Journeyman Flashcards
what type of air filterlast longest
pleeded
how to check for voide in grout- tape with a
hammer
what type of pump should be used in hot fluid
center mount
how are nuts on tanchinbolt tighten
by hand
how do you stration a crank shaft
hydrolic jack press
the most accurate mothod of checking the bearingclearance but also the most time consuming
measurement
the most common cause of dearing failure is
lack of lubrication
what is a sentind valve used for
a worning device
when you want 100% of powerfrom a turbine
open extration control valve and close
most efficient steam turbin is a
condusing turbin
what determines the efficiency of a turbine
temperature going accrare the turbine
what needs to do done to a turbine when taken off a turbine cover
remake running key and install assembly key
what needs to be done when putting a turbine cover back on
remove assembly key and install running key
what is mounted on the turbine causing exposed to the internal steampressure for avorring devise
sentinel valve
buildup can be removed in a turbine using
blasting then with walnut shells or rice or high pressure dry ice
how is a frichion bearing held in place in a steam turbine
molted babbid forms to the key
how many lock bearings are on a shaft
1
where are the defusers located in a gas turbine
between the compresser and cumbustion chamber
low pressure steam turbin is vibrating to muchhow can it be fixed
tighten the lock wier
can two universel cuplingsface perfect with each other
no cases burnelling of the bearings
what is the best method on filling bins or contoners with a convater
tripper
what is found in the side of the side lodding shoots to overcome this proplem, baffles are installed in the chute to slow material and direct it to the centre of the belt
what should slherting be made from
a softer material
if material was falling threw the skeeting you would have to
decrease skeeting clearance
if a convater is slepping on start up
you add more weight to your counter weight to stop the slipping
what is the strongest belt splice
hot volcanizing it can achieving 90% belt strength
what is the benfit of side legging
change legging with out removing the belt
what would cause a belt to touch the hole way around
incorrect belt splice
to maintain efficiency on a drag convator
keep tension on chain
a fluid coupling fusible plug
where the plug in the coupling melts on high heat and loses all fluid
in a prematic conveying system wear takes place mostly on the inside of the outside radius on pipe bends
the curved section
if a gear box is running hot there is probably to much
oil
if your using a plumbot outside have it in a bucket of
oil so it cant blow in the wind
check the level all around after tightening theanchor bolt nuts to ______of their final torque value
50%
how deep do you put a fixed anchor bolts
depth not less then 25D
typically foundations are set 3/4 inches to 1 1/2 inches ( 19mm to 38mm) low to allow for grout
plan view is looking down, elivatio view is the side view to see elivation
welding current can damage bearing. ensure that the bearing is not between theground of the welding machine and the welding location
off set centreroller are used for where there is low head room
one section of the beltruns off at all points on the line. the cause of this could be
belt is improperly spliced or out of square to fix this resplice
belt slips on starting this can be caused by counter weights are to light to correct this increase the counter weight or increase the screw take up tension
when using strobe light to do vibration analyzer you can use it to find the ________
phase angle
where can you get machine normal operating vibration
the machines operator
to determine the angle between O and T measure the angle with ______
a protractor
static unbalance is sometimes called force or _______
kinematic unbalance
it is caused when the shaft weight is ______ along the length
evenly distributed
the primary purpose of prevention maintance is to
increase production
the difference between pretventive and predictive maintance is
when maintance is performed
small plant maintance operation s may very upon ______
a logbook (logbook must be with machine to keep record maintance work)
Before putting a electric motor to use preform a _________
electrical insulation resistance test
the scale of emissivity ranges from _______
0.00 (where there is no emission) to 1.00 (where the object is completely emitting energy)
ISO is ?
international organization for standardization
where should a oil sample be taken
after the equpment of interest
when should you take a oil sample
when the equpment is operating under a load
ultrasonic thickness gavging can measure
thickness to a accuracy of 1%
when should oil be on a rolling elimant with oil
half way up the lower ballroller
how mach should grease be in a rolling elimant
3rd to half
what type of impeller is good for long fiber materals
open face
what makes the best back fill
crushed concreat
best way to lift a turbine is a
spreder bar
how do friction bearing self alining
spherical seat
what kind of grease goes in a robot
robot grease
tools and equipment used to install, diagnose, maintain and repair _______ and __________
robotics and automative
When the downward force at C2 is 100lbs and D2 is 2.5 inches, the upward force at C1 will be _______ lbs if D1 = 4 inches
384
Add the following decimals and express the answer to three decimal places.
