misalignment)

➢ Poor coupling selection

➢ Operation beyond design capabilities

Telltale signs of failure

The only way to improve coupling life is to understand what caused the failure and to
correct it prior to installing a new coupling. Every failed coupling provides some
evidence about what caused the failure. Some failures can be seen readily, while
others require some investigation.
Some external signs that indicate potential coupling failure include:

➢ Abnormal noise, such as screeching, squealing or chattering

➢ Excessive vibration or wobble

➢ Failed seals indicated by lubricant leakage or contamination

Misalignment

The incorrect arrangement or position of one shaft in relation to another shaft.

There are three types of shaft misalignment: -

(A) Radial Where the axis of the two shafts to be joined are parallel but offset.

(B) Angular Where the two shafts are at a slight angle to each other.

(C) Float/Axial Where there is too much or too little axial movement in one or both
shafts.

key extraction

A) General

Keys need to be extracted when components are changed or repaired and when
new keys are tried whilst being fitted.

During extraction it is very important that NO DAMAGE is done to the keyways, shaft
and hub. Keys should always be treated with care, although in some cases the
process of extraction will make them unfit to use again.

The method of extraction will depend on:

➢ the type of key used

➢ the availability of new keys
➢ the access of the working area
➢ the safety of personnel working in the area
SAFETY NOTE

Before carrying out work on any key, the drive must be isolated and locked off
electrically and mechanically and a permit to work must be obtained from a
responsible person

Considerable force is sometimes necessary to remove a tight fitting key. When it

does move, it can travel over quite a distance and inflict damage relative to the force
applied to move it.care must always be taken to ensure the safety not only of the
personnel engaged on the removal but also any other personnel working in the
vicinity

B) Method of extraction

Jacking screws –

used for parallel keys. The key is drilled and tapped before final fitting, the size and
number of screw point depending on the length of the key. To remove the key
suitable screws or bolts are carefully tighten down (one or two turns off each in
sequence). the key will then lift from the keyways in a controlled manner.

Key Drifts-

Used when the small chamfered end (tail) of a tapper key is accessible. If necessary,
small pieces of steel called dominoes can be inserted between the drift and key in
order to extend the effective reach of drift,
Drilling –

used when the end (tail) of a tapper key is not accessible. Using the largest possible
tapping drill size, a hole is drilled through the length of the key. The hole is then
tapped with a suitable fine thread, A stud can then be screwed into the tapped hole
and either used to press against the keyway end in order to force the key out or used
with a strong back between the stud head and hub to force the key out.

Pinch Bar –

Used for tapper keys with a GIB head to prevent damage to the hub, Protection
pieces must be placed between the hub and the pinch bar.

Wedges

also used for taper key with a GIB head. The two wedges provide an on-line force
which reduces the chance of the key bending. As with a pinch bar, suitable
protection pieces must be used to prevent damage to the hub.
Strong Back

Used when the complete hub is to be removed from a shaft fitted with a parallel or
woodruff key. Care must be taken to ensure that the jacking screw does not damage
the end of the shaft.

In the case of woodruff Key, once the hub is removed the key is simply tapped out of
the keyway using a small soft metal drift

PART 3 - KEY SIZE

Selection of the correct size and type of key is critically important.

Normally it is a simple matter of comparison with the key already in place or of

approximate measurement of the keyways to enable the appropriate key to be drawn
from the stores. In this case the keyway can be measured by using an engineer’s
steel rule.

Occasionally a parallel or taper key may have to be made. In this case the keyway
can be measured accurately by using:

➢ a vernier caliper to measure the length of the keyway

➢ suitably sized slip gauges to measure the width of the keyway
➢ a suitably sized micrometer and parallel rollers to measure the depth of the
keyway.

When making a key, the following rules must be applied to ensure that the key will
be adequate for the purpose.

a) The key must be made out of key steel.

b) For parallel keys:

➢ the key width must be a quarter of the shaft diameter

➢ the keyway depth must be a sixth of the shaft diameter
➢ the minimum key length must be one and a half times the shaft diameter
➢ the depth of the keyway in both shaft and hub must be half the width of the
key.

c) For taper keys the rules in (b) apply. In addition, the taper must be 1 in 100.

Woodruff keys are manufactured and sized using a system of digits. For example, in
the UK, keys are numbered such that the last two digits of the key number give the
key diameter in 1/8ths of an inch and the digit or digits preceding them give the width
of the key in 1/32nds of an inch.

