Millwright Mix 3 Flashcards
When maintaining the point of a center punch how is the center punch held?
Perpendicular with grinding surface of wheel and rotate while grinding
What is the procedure to maintain a handheld grinder that is sparking in the housing?
Remove armature and replace brushes
How is a class A fire extinguisher stored?
Vertically and in an environmentally controlled area
When are safety lanyards checked?
Before every use
What is the tap drill size for a 5/8” UNC-11- 2B thread?
0.534”
When operating a magnetic base drill in an overhead position which precaution is taken?
Secure with safety strap
When performing a manual control lockout what deactivates the control?
Programmable logic board PLC
When performing work in an industrial setting what is the most important thing to consider?
Wearing PPE
Which additive is added to oil when lubricating hypoid gears?
Extreme pressure EEP additive
The total indicator reading on the rim of a coupler is .012”. The faces of the coupling are parallel and the motor is low. Which size of the shim is used under the motor feet?
.006”
Which type of thread is used in bench vises?
Square
What is the procedure to verify the diameter of a piece of round stock along its length to a thousandth of an inch?
Use a Vernier caliper at 1’ intervals
What is the 1st step of the installation of a base plate for a new machine?
establish center lines
What procedure is followed to determine the center point on the end of a shaft?
Scribe a line using a center head and rule, rotate 90ﾟ and scribe another line.
When installing a packing robot what is the 1st step when using an optical level?
Center the fish eye bubble
What causes a noisy neutral flame when cutting mild steel?
There’s too much acetylene in the flame mixture
Which type of material is cut with an oxy-acetylene torch?
Mild steel
There should the ground cable be connected when arc Welding?
Close to the work as possible
The benchmark reference lines reading is 58.750” and the average sole plate reading is 9.125” what is the sole plate elevation?
49.625 “ HI-FS=ELEVATION
Dimension Y is 15’ 4” and dimension Z is 20’ 5” what would dimension X be to ensure the conveyors are installed perpendicular to each other?
25’ 6”
When a .050” shim is required to level one end of a 18” level on a 6’ bed plate. How much shim is required to level the plate?
.200” (high over low)
What is the most important step before performing maintenance work on a pressurized system?
Bleed the system
Which document contains information on scheduled maintenance to be performed?
Work order
A load is being lifted with 12’ slings. What is the distance between the lift points when using the recommended safe Working angle of 60ﾟ at the Apex?
12ft Equilateral triangle
The working load of the choker sling arrangement is 22500lbs. What is the working load rating of the same sling used in a straight vertical lift?
30000 lbs
What is used to lift a motor pump base with a machined surface?
Softeners and Web slings
When checking diameter of a wire rope where is it measured?
Across the widest point
Which type of block is used to change the angle of the pull of a wire rope?
Snatch block
A Crane requires a secure lifting area of 400 ft² what is the lift radius is required?
11.3 ft ( A=pi R squared)
During a post-lift inspection of a hoist rope. 3 wires in one strand over 1 lay are broken, what is done?
Take out of service and replace rope
After using a term buckle, what is the term buckle inspected for?
Deformation, cracks and thread damage
A pin has been welded into a shackle what is done?
Dispose of shackle
Which length of rope is needed to complete 3 dead wraps when replacing the cables on a 12” diameter drum?
113”
When inspecting eye bolts it is discovered that 1 of the eye bolts is bent, what is done?
Dispose of eye bolt
What is the procedure for coiling a fiber rope for storage?
Coil the rope in a clockwise direction, loop the rope tie, with two 1/2 hitchess while leaving a short end for hanging and hang on a peg
How are slings stored?
controlled environment and hanging vertically
What is the start up procedure after installing a steam turbine
Start the jacking pump to lift turbine, start turning gear, start auxiliary pump, shut down jacking pump and preheat turbine
Upon startup an electrical 3 phase motor will not achieve desired RPM and emits a loud humming noise what is the cause?
Power supply is single phase
A diesel engine is used to power a backup generator. After a long period of inactivity, excessive cranking is required to make the engine start. What is the cause?
Glow plug failure
What is the procedure to replace a bearing in a front cover of an electrical motor?
Support shaft, remove front cover, replace bearing then replace seal
What is used to clean dirty gas turbine compressor blades?
Walnut shells
When maintaining a large electrical motor in a high load, high temperature environment. Which type of lubrication editive is used?