0.4789 + 3.125 + 9.656
13.259
What are common materials used as electrical conductors?
Silver, copper, aluminum
Large impulse turbines will use what of rotor?
A. Build up rotors
B. Solid rotors
C. Combination of solid and build up rotors
D. All of the above
D. All of the above
The shape of a ball bearing is ______ when a load is applied to the ball
Elliptical
Not a stress, but the result of stresses
Fatigue
The two main estimates
Cost and time
What is the primary purpose of preventative maintenance?
Increase production
80 chain is what size?
8/8 = 1 inch
What coupling requires lube?
Metal to metal (grind, gear, chain) not metallic disk
Where are vibration readings taken from?
HVA - Horizontal Vertical Alignment
When do you take an oil sample?
When the unit is running
What would cause oil in the gearbox to go milky?
A gearbox constantly starting/stopping can cause condensation and make the oil milky
How do you weld long distances without distorting?
Short stitches along seem (tacks/back stepping)
How do you shorten a chain sling?
Grab hook
60 degree angle between two slings, 12’ long. What is the distance between the I bolts?
12’
How do you reverse the flow in a vane pump?
Flip the cam 180 degrees
How should packing be staggered if 4 rings are used?
90 degrees
What should you do before putting packing in place?
Roll it out to flatten it.
A PRV is blowing OFF in the intercooler of a two stage reciprocating compressor, why
The 2nd stage inlet valve is leaking/bypassing
If there is excessive heating in a 2 stage reciprocating compressor, what is the issue?
Faulty intercooler (red fins plugged)
How do you fix tears in a conveyor belt.
Belt clips (bolt type fasteners)
How high should a personal work platform be before it needs guardrails?
1.22m / 4 feet
How high should a hand rail and mid rail be?
4 feet and mid rail half down at 2 feet
What kind of oil goes in the crank case of a compressor?
Non-detergent. Detergent oil can cause carbon build up/hot spots
If a lobes pump output volume decreases over time, how do you fix it?
Decrease clearance
What is the result of heating up an HS8 bit
to cherry red and dipping it in oil?
Hardening
What does ‘2’ in EP2 grease mean?
Penetration (the higher the number (up to 6), the harder the grease
Chatter in gearbox?
Broken tooth
High chrome levels in oil, why?
Low oil level. Heat causes ball bearings to wear prematurely
What type of welding would you use for a large gap?
Mig
What is the general practice for filling a hydraulic tank for the first time?
Offline filter/ filter cart
How often should you inspect fall arrest equipment?
Before every use
If a belt is travelling off centre, how do you adjust it?
Adjust tail pulley
You find a bent eyebolt, what do you do?
You take it out of service and destroy
During a lift, there is a signal man designated for the operator, the load is heading toward a power line. What do you do?
Emergency stop
What is the best way to lift a 20T turbine rotor?
Spreader beam
A 3 phase motor fails to operate properly and starts to hum, it’s likely
A blown fuse
How do you detect bird caging?
When there is no load
What is the best way to detect surface cracks in a weld?
Dye penetrant
Crane signal for boom down?
Thumb down
Crane signal for stop (Non emergency)
Arm in and out
What do you use to store machine data?
Computer database
What should you do during a large lift to ensure the safety of people?
Red tape area and remove all no-lift personnel
What do you do to a drill bit before drilling brass?
Brassing the drill - flattening the cutting edge
What do you use if you don’t have a clamp to pull chain ends together?
Lace
If you have contaminants outside a gearbox, what seal do you use to keep the contaminants out?
Double lip seal
What do you do for commissioning a new piece of equipment if you have no manufacturer specs?
Check oil level and jog
The most efficient way to keep a gearbox lubricated?
Scrapers and troughs
How do you prevent material from getting trapped between the belt and the tail pulley?
Install v-plow just before the tail pulley (inside of belt)
How is a gearbox sized?
Vertical distance between shafts
Oil level on a bearing?
Half way up the lowest rolling element
When replacing skirting on a conveyor
Use a softer material than belt - no clearance gap
How do you shorten a type of chain?