Therefor a key number 1012 has a:

➢ diameter of 12/8ths or 1.5 inches (shown by the 12)

➢ width of 10/32nds or 0/325 inches (shown by the 10)

A) Preparation before Checking the Size of a Keyway

➢ Examine the selected keyway removing any dirt and burrs

➢ Measure the keyway using an engineer’s rule to obtain approximate length,
width and depth. Note down the measurements.
➢ Select a suitably sized vernier caliper, micrometer and rollers together with a
set of slip gauges.

B) Procedure to Check the Width of a Keyway

➢ Select two or more slip gauges that when joined will be close to the
approximate size
➢ Clean the slip gauges using a soft cloth or chamois
➢ Join the slip gauges with a slight rotary motion. The gauges should stick firmly
to each other. This process is called wringing.
➢ Try the wringed gauges in the keyway. To ensure the correct measurement
the gauges should be a push fit for the complete depth of the keyway
➢ Use different gauges until the correct push fit is obtained

➢ When the correct push fit is obtained note down the size of the individual
gauges that are wringed together (if necessary, refer to the calibration chart
supplied with the slip gauge set to obtain the individual gauge sizes)
➢ The final accurate width is determined by adding the individual gauge sizes
together.
➢ Note down this width

C) Procedure to Check the Length of a Keyway

➢ Select a suitable sized vernier caliper.

 ➢ Note down the combined dimension of the calliper points and call it "X". (This
dimension must be, added to the reading on the vernier scale to account for
the space taken up by the calliper points.
➢ Hold the fixed jaw of the vernier with one hand and the sliding jaw in the other
hand. Place the calliper point of the fixed jaw to one end of the keyway and
move the sliding jaw along until it touches the opposite point at the other end
of the keyway.

Tighten the locking screw (directly above the fine adjustment screw?). Also tighten
the locking screw on the sliding jaw just enough to allow freedom of movement for
fine adjustment to take place.

➢ turn the fine adjustment screw at the same time moving the vernier up and
down until a smooth sliding fit so obtained.
➢ apply a slight rotary movement to the vernier to make sure that the jaws are
fully extended and reading across the apex points at the end of the keyways.
➢ lock the sliding jaw and remove the vernier from the keyway.
➢ take the reading and call it "Y".
➢ to calculate the keyway length, add the combined dimension of the calliper
points "X" to the vernier reading "Y”. The resultant is the accurate length of
the keyway.
➢ Note down this accurate length.
D) Procedure to check the depth of a keyway.

➢ Select a suitable sized micrometer and roller gauges.

➢ adjust the micrometer to measure the shaft diameter. Note down the
measurement and call it "A".
➢ select a roller having a diameter of less than the keyway width and a length
less than the keyway length. Note down the roller diameter and call it "B".
➢ place the roller lengthways into the keyway.
➢ Adjust the micrometer to measure the distance over the shaft and roller. Note
down the measurement and call it "C".

➢ Subtract “B” from “C” and call the answer “D”

➢ Subtract answer “D” from “A”. The answer is the accurate keyway depth. Note
down this depth.

Cross Checking

To carry out a simple cross check compare the accurate width, length, and depth
with the approximate figures measured with the engineer’s rule. If there is a large
difference check all measurements again.

KEY FITTING

SAFETY NOTE

Before carrying out work on any key, the drive must be isolated and locked off
electrically and mechanically and a Permit to Work must be obtained from a
responsible person.

Considerable force is sometimes necessary to remove a tight-fitting key. When it

does move, it can travel over quite a distance and inflict damage relative to the force
applied to move it. Care must always be taken to ensure the safety not only of the
personnel engaged on the removal but also any other personnel working in the
vicinity
A) Parallel Keys:

The procedure for fitting a parallel key is:

a) Select a parallel key of the required size and length.

b) Inspect and clean the shaft, hub, and keyways, and, at the same time, remove
any burrs.

c) Try the hub on the shaft and check that the keyways are the same size and can
be aligned correctly.

d) Try the key against the shaft keyway. If the key is much too wide, remove the
excess by filling. If the key is only slightly too wide, continue to the next step.

e) Apply lubricating oil mixed with marking compound to the key.

f) Using a soft mallet, tap the key into the keyway.

g) Remove the key and note any high spots.

h) Remove the high spots with a file or scraper.