Extreme pressure (EP)
Which type of Babbitt bearing is used when installing a heavily loaded shaft where the load will be slightly above horizontal?
Angle
A standard spherical roller bearing is to be installed but a reference table is not available. By how much is the initial clearance reduced?
50%
75% -for ball bearing
What is used to install an 18” internal diameter bearing that has an interference fit on the shaft?
Induction heater
During a routine inspection, a pillow block bearing has dark discoloration seen on rolling elements. What is the cause?
Overheating
The bore of a bearing housing is worn oversized. What is the cause?
Excessive creep
CREEP is the change in length or shape over an extended period of time due to a continuously applied static stress. It is an undesirable deformation that can be accelerated by the application of heat. Other factors that affect creep are the material type and age.
A lip seal is installed to prevent bearing contamination. Oil is still regularly found on the housing. What is done to prevent this from happening?
Install a double lip seal
How is a bearing outer race removed from the housing when there is no room for a puller?
Welding a bead on it
How is a ball bearing cleaned?
By washing in fresh solvent and let air dry
When packing a low speed ball bearing with grease how is the bearing packed?
By Hand
With a dial indicator mounted on the motor shaft, the face reading recorded were .000 and the total indicator reading on the rim was + .016 at the 6 o’clock position. How is the motor position to obtain a .000 reading?
Raised .008
When checking vertical angular alignment the gap size difference is .018” the distance between the hold down bolts on the side of the motor is 6” and the coupling diameter is 4”. By much must the motor be shimmed?
.027 “ bolts/coupling × gap
A pneumatic clutch on a line shaft has engaged slowly. What is the cause?
Insufficient air volume
When checking for vertical angular misalignment, the dial indicator needle moves in a clockwise direction when the coupling is rotated a 180ﾟ from the 12 o’clock position what does this indicate?
The gap is wider at the top
When performing coupling alignment which misalignment condition is corrected 1st?
Vertical angular
How is a failed grid coupling repaired without moving the hubs or equipment?
By installing a clamped donut
A friction clutch is producing a shock load by grabbing. What is done to correct this?
Adjust throw out bearing
What is the minimum wrap of engagement when installing a synchronous belt?
6 teeth or 60°
A machine has a broken V-belt in a difficult area to access. What is a temporary fix until a permanent belt can be installed?
Installing belt clips in original V belt
What is done to change the speed of a V-belt type variable speed drive?
Increase spring tension
Upon inspection abnormal wear is noticed on one side of the sprocket. What is done to repair it?
Realign sprockets
What is the procedure for removing a split taper bushing from a sprocket?
Remove hub bolts, insert all jacking bolts and apply even pressure
What is the procedure to change the length of a standard roller chain without the use of an offset link?
Remove connector link and replace with 3 pitch length
Drive belts have been adjusted due to squealing. 8 hours later, the belt squealed again. What is done?
Replace belts
While performing routine maintenance on a belt drive there is uneven wear on the sides of the belt what is done?
Realign the sheaves
When gears are installed. What is checked or measured to ensure the teeth are meshed properly?
Backlash
A new wormgear reduction unit is installed. What is done after bluing?
Adjust shims for proper contact
What Is checked to ensure adequate lubrication when rebuilding a gear reducer?
Dams, passageways and scrapers are clear
What is plastic gauge used for, after a gearbox is repaired?
Determine the clearance
When installing a refurbished fan. What is done when commissioning?
Attach weights on the outer rim during dynamic balancing
A fan that has the capacity to supply 2000 ft³ per minute is only delivering 1500 CFM using a 2-1/2 HP motor. The motor is tripping out from overload. What is the HP required to obtain 2000 CFM?
3.33 hp (High over low)
There is excessive internal noise in a lobe-type blower in a pneumatic conveyor system. What is the cause?
Timing gear wear
What is the procedure to repair a crack in a fan shroud?
Drill holes at both ends of crack and Weld crack
What is the procedure for cleaning fan blades?
Lock out system, clean, check for damage and restart
What is the procedure for commissioning a centrifugal water cooled compressor?
Level, connect and check motor rotation
The motor on a centrifugal compressor has stopped before meeting the set point at the receiver. What causes this to occur?
Faulty pressure switch
There is a decrease in the volumetric efficiency of reciprocating air compressor. What is the cause?
