Maintenance and Operation of Lubricant Systems

Maintenance and Operation of lubri natest SystemsActivity 1 Explain the economic consumption and the applications of three variant typefaces of lubri stinkpott.Greases ar solid or solid lubricators and gener all in ally populate of soaps, mineral anoint, and various additives. These atomic number 18 eminently viscous ad adhere puff up to metal out-of-doorss. Although utilise extensively in machinery, covers be of limited use in manufacturing processes.Graphite is creaky in shear al single its basal planes and therefore has a low coefficient of encounter in that direction. It is an strong solid lubricant, particularly at elevated temperatures. In a vacuum or an inert gun for hire atmosphere, friction is actually high in fact, plumbago can be abrasive in these situations. We can apply graphite either by rubbing it on surfaces or by making it part of a colloidal (dispersion of small particles).Glasses is a solid material, glass becomes viscous at elevated temperatur es and, therefore, can dole out as a liquid lubricant. Viscosity is a function of temperatures, only if not of pressure, and depends on the type of glass. Poor thermal conductivity as well as makes glass attractive, since it acts as a thermal ostracizerier amidst hot work pieces and comparatively modify dies. Glass lubrication is typically used in such applications as hot extrusion and forging.Activity 2 Describe the operation and maintenance of three unlike lubrications schemes. oil circulatory systemsIn oil colour circulatory systems, the oil is continuously supplied to various moving move and billings. In such systems, oil acts both as lubricant and as well as as coolant by earning a path pepperiness generated in the commissions/moving parts. The oil after lubrication is returned to reservoir either directly or through get acrosss. These systems ar medium- long, employing reservoirs of capacity ranging from some hundreds of liters to thousands of liters. The pum ps argon heavily duty, in hunt downed for continuous running, with flow rate ranging from few tens of LPM to few thousands of LPM. These systems ar widely used for plants like Cement, Sugar, Paper, berth genesis. Steel as well as heavy duty machineries.Full Force fertilise systemsIn a replete feed lubrication system, the main bearings, magnetic pole bearings, cam radiation bearings, and the complete valve mechanism atomic number 18 lubricated by oil under pressure. In addition, the full force-feed lubrication system provides lubrication under pressure to the plungers and the piston pins. This is accomplished by holes drilled the length of the connecting pole, creating an oil line of achievement from the connecting rod bearingTo the piston pin bearing. This passage not only feeds the piston pin bearings but overly provides lubrication for the pistons and piston chamber walls. This system is used in virtually all engines that atomic number 18 equipped with full-floating piston pins.Force Feed systemsA fairly to a greater extent complete pressurization of lubrication is achieved in the force-feed lubrication system Oil is forced by the oil pump from the crankcase to the main bearings and the cam know bearings. Unlike the combination system the connecting-rod bearings be also federal official oil under pressure from the pump.Oil passages are drilled in the crankshaft to lead oil to the connecting-rod bearings. The passages deliver oil from the main bearing journals to the rod bearing journals. In some engines, these opening are holes that line up once for e actually crankshaft revolution. In other engines, there are annular grooves in the main bearings through which oil can feed constantly into the hole in the crankshaft.The pressurized oil that lubricates the connecting-rod bearings goes on to lubricate the pistons and walls by squirting out through strategically drilled holes. This lubrication system is used in virtually all engines that are equi pped with semifloating piston pins.Activity 3 Describe the operation of ace pestle, one type of packing and ii assorted types of bearing with a typical application for separately one.Seal End face postage stamps This type of seal uses both rigid and flexible fundamentals that take contact at a sealing interface and slide on each other, allowing a rotating divisor to a pass through a sealed case. The elements are hydraulically and mechanicly load uped with a spring or other device to state contact.In general the end face seal is sealed to the pump end home office by a gasket or O- ring and also the rotating seal face runs against the stationary seat (the opposing surface lapped to high degree of flatness).An end face robotic seal, also known as a mechanical face seal but usually patently as a mechanical seal, is a type of seal utilised in rotating equipment, such as pumps and compressors.Packing O-ring Is a packing and it is also known as tonic joint, it is a mechanical gasket in the shape of a torus. It has a cross-section with a disc-shaped it is also a loop of elastomer. O-rings are one of the most common seals used in machine design because they are inexpensive and easy to make, reliable, and devour simple mounting requirements. They can seal tens of megapascals (thousands of psi) pressure.An O-ring is basically defined by its section dia clip and the interior diameter of the O-Ring.O rings fork out m all advantageous features includingLow cost suit tranquildynamic dutiesspace efficientseals in both directionsfluid pressure assists sealingSuitable for all fluids-using appropriate elastomers.Two diametric types of bearings field of battle bearingIn general plain bearing drive home rubbing surfaces usually with lubricants. The stiffness of plain bearing are Good, provided wear is low, but some on the loose(p) is unremarkably present. It also has a very low speed to a very high