Birla Institute of Technology & Science, Pilani Work-Integrated Learning Programmes Division First Semester 2010-2011 Mid-Semester Test

(EC-1 Regular)

Solution
Course No. Course Title Nature of Exam Weightage Duration Date of Exam Solution. 1
Early phase or infant mortality Failure rate Wear out region

: ENGG ZC242 : MAINTENANCE & SAFETY : Closed Book : 40% : 2 Hours : 29/08/2010 (AN)

Operations phase

Typical failure rate curve for electronic components

Failure rate

Time Typical failure rate curve for mechanical components

For electronic and mechanical components, typical failure curves are shown above. It can be seen that failure rate is different in mechanical and electronic components. In the early phase both component shows almost same failure rate but in operation phase failure rate of mechanical components is more as wearing is there due to moving parts whereas in electronic components no moving parts are there. And in third region ie wear out region or end of life of the components failure rate is very high in mechanical components as compared to electronic components as fatigue and creep also add in account.

Solution. 2 To confirm the wear of piston in an automobile engine without disassembling the engine, the sample of lubricating oil is taken and checked for the wear out particles in the oil. If wearing is there, wear out particles of piston will be present in the oil and thus confirms the wearing of piston. Other symptom of wearing of piston is the increase in consumption of lubricant. Solution.3 Non destructive testing (NDT) is a group of analysis techniques used in science and industry to evaluate the properties of a material, component or system without causing damage to them. NDT doesnt alter the article being inspected, it is a valuable technique that can save both money and time in product evaluation, troubleshooting, and research. Common NDT methods include ultrasonic, magnetic-particle, liquid penetrant, radiographic, and eddy-current testing. To detect the internal cracks in mild steel machine part following NDT methods can be used: 1. Eddy current testing- It uses electromagnetic induction to detect flaws in conductive materials. In a eddy current testing a circular coil carrying current is placed near to the test specimen (electrically conductive).The alternating current in the coil generates changing magnetic field which interacts with test specimen and generates eddy current. Variations in the electrical conductivity or magnetic permeability of the test object, or the presence of any flaws, will cause a change in eddy current and a corresponding change in the phase and amplitude of the measured current. eddy-current testing can detect very small cracks in or near the surface of the material and physically complex geometries can be investigated. Ultrasonic testing (UT)- In this very short ultrasonic pulse-waves with frequencies ranging from 0.1-15 MHz and sometimes up to 50 MHz are launched into materials to detect internal flaws. In ultrasonic testing, an ultrasound transducer connected to a diagnostic machine is passed over the object being inspected. The transducer is typically separated from the test object by a thin film of liquid couplant (such as oil) or by water. There are two methods of receiving the ultrasound waveform, reflection and attenuation. In reflection mode, the transducer performs both the sending and the receiving of the pulsed waves as the "sound" is reflected back to the device. The machine displays the results in the form of a signal with an amplitude representing the intensity of the reflection and the distance, representing the arrival time of the reflection. In attenuation mode, a transmitter sends ultrasound through one surface, and a separate receiver detects the amount that has reached it on another surface after travelling through the medium. Imperfections or other conditions in the space between the transmitter and receiver reduce the amount of sound transmitted, thus revealing their presence. Magnetic particle inspection (MPI) is a non-destructive testing (NDT) process for detecting surface and subsurface discontinuities in ferrous materials. The process puts a magnetic field into the part. When a ferromagnetic component is magnetised, magnetic discontinuities that lie in the direction perpendicular to the field direction will result in the formation of strong leakage field and its presence can be visibly detected by utilising finely divided magnetic particles. The magnetic bridge so formed indicate the location , size and shape of the discontinuity.

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Solution.4 The difference between RCM (reliability centred maintenance) and RCA( root cause analysis) is that RCM treats the symptom while RCA finds and correct the same. The purpose of RCM is to determine the maintenance requirement of any equipment and provide a flow diagram that gives details on what type of maintenance to use. But the purpose of RCA is to uncover the root causes, why an event is occurring? So that necessary steps can be taken to eliminate the event entirely. RCA uses a logic tree that stresses verification at every level. For example, consider a person who has chronic headaches for some unknown reason. RCM would analyze all possible reasons like stress, disease, allergies,

loud noise, bright light, lack of rest etc. RCM would tell this person to take aspirin in order to mitigate the consequences of headache in its primary stage. But RCA would uncover the reasons why headache is recurring and provide resolution for its complete elimination. Solution. 5 Spare parts Management plays an important role in achieving the desired plant availability at an optimum cost. The objective of spare parts management is to ensure the availability of spares for maintenance and repairs of the plant and machinery as and when required at an optimum cost. Also, the spares should be of right quality. There are many actions required to ensure the spare parts management effective. The need of spare part control is the minimization of the associated cost by balancing the cost of holding against the cost of running. Spare part management is very important as it: 1. Prevent production lost due to stoppage 2. Reduce the cost of temporary hire 3. Minimize the cost of replenishing stock 4. Minimize the cost of holding stock 5. Minimizing the down time.

Solution. 6 Basic assumptions for calculation ,optimum order quantity: 1. The demand of item is known 2. The lead time is known 3. The receipt of order occurs in a single instant 4. Quantity discount are not calculated as part of the model 5. Stock out or shortage do not occur. The following are the variables: Q*= Optimal order quantity C=cost per order event(not per unit) R= monthly demand of the product P=purchase cost per unit F=holding cost factor, the factor of purchase cost that is used for holding cost H= holding cost per unit month Total cost= purchase cost+ order cost+ holding cost TC(Q)= PR + CR/Q + PRQ/2

Taking derivative both sides and setting equal to zero. dTC(Q)/dQ = d/dQ(PR + CR/Q + PRQ/2) =0 PF/2 CR/Q2 =0 PF/2 = CR/Q2 Q2 = 2CR/PF Q = (2CR/PF) Q= (2CR/H)

Solution. 7 Following points are to be noted in selecting of the lubrication: 1. Operating temperature is important as it effects the viscosity of the lubricant and thus increase or decrease the lubricating effect and causing damage to machine parts. 2. Compatibility with the material as some grease can cause leaching in elastomers and plastics. 3. Load and wear resistance. If the wear and load are excessive heavy viscous oils are applied. In addition, extra pressure(EP) additives are added to the lubricant to resist wear. Synthetic ester greases are ideal for such applications. 4. Type of device like electrical contacts having low current of contacts having high arc initiation. 5. Type of delivery system. 6. Cost of lubricants. Solution .8 1.] Centipoise- A component unit of viscosity, equal to one hundredth of the unit of viscosity, Poise. 2.] Centistroke- A unit of viscosity commonly used when a liquid falls through a capillary tube under its own weight. It is related to centipoises by equation: i. Centistokes density = centipoises 3.] Cloud Point- As oil is progressively cooled the temperature at which wax starts to separate from oil, producing cloudy appearance. 4.] Base Number-A measure of basicity (alkalinity) of a lubricant, which is obtained by reacting it with acid of known strength until neutralization. 5.] Tribology- composite scientific study of friction, wear and lubrication so as to minimize the harmful effects upon machinery.