Decrease in required compressor displacement
What is the procedure to replace the air/oil separator filters on a compressor?
Depressurize, remove cover, remove filter and gaskets, install new filter and gaskets and reinstall cover
New rod packing rings have been installed in a reciprocating compressor. What is done at start up?
Adjust packing lubrication flow rate
What is the procedure for hard shimming a pump base before grouting with non-expanding grout?
Rough the area to be grouted, level base, set discharge flange to elevation, hard shim on both sides of anchor bolt, torque to 1/2 torque and keep pad clean and moist until ready to grout.
Before reinstalling a centrifugal pump what is checked 1st?
If the impeller turns freely
A centrifugal pump has been recently installed and is producing excessive flow. What is the cause?
Oversized impeller
A centrifugal pump is vibrating and noisy. What causes this condition?
Pump bearing worn
The system efficiency of a centrifugal pump has decreased overtime. What is done?
Replace wear rings
What is the procedure to install bearings in the centrifugal pump?
Check shaft, install bearings, assemble pump and check clarences
A centrifugal pump in operation has heavily contaminated oil. The pump cannot be taken out of service. Which corrective action is taken?
Slowly purge the oil while adding fresh oil
What is installed on a conveyor to prevent material from spilling out over the conveyor at a loading point?
Skirting
How is side lagging replaced on a pulley?
Remove old lagging insections, clean the pulley surface, and install new lagging sections by rotating the pulley as required
Conveyor belt A is feeding belt B, belt B is overloaded. What is done to correct this situation?
Change sheaves on conveyor A to decrease speed
The process material is clinging to the return side of a 24” conveyor belt what is the cause?
Misaligned scrapers
What is the function of slotted bolt holes on the support idler frames?
To correct belt tracking
What is done to correct tracking on a long unloaded conveyor?
Adjust support idler’s square to belt travel
The skirt board on a conveyor is worn out. What is done to the replacement board to prevent jamming of the aggregate?
Decrease skirt board clearance in the direction of belt travel
The end cap of a multi pass heat exchanger leaks internally when the exchange is brought into operation. What is the cause?
Damage Gasket
A confined entry permit has been obtained and safety requirements have been met. What is the procedure to maintain a processed tank?
Flush tank, repair defect and clean tank
How much force is created when 150 PSI is applied to a 5” diameter piston?
2945 lbs (F=PxA)
In a hydroesthetic drive the internal gear pump has a blown out shaft seal. What is the cause?
Plugged or restriction on discharge line
During operation a pump exhibits high vibration, then seizes. Upon disassembly, the pump veins are broken and seals are ruptured. What is the cause?
Insufficient lubrication
Hydraulic pump displacement is 17 GPM and the reservoir is 11GAL. The system experiences above normal operating temperatures while running. What is the cause?
Insufficient Reservoir capacity
A hydraulic system has a high particulate content that is constantly plugging the suction screen. What is done to correct the problem?
Install baffle plates in the oil reservoir
The output pressure on a hydraulic accumulator is lost. What is the cause?
Bladder is ruptured
A hydraulic motor fails to produce enough torque to turn an increased load. What is done to correct this problem?
Increase relief valve setting
Which size pneumatic cylinder must be installed to develop 1500lbs of force with 150 PSI system pressure?
10 sq. In. (A=F/P)
A vacuum pump is running above the normal operating temperature. What is the cause?
Increased demand on system
A vacuum pump is unable to achieve the specified maximum value of 29.92” HG at sea level what is the cause?
Atmospheric contamination
When balancing a newly installed piece of rotating equipment. Where is the pertinent information found?
Manufacturers specification
Where can the performance history of a machine be located?
In the computer maintenance management system
Which type of non-destructive testing requires special precautions to be observed when working in the area?
Radiography (xray)
What is the sequence when commissioning a system?
Start equipment from end of process to start of process
When commissioning a new dry fluid coupling what is done to reduce the shock load on the output shaft?
Decrease speed
When commissioning a small turbine that has a governor, what is done to ensure the mechanical over speed trip is functioning?
Run the equipment to the designed trip speed and repeat 2 or 3 times
In the start-up procedure of a centrifugal pump, what valve is open last?
Discharge
When commissioning a portable hydraulic system, what is the sequence of installation of the filtration system?
Strainer, relief valve and filter
When starting up a fluid drive system, air is found in the fluid. What is the cause?
Reservoir level is low