sleep. Plain bearing is the simplest type of bearing, widely used, relatively high friction, suffers from stiction in some applications. Some bearings use handle lubrication and be suck similarly to fluid bearings. At high speeds life can be very short.Rolling-element bearingA pealing-element rotary bearing uses a shaft in a much larger hole, and cylinders called buns tightly fill the space mingled with the shaft and hole. As the shaft turns, each whorl acts as the logs in the above example. Yet, since the bearing is round, the rollers never decline out from under the load. A rolling-element bearing is a bearing which carries a load by placing round elements between the 2 pieces. The relative motion of the pieces causes the round elements to roll with very little rolling resistance and with little sliding. It is the earliest and best-known rolling-element bearings are sets of logs laid on the terms with a large stone distract on top. As the stone is pulled, the logs roll on the ground with little sliding friction. As each log comes out the back, it is moved to the front where the block then rolls on to it.Activity 4 Describe two different types of screwed fasting and two different types of rivet giving a typical application for each one.Two different types of screwed fastingBolts and loopyBolts and soft can be made from mark, brass, aluminum alloys and plastic. in that location are all sorts of bolts and nuts with different sizes for exampleM6x25 high tensile bolt BZPM2 full not zincThe above metric blots and nuts and specified as steel.The specifications for bolts and nutsExample M8x1.550M specifies that it is metric.The number next to the letter M which is 8 specifies the diameter in millimeters.1.5 specifies the tread pitch in millimeters.50 specifies the length of the shank in millimeters.There are other bolts for exampleTap boltA bolt that is threaded all the way to the head.Eye boltA bolt with a looped head.Toggle boltA bolt with a special nut known as a wing. It is knowing to be used where there is no access to side of the material where the nut is located. Usually the wing is spring loaded and expands after existence inserted into the hole.The strength of the boltsCan be identified by reading the numbers stamped on the head of the bolts, these are referred to the grad of the bolt used in certain applications with the strength of the bolt.High-strength steel bolts usually have a hexagonal head with an International Organization for Standardization(ISO) strength rating stamped on the head.Studs and nutsStudsRoad studs These are generally used on hard surfaces, such as roads or very had ground. They are normally 4 to 6 sided, small and flat in size and blunt.Ice studs these are also designed for use on hard surfaces, but generally have a capaciouser, sharper focalize than road studs, to provide traction on slippery surfaces.Grass studs are also known as bullet studs , they come in many different lengths but are always larger and maker than road studs and generally narrow so they can dig into hard, dry ground.Mud Studs are used on extremely soft or wet riding surfaces where deep traction is shooted. They are bigger thanRoad Studsbut often rounded on top and come in several different lengths.Mud Studscan also be square in shape, known asBlock Studs.SomeMud Studsare knownasOlympic Studs*which are long and sharp and used for extremely slippery groundTwo different types of rivetsBlind rivets.These types of blind rivets have non-locking mandrels and are avoided for critical structural joints because the mandrels may fall out, due to vibration or other reasons, leaving a hollow rivet that will have a significantly lower load carrying capability than solid rivets. In addition, because of the mandrel they are more horizontal to failure from corrosion and vibration.A drive rivetA drive rivet is an look of blind rivet that has a little mandrel protruding from the head that is driven in with a hammer to flicker out the end inserted in the hole. This is usually used to rivet wood panels into bunk since the hole does not need to be drilled all the way through the panel, producing a good-looking pleasing appearance.They can also be used withplastic,metal,Other materials and require no special saddle horse tool other than a hammer and possibly a backing block.P5-Decribe the operation of two different types of cam and associates and two different types of linage mechanism.Two different types of cam and followersCam followers are alike(p) to needle or cylindrical roller bearings with a thick-walled external ring.The crowned out surface of the outer ring prevents border stresses if the roller runs in a twisted or inclined location. They are grease full ready-to-mount units appropriate for all types of cam drives, leadings and conveyor systems.In its place of an inner ring cam followers have a hard threaded pin to permit the cam follower to be quickly and advantageously disposed to the machine mechanism by means of a hexagonal nut. Axial guidance is provided through an inhering flange on the external ring at the top of the pin and a side.Cam followers are obtainable in three different internal designs. Usually, the cam followers have concentric seating on the pin, but some are also accessible with a strange collar shrunk on to the stud. Cam follower bearings with collar allow an optimum interaction with the cam and allow fewer stringent developed tolerances for the mechanism.Two different types of linkage mechanismA mechanical linkage is a sequence of rigid links conjugate through joints to shape a closed series, or a series of closed range of mountainss. Every linkage has two or more joints, and the joints have a variety of degrees of freedom to allow movement between the relations. A linkage is called a mechanism if two or more links are personal chattel with respect to a fixed link.Four-bar linkage mechanismsThe four-bar linkage is one more mechanism which finds general uses. It is bring in applications su ch aswindscreen wiper drives,Vehicle suspension units andEveryday uses such as the hinges on kitchen cupboard doors and squeeze-mop mechanisms.Two of the links spin about fixed centers and are connected by a coupler linkage. The fourth link is shaped by the frame or bed plate that contains the permanent centers of rotary motion. It essential be noted that the number of inversion of machinery is equal to the number of links, which in this case is four links.Reverse motion linkage.As the top bar moves to the left field the base bar moves to the right. The bars move in reverse directions. an additional way of describing this linkage is the direction of movement in one bar is reversed in the other rod. The fixed pivot is the centre of rotation.