I) Repeat steps e,f,g and h until the key is touching all over and can be driven home
by sharp blow of the mallet.
J) position the hub and check the clearance between the top of the key and the hub
keyway. If necessary, file the top of the key down to give the required clearance.

K) Try the hub over the key. It should be a light drive fit. Remove high spots with
scraper.

l) Fit the hub to its final position using a mallet to drive it home.

B) Taper Keys

To fit a taper key: -

a) Select a taper key of the required size and length.

b) Inspect and clean the shaft, hub, and keyways and at the same time remove any
burrs.

c)Try the hub on the shaft and check that the keyways are the same size and can be
an aligned correctly.
d) Try the key against the shaft keyway. If the key is much too wide, remove the
excess by filing. If the key is only slightly too wide, continue to the next step.

e) Apply lubricating oil mixed with marking compound to the key.

f) Using a soft mallet, tap the key into the keyway.

g) Remove the key and note any high spots.

h) Remove the high spots with a file or scraper.

I) Repeat steps e,f,g and h untill the key is touching all over and can be driven home
by a sharp blow of the mallet.

j) Place the hub in correct position on the shaft, insert the key and gently tap it home
until it locks the hub in position.

k)If the key does not enter as far as required, file down the back of the key evenly so
that the taper is not altered.

l) Repeat step i) and k) until the key will almost enter far enough and then drive it
home firmly.

m) Finally, check that the hub is still correctly positioned on the shaft.
C) Woodruff Keys

To fit a woodruff key:

a) Select a key of the required size.

b) Inspect and clean the shaft, hub, and keyways and at the same time remove any
burrs.

c) Fit the key into the shaft keyways ensuring that the top of the key is parallel to the
edge of the keyway.

d) Fit the hub over the key and tighten the locknut or other fixing device.

e) Check that the hub is correctly positioned on the shaft.

Pumps

Centrifugal Pump

Centrifugal Pumps are the most popular and commonly used type of pump for the
transfer of fluids. Centrifugal pump is a hydraulic machine which converts
mechanical energy into hydraulic energy by the use of centrifugal force acting on the
fluid. These are the most popular and commonly used type of pumps for the transfer
of fluids from low level to high level.

When a certain mass of liquid is made to rotate by an external source, it is thrown

away from the centrifugal axis of rotation and a head is impressed which enables it
to rise to a higher level. Centrifugal Pumps can be used for viscous and non-viscous
liquids and has higher efficiency.
Parts of Centrifugal Pump

1. Impeller It is a wheel or rotor which is provided with a series of backward curved

blades or vanes. It is mounded on the shaft which is coupled to an external source of
energy which imparts the liquid energy to the impeller there by making it to rotate.

2. Casing It is a pipe or body which is connected at the upper end to the inlet of the
pump to the center of impeller which is commonly known as eye. The lower end dips
into liquid in to lift. The lower end is fitted in to foot valve and strainer.

3. Delivery Pipe

4. Suction Pipe with Foot Valve and Strainer

Working of Centrifugal Pump

The first step in the operation of a centrifugal pump is priming. Priming is the
operation in which suction pipe casing of the pump and the position of fluid with the
liquid which is to be pumped so that all the air from the position of pump is driven out
and no air is left. The necessity of priming of a centrifugal pump is due to the fact
that the pressure generated at the centrifugal pump impeller is directly proportional
to density of fluid that is in contact with it.
After the pump is primed the delivery valve is still kept closed and electric motor is
started to rotate the impeller. The delivery valve is kept closed in order to reduce
valve is opened the liquid is made to flow in an outward radial direction there by
vanes of impeller at the outer circumference with high velocity at outer circumference
due to centrifugal action vacuum is created.

This cause liquid from sump to rush through suction pipe to eye of impeller thereby
replacing long discharge from center circumference of the impeller is utilized in lifting
liquid to required height through delivery pipe.
Piston/Plunger Pump

A plunger pump is a type of positive

displacement pump where the high-pressure seal
is stationary and a smooth cylindrical plunger
slides through the seal. This makes them different
from piston pumps and allows them to be used at
higher pressures.

A piston pump is a type of positive displacement

pump where the high-pressure seal reciprocates
with the piston. Piston pumps can be used to
move liquids or compress gases. They can
operate over a wide range of pressures. High
pressure operation can be achieved without a
strong effect on flow rate.