A chain breaker
How do you detect soft foot using a dial indicator?
Tighten all feet, set up dial on one foot, then loosen that foot.
What should you do with a sling if it has been overloaded?
Remove it from service
What should be done before coupling a prime mover to a pump?
Check rotation
How do you measure wire rope?
By the largest diameter
How should you torque a flange or bolts?
Top, bottom, criss-cross
If you find metal shavings under the chain/sprocket
Check for misalignment or wearing
If too much oil in the sight glass when machine is running
Monitor for excessive heat
What is the size of a keyway in relation to a shaft?
1/4 shaft diameter
While commissioning a water cooled centrifugal compressor
Check rotation, check cooling water
What type of shackle do you use for lifting people?
Safety type, anchor style, 4 part
How is a shackle sized?
By the body
Eyebolt angles
Shouldered = 45degrees
No Shoulder = no angle
If you are lifting a heavy load horizontally with a crane you should use
A snatch block
An internal leak in the cylinder means
The piston seals are gone/bad
What types of packing needs a support ring?
U-ring packing
What packing is unbalanced?
Cup packing
What does breakdown maintenance cause?
Causes workers to react in a breakdown situation or increases production cost
When determining pipe strain, where should there not be any strain?
Across the couplings
What is reverse polarity on a welding machine?
Electrode positive
What should you do when transferring flammable liquid from one container to another?
Grounded/remove all ignition sources
When commissioning a food system/pump, what do you use?
Potable water (drinking water) or the product
If a sling hits against a wall, what do you do after?
Inspect the sling
What valve is all the way open on an oxygen/acytelene set up
Oxygen
Before alignment is complete, what is done to speed up the process?
Pre-alignment checks/rough alignment
After starting a hydraulic pump, it sounds like rocks in the line, why?
Aeration/aerated
Commissioning in starting a compressor, what is done?
Run unloaded for half an hour
What do you do when commissioning a refurbished fan?
Balance
What maintenance program follows a schedule?
Preventative
When setting up a baseline for a machine, what is done?
Vibration analysis/pressures/temperatures
What does a receiver always need?
Max pressure relief valve
What is the proper way to clean a bearing?
Solution, hot soapy water
What is the first thing you do when starting up an axial piston pump?
Barr over, check rotation, prime
What is a turnbuckle used for?
Adjusting length or levelling
If a diaphragm pump is not releasing enough discharge, what do you do?
Turn up the air pressure
What type of oil is used in a 4 stroke internal combustion engine?
Detergent oil
When is a wedge socket used?
To easily and quickly attach rope
A conveyor is turned on but not moving, why?
Trip cable is engaged
What do you do if there is no line of sight between the operator and load / signal person?
Get a second signal person
What type of rigging would you use to lift a bundle of piping?
Double wrapped choke
Labyrinth seal is leaking, what is the cause?
Plugged drain
What is the purpose of flux when brazing?
It prevents oxidation
How wide is the join of a 10 ply belt?
Width of belt at least
You install a new chain but do not have a new sprocket, what do you do so no speed is lost?
Reverse sprocket
How do you change an insert in a coupling?
Loosed one set screw, slide back, replace insert, slide back, and re-install set screw
How do you inspect a hook on a daily inspection?
Visual
A wire rope has 3 strands broken, what do you do?
Take it out of service/discard
What will cause a gear coupling to fail?
Misalignment
If a conveyor is going off track, what do you do?
Adjust tail pulley
Where do you place a lantern ring in a pump?
Under cooling water gland
How many threads are there on a metric micrometer
50Tpi (standard has 40)
How do you know when to change the filter on a hydraulic system?
Pressure drop across filter
How many years is a hard hat good for?
1 year
What do you do with a job site container that is not marked?
You dispose of it
Last step once pump is reassembled?
Barr over
Pump starting up with high amperage draw, why?
Packing too tight
How to increase efficiency in a horizontal chain?
Correct adjustment to 2% center to center
What is the clearance in gears?
Backlash
What is used to check or patterns on gears?
How do you know when to change the filter on a hydraulic system?
Pressure drop across filter
How many years is a hard hat good for?
1 year
What do you do with a job site container that is not marked?
Dispose of it
Last step once pump is reassembled?
Barr over
Pump starting up with high amperage draw, why?