(P6) describe the formation and operation ofTwo different kinds of belt driveFlat beltsFlat belts are used more often than not for transmitting light tons. Since they are flexible, this makes them appropriate for applications where there is so me misalignment among shafts they possibly will be cross to give op aim directions of turning round to the pulleys. They can also be twisted to attach shaft which are not in the selfsame(prenominal) plane.Vee beltsVee belts (also recognized as V-belt or wedge rope) solved the slippage and arrangement problem. It is currently the essential belt for power contagious disease. They offer the best mixture of grip, pace of movement, load of the bearings, and long service life. They are usually continuous, and their common cross-section shape is trapezoidal. The V shape of the belt tracks in a mating groove in the pulley (or sheave), with the effect that the belt cannot slip off. The belt also tends to hold into the groove as the load increases the larger the load, the larger the wedging action improving tortuousness transmittance and making the vee belt an helpful solution, needing less width and tension than flat belts.Two different kinds of chain driveA chain is a method of polish offring rotary motion between two gibe shafts. The chain drive is autocratic, efficient and high torques can be transmitted. The chain is generally made from steel although plastic chains have been developed.Roller Chain Roller chain or bush roller chain is the type of chain most frequently used for transmission of mechanical power onbicycles,motorcycles,and in industrial and agricultural machinery.It is a straightforward, dependable, and efficient means of power transmission.Two different kinds of paraphernalia train.Epicyclic inclineing or planetary accessorying is a gear system that exists of one or more external gears, or planet mechanism, rotating about a central, or sun gear. Typically, the planet gears are mounted on a movable arm or carrier which itself may unfold relative to the sun gear. Epicyclic gearing systems may also incorporate the use of an outer ring gear or annulus, which meshes with the planet gears.(P7) Describe the arrangement and operation ofTwo differ ent kinds of transmission shaftPower transmission shafts are mainly used in two wheeler and four wheeler vehicles. These shafts consist of metal joint elements and a metal pipe connected to each other. To provide more rigidity to shafts, a plastic pipe is inserted into metal pipe thus forming a composite power transmission shaft having more strength and rigidity.Automotive transmission shafts are especially designed and used in two wheelers as well as four wheelers. These shafts are integral hollow type shafts that maintain a perfect balance between static strength and fatigue strength.Two different types of Couplings radiation therapy joins are used in machinery for several purposes, the most common ones areTo provide for the connection of shafts of units those are manufactured separately such as a motor and generator and to provide for disconnection for repairs or alternations.To provide for misalignment of the shafts or to introduce mechanical flexibility.To reduce the transmi ssion of shock loads from one shaft to another.Rigid Slip Couplings This type of coupling has no flexibility therefore it is essential for the shafts that aretobe connected to be in good alignment, both laterally and angularity, in order riotous loadson the coupling, on the shafts, or on the shaft bearings.Rigid couplings do not accommodate misalignment and consequently should not be usedindiscriminately.Types of Rigid CouplingsSleeve or muff coupling It is the simplest type of rigid coupling, made of cast put right. Itconsists of a hollow cylinder whose innerdiameter is the same as that of the shaft. It is belongted over the ends of the two shafts by means of a gibhead key.Clamp coupling Clamp coupling is some snips called a compression coupling or a ribbed coupling. Clamp coupling is a modification and an improvement of the sleeve coupling. This coupling is made in two parts which are machined to fit the shaft and are finished off around the periphery and on both ends.Flange c oupling A flange coupling usually applies to a coupling having two separate cast iron flanges. Each flange is mounted on the shaft end and keyed to it. The faces are turned up at right angle to the axis of the shaft.Two different kinds of sightDog clutch is a type ofclutchthat couples two turning shafts or other rotating mechanism not byfrictionbut by interference. The two parts of the clutch are designed such that one will push the other, causing both to rotate at the same speed and will never slip. Dog clutches are used at bottom manual automotive transmissions to lock different gears to the rotating input and output shafts.Cone clutch serves the same purpose as a disk or plateclutch. However, instead of mating two spinning disks, the cone clutch uses two conical surfaces to transmit torque by friction. The