Common problems and probable cause

1. Delivery Failure – The pump is not able to deliver at the required pressure.

➢ Ensure that the pump is primed properly

➢ Check if the pump is moving with sufficient speed

➢ Check for air leakage

➢ Ensure that the impeller/gear/screw or other liquid driving mechanism is not

broken or damaged

➢ The pump shaft should move in the right direction

➢ Check that the suction lift is not more than required

➢ Ensure the temperature of liquid is not below the “pump-able” limit of the
pump.

2. Priming Failure – Priming is required in order to start most of the pumps. If the
pump is not able to prime properly, check the following:

➢ Leakage in pump joint

➢ Leakage in gland joint

 ➢ Air leakage

➢ Faulty priming drive

3. Inability to Build Pressure – If the pump is not able to build enough pressure in
order to ensure smooth flow of liquid, then check

➢ If the priming is done properly

➢ The air cocks are not open

➢ internal moving parts (impeller/ screw etc.) are not damaged

➢ Wear Rings are not worn out or damaged

➢ The pump is running at the right speed

➢ There are no other mechanical defects in the pump

➢ Check for cavitation in the casing of the pump

4. Reduced Capacity: Several times due to continuous running, the capacity of the
pump reduces drastically. If the capacity of the pump has been reduced or there is
insufficient capacity, check

➢ The pump is running at proper speed

➢ There is no air leakage

➢ There is no obstruction in the suction pipe

➢ Ensure that the suction lift and temperature are not too high

➢ The total dynamic head is not larger than the rated

➢ The setting of the pump relief valve is not below required value

5. Loss of liquid-If the pump loses liquid, after starting or during running, check

➢ Check if the suction lift is as required

➢ Check for any kind of leakage in the suction line

➢ Check the temperature of the liquid

 ➢ Ensure the relief valve of the pump is set at right value to avoid loss of liquid
to overflow line

6. Excessive Vibration: Sometimes the pump vibrates a lot making a loud noise. If
there is a lot of vibration in the pump, check the following:

➢ Ensure there is no loose foundation

➢ The alignment of the pump is proper

➢ There is no impeller imbalance or erosion

➢ There are no mechanical faults

➢ The distance piece between the pump shaft and motor shaft is of correct
length and is not worn out

➢ The rubber bush piece connecting the motor and pump shaft is not worn out

➢ There are no worn bearings or bent shafts

Bearings

Bearings are used for carrying loads while allowing relative motion(rotation) with
minimum friction.

Types of bearings:

➢ Rolling contact or anti-friction bearing

➢ Journal or sleeve bearings (sliding contact/friction bearing)

A Journal Bearing / plain bearing, or more commonly sliding bearing and slide
bearing, is the simplest type of bearing, comprising just a bearing surface and no
rolling elements. Therefore, the journal slides over the bearing surface. The simplest
example of a plain bearing is a shaft rotating in a hole.

In rolling contact bearings, the contact between the bearing surfaces is rolling that
is point contact instead of sliding/line as in plain bearings.
Types of Anti friction Bearings

1.Ball Bearing

(a) Deep groove ball bearing: - This type of bearing

is capable of taking radial load and partial thrust load.

(b) Angular contact bearing: - This type of bearing is

capable of carrying higher thrust load than deep

groove ball bearing due to extra support in axial

direction; But this thrust load must be exerted from

one direction.

(c) Self Aligning Bearing: - This type of bearing can

bear high shaft misalignment.

(d) Single Row Bearing: - In this type of bearing, the

balls are arranged in a single line between inner race

and outer race.

(e) Double row bearing: - In this type of bearing, the

balls between the inner race and outer race are

arranged in two lines and can take load twice as

much as a single row and take less space than two

single row bearings.

2. Roller Bearing

Anti-friction bearing uses roller bearings when high

load is transferred.

Types of roller bearings: -

(i) State Roller Bearing: - It supports high radial load

but does not support thrust load at all.

(ii) Tapered roller bearing: - It supports high radial

and thrust load.

(iii) Spherical Roller Thrust Bearing: - It also supports

radial and thrust load. It is very useful in case of

over load and shaft misalignment.

3. Needle roller bearing

Thin and long rollers of low diameter are used inside

this bearing. It stays between the two races in a roller

cage or without a cage. The length of these rollers is

kept 5 to 10 times the diameter. These wears are

used in very heavy loads and low places in Bali

places.

4. Thrust bearing

Thrust bearing is used when the load on the soft falls

parallel to the axis. Instead of inner race and outer

race, soft washer and housing washer are used.