Packing too tight
How to increase efficiency in a horizontal chain
Correct adjustment to 2%, center to center
What is the clearance in gears?
Backlash
What is used to check backlash or mesh patterns on gears?
Dial indicators
What is the procedure for placing a sole plate on a footing?
Establish centreline, clean bottom, clean shim area on plate and concrete, prepare anchor bolts, install base plate
Procedure for putting a new gasket in a piping system
Wet the gasket
Procedure to change motor on indirect drive?
Snug jacking bolts on one side and remove/replace
Procedure to take apart gearbox
Drain oil, clean, match mark, disassemble
Checking shaft movement is called:
Concentricity
If a piece of steal does not fit into the lathe, what do you do?
Flip jaws
If a DCV valve is not working, what do you check first?
Solenoids
Pump has discharge flow but is not filling tank, why?
Blocked vent/drain open/blocked strainer or discharge
What is the purpose of a baffle?
Places between inlet and outlet Let’s cool, let’s contaminants settle, let’s air escape
Law of conservation of energy:
Energy cannot be created or destroyed, it can only change form
What is the cracking pressure of a check valve?
3-5psi
After honing/deglazing what do you use?
Warm, soapy water
How many watts does a standard 8hp motor have?
1hp =746watts, 8hp = 5968watts
What is the tie wire used for in turbines?
Joins blades to stop vibration
What direction do you tighten a cam ring in a bearing?
Direction of shaft rotation
Steps to setting clearance in a centrifugal pump:
- LOTO
- Move impeller to the rear
- Assemble pump
- Set up dial and move impeller forward until it touches inlet
- Zero dial
- Move impeller back to required clearance
Which bearing on a shaft gets stabilizer rings?
The fixed bearing (the one closest to the coupling)
What do you do with labyrinth/lip seals for bearings?
You grease them
When cleaning electrostatic precipitator, what do you clean?
The plates
A bearing with a “K” denotes what?
Tampered bearing
What’s the leading cause of bearing failure?
Lack of lube
Which gearbox can you not run in reverse?
Single start / worm drive - single start
Minimum amount of teeth to make contact in V-belt
6 teeth
How much deflection should be on a belt?
1/64” deflection for every inch of length
What type of wire rope should not be used on a single part lift!
Lang
What type of rope floats?
Poly
What is the strongest type of natural rope?
Hemp
Of a pneumatic actuator is hammering out on it’s extension stroke, what should you do?
Adjust cushions
In what state should a hydraulic Jack be before storing?
Fully retracted (pressure released and fully de-energized)
What is the start-up procedure when installing a steam turbine?
Start the jacking pump to lift the turbine, start turning the gears, start aux oil pumps, and shut down jacking pump and preheat turbine.
A stationary diesel engine is overheating on a hot day, why?
Damaged rad fan
What is the diameter of #6 machine screw?
0.138”
A pump is operating normally, the auction side filter is changed with a filter of the same micron the pump rattled at start up, why?
Aeration (air in the line)
What is the sequence for repacking a pump?
Clean, cut, roll them out to flatten, install by staggering by 90 degrees, hand tight nuts, start, adjust to 40-60 drips per minute
Bearing is running hot due to excessive load, what is done to correct this problem?
Bigger bearing
What is adjusted when a chain conveyor system is jumping?
Adjust chain tension
Which points are used to triangulate when checking squareness to centreline?
Longest points and centreline
A hand grinder is sparking in the case, what do you do?
Change brushes and clean
What do you use to measure between the O vector and the T vector?
A protractor
Purpose of a strobe light?
To find the phase angle
What is the symbol for double insulated?
A square inside another square
Long horizontal pull with a crane use
Snatch block
Long horizontal pull without a crane use
A tirfor
Chain on chain hoist that can be replaced
Hand line/pull chain
Black smoke from a diesel engine indicates what?
Turbo, dirty oil filter
Roller bearings tightened to half the initial clearance
Ball bearing La tightened until slight drag
Where do you fill the oil for preservation?
All the way full (storage)
Which bearing is fixed?
Closest to coupling, drive end
Rings close to the bearing are?
Stabilizer rings
For filling with grease:
Slow turning housing 1/2 full
Fast turning housing 1/8 full
What gets oil to where it needs to be?