Maintenance of Bearings

1. Handle with care- Bearings are delicate enough to get damaged quickly. As

such, it is very important that they are stored horizontally in a clean and dry

environment with their packaging intact. Do not expose them to any airborne

contaminants, as even a tiny speck of dirt can cause premature failure. Never

hammer or pound them, or apply a direct force on it or its outer ring, which can

cause damage to the rolling elements, resulting in misalignment. The most important

thing to remember is to never remove bearings from their packaging until ready for

use.

2. Check the bearing housing and shaft- Whenever a bearing is used for

mounting, it is crucial that the housing and shaft are inspected for any sort of

physical condition or damage. Always use a soft cloth to wipe the surfaces clean and

make sure any nicks and burrs are removed.

3. Mount the bearings correctly- The method used to mount the bearings depends

on the type of bearing. For example, bearings with cylindrical bores are generally

mounted through a press fit method. Bearings with tapered bores can be mounted

directly on tapered or cylindrical shafts with the use of tapered sleeves. However,

pressure should be applied only with a press fit because without it the raceways can

become damaged.

4. Avoid preheating or overheating- The maximum heating allowed on the

bearings depends on the heat treatment of the material. If they are heated above the

permitted limit, they can permanently deform or soften the bearing steel, lowering

load carrying capacity and resulting in a failure. Always heat the bearings using

induction heaters, and never with an open flame.

5. Always use the proper tools- Specialized tools like bearing pullers, bearing

fitting tool kits, oil injector kits, hydraulic nuts, or induction heaters should be used in

the mounting and dismounting processes. These tools ensure the smooth process of

mounting or dismounting, in order to minimize the risk of damage.

6. Avoid corrosion- It is crucial that you should not expose bearings to the

presence of water for a long time, as it will lead to rust and corrosion. It will also

cause the premature failure of the bearings, which can affect the machine

performance and productivity. As a result, it will increase your operating costs. Also,

make sure to wear gloves when handling bearings. Perspiration can also lead to rust

and corrosion.

7. Proper lubrication- If you want to have a prolonged life of your bearings, it is

crucial that they should be properly lubricated. The correct lubricant depends on the

environmental conditions, temperature, speed and load. In this case, it is advisable

that you should follow your manufacturer’s recommendations.

DC Brake Assy BCH make
INSTALLATION OF BCH BRAKE ASSEMBLY

Installation of BCH brake

Procedure

Centre of the brake shoe must coincide with that of brake drum, to do so. packing
may be provided below the brake with its shoes in hold position.

➢ The drum tolerance should be 0.1mm per 100 mm of drum dia.

➢ Radial run out (ovality and taperity) of the brake drum should not exceed 0.03
mm per 100 mm (or half the tolerance of the dia) of drum dia.
➢ The working surface of the drum should have hardness not less than HB - 250
and surface finish not less than VVIT.
➢ Non parallelism between working surface of brake shoe lining and brake drum
should not exceed 0.1-0.3 mm per 100 mm width of drum.
➢ No traces of corrosion, oil paint. etc. should exists on the working surface.
➢ Assemble the brake wheel (17) on the motor shaft.
➢ Back off the pull rod (4) by loosening nut (1) about I " (25 mm)
➢ Turn the bolt assembly (6) to lift the wedge assembly (7) at the top of the inner
shoe (15)
➢ Slide the brake into the place around the brake wheel and insert the bolt into
the base mounting surface.
➢ Loosen the holding screws (21) on both shoe levers living only a light grip.
➢ Push the shoe levers (15) and (19) against the brake wheel and whether the
shoes fit evenly across the wheel face.
➢ Adjust the base into the best position to get the most favourable fit of the shoes
against the wheel face.
➢ If the mounting surface is not flat or is not parallel to the shaft axis, shimming
may be necessary. Tighten the holding bolts to hold the base firmly.
➢ Remove packing against torque adjusting screw (13) and wires / clamps from
the top of armature.
➢ Tighten the pull rod nut (1) until the outer armature (10) and sounding pin (12)
is flushed when pressed with hand.
➢ Turn the screw (6) on the top of inner shoe lever counter clockwise to move the
wedge down ward until the inner armature (8) and sounding pin (12) is flushed
when pressed with hand.
➢ Tighten screws (21) on the shoes. Connect the supply and operate the brake

TORQUE ADJUSTMENT OF BCH BRAKE

Procedure

Torque adjustment: - Maximum torque is obtained by turning the torque adjuster

(13) clockwise until the gland inside is tight against the stop. Torque less than the
maximum value is obtained by turning the torque adjuster (13) counter clockwise.
Check the name plates on the brake and table for the torque setting and duty of the
brake.

Note: 1. When the brake is properly adjusted for proper stroke. the torque
adjuster washer face stands clear of the armature (10) surface. As the lining wears
this clearance decreases. If the adjustment is neglected, the brake operation
becomes sluggish and when the torque adjuster washer touches the armature
surface (10), the torque drops rapidly reaching zero when the clearance is used up.
The clearance dimension is not a measurable value but depends upon proper
adjustment of individual brakes.

2. Please refer Table for torque adjustment at Annexure: Table - I

INSPECTION CHECKLIST FOR BCH BRAKE

Procedure

Regular Checking: -

➢ Check Armature stroke for gripping of drum by both the shoes to avoid burning
of shoe and improper braking.
➢ Ensure the releasing movements of both the brake shoes for uniform and equal
gap between brake shoe and drum surface.
➢ Check wear and tear of brake lining by visual inspection and ensure that fixing
bolts of brake liner must not rub against the drum.
➢ Check tightness of all bolts and nuts with the help of appropriate spanners
Check torque adjusting screw lock by turning the torque adjuster clockwise until
the gland inside is tight against the stop.
➢ Ensure that surface of shoe / drum to remain clean.
➢ Ensure that temperature of magnet is below 150 ° C.
➢ Check that working length of main spring is as per the Torque required.
➢ Check insulation of conductors as per norms.
➢ Ensure that arms, magnet and bracket oscillation on their pins re within the
tolerance limit to avoid seizing and free play
➢ Check by visual inspection that there is no crack or damage to parts (part,
spring and bracket)

➢ Ensure brake shoes in definite position Ensure that temperature of drum is

below 200 ° C.
➢ Keep the surface of the drum smooth and clan, free from oil, corrosion and dirt
➢ Do Cleaning. Greasing and tightening (CGT) wherever required.
RENEWAL OF BRAKE SHOE LINING AND READJUSTMENT

Procedure

Adjustment of brake.

A. Check that the surface of the shoe / drum must be clean, free from oil and dirt. If
not, clean it.

B. Check the opening and closing of both the brake shoes by measuring the gaps of
brake shoes with the help of Filler gauge.

➢ For inner brake shoe gap adjustment, readjust it by wedge adjusting bolt (6)
moving it clockwise / anticlockwise.
➢ For outer brake shoe gap adjustment, readjust it by lock nut (1) moving it
clockwise / anticlockwise.

Important:

In energized condition, both brake shoe linings must have a gap of 0.5 to 1 mm per
100 mm of brake dia from the brake drum.

C. Check the installation and depression of sounding pin (12) by visual inspection
and ensure that depression of sounding pin (12) must remain more than 1/64 "
(0.4mm) below the surface of armature. If not, readjust for the wear of the lining of
brake shoes as given below:

➢ Tighten nut (I) on the pull rod (4) until the sounding pin (12) in the outer
armature (10) flushes with the surface of the armature in de - energized
condition.
➢ Turn the bolt (6) counter clockwise till the inner armature (8) and the sounding
pin (12) flushes with the surface in the de - energized condition.

Important:

If both the brake shoe linings are similar, the sounding pins must flush with armature
surface.

Renewal of brake shoe lining -

Check wear and tear of brake lining by visual inspection and ensure that fixing bolts
of brake liner must not rub against the drum.

➢ If the fixing bolts of brake liner are not rubbing against the drum. do not renew
the brake shoe lining. Do only proper readjustment of brake.
➢ If the fixing bolts of brake liner are rubbing against the drum or likely to rub the
drum follow the following steps to renew the brake shoe lining.
 >> Back off the nut (1) on the pull rod (4) turn the bolt (6) to lift the wedge to
relieve the pressure between the chosen shoe and wheel.

>> Remove screw (21) from the shoe which is to be taken out.

>> Slide out the shoe sideways.

>> After removing the old lining and nuts bolts, clamp the new lining in such a
way that it lies closely in the shoe.

>> Drill holes (different for different sizes of brakes) through the lining from the
rear of the shoe.

>> Counter bore from the front of the lining and fit the bolts / nuts.

>>When replacing the shoe, slide it into the grove and put in the screws
loosely.

>> press the shoe against the wheel and tighten the screw (21).

>>Readjust the brake as mentioned above.