Troughs and scrapers
If pushing on a bearing, do you push on the inner or outter race?
Inner race
What is the radius put on the end of the shaft for?
Easy bearing/hub install
What is the shoulder put on the end of the shaft for?
Strength
What do you heat a mandrel to before pouring babbitt?
120 degrees Celsius
What temperature do you pour Babbitt?
350 degrees Celsius (pour point)
Which coupling does not have the hub removed?
Donut (not clamped type though)
How are couplings/clutches/brakes and transmissions rated?
HP/RPM
If a clutch wears an outer diameter, what is the main cause?
Misalignment
Mechanical clutch doesn’t disengage, what do you do?
Linkages need to be adjusted
If a clutch is slipping, what is the reason?
Springs are weak
How do you reduce vibration in a chain?
Use 2 smaller chains
Huntington Sprocket
Has uneven number of teeth and a couple pitch chain
Chain slack
1/4 of pitch if vertical. 2% if horizontal, tighter if reversing
A high speed chain uses what line system?
Mist
If belt keeps squealing
Replace
To check for chain stretch
Compare to a new chain
What is the reason a belt rolls over on a sheave, why?
Worn sheave
What kind of sag does a laser not allow for?
Bracket sag
What is a worm wheel made of?
Brass
Bracket sag is always
A negative number
Class 1 light = visible
Class 2 light = invisible
What do you do if a fan is running hot?
Increase RPM’s
Crown on a crown pulley has a taper of what?
1/8” per foot
How do you pressure test a process tank?
Hydrostatic
To fill bins under a conveyor, what do you use?
Tripper
A tank should be how many times the delivery flow rate of the pump?
2-3
How do you find the centre of a shaft?
Centre head and ruler (centre square)
A pump with a suction head means what?
Higher discharge
Where do you place a scraper on a belt?
Scraper at head pulley
What type of sling would have the least amount of electricity?
Wire or chain
EP oil in hypoid gears?
Extreme pressure
Replacing reed valve on engine?
Like a check valve, placed between carb and crankcase
Trip on a governor?
On steam turbine, bring up to speed and manually trip it.
Babbitt bearing?
Relieve first and Chamber
When replacing a cover on a bearing on a boiler feeder, top half of cover not seating, what do you do?
Turn 180 degrees for dowels to line up
What is the name of a pressure gauge on inlet of a compressor?
Manometer
A motor conveyor kicks out often, why?
It is overloaded
When commissioning a long line of machinery, what order?
Last to first
After deburring a piece of metal, what do you do next?
Measurements
Bucket dump jumping and spilling, why?
Belt/chain loose, sprocket missing teeth
80 grade pipe, where do you check for deterioration?
Outside corners (elbow)
Rotation of camlock?
With direction of rotation
Locking on a bearing?
Internal snap ring
A Jack to use from a distance
A portable jack
Vertical welding arc?
Arc length short as possible (bottom to top)
Thermal growth, how to you shim motor to offset growth?
Set motor higher
As temperature of oil increases, viscosity _______
Decreases
Pneumatic diaphragm pump fails to deliver flow at out put, even when the diaphragm is in good condition, why?
Debris between diaphragm and casing (housing)
How do you maintain alignment when changing out a motor on a pump with jacking bolts?
Leave one side of the jacking bolts tight, slack off other side, replace motor, tighten slack side
How to replace a spider from a coupling?
Slack one hub, move back, replace spider and retighten
Steps to fill accumulator:
-turn the gas chuck in until the pressure reads on the gauge
-do not turn gas chuck all the way as it will damage the valve
-slowly open the nitrogen bottle valve
-let the accumulator fill slowly
Pipe anchor question, what do you do before grouting?
Level
Coupling in a condensate pump fails, what is the reason?
Didn’t account for thermal growth (heat/hot)
Bearing is constantly failing on an indirect drive pump, why?
Drive belt too tight
How do you check for vibration?
Transducer
When starting an axial piston pump, what is the first step?
Prime pump
What do you need to mount a tapered bearing on a straight shaft?
Adapter sleeve
Engine has sat idle for a long period, excessive cranking before starting, what is the cause?
External injector leakage/faulty glow plugs
Efficiency of a pump decreases, what is the cause?
Worn rings/ increase clearance in wear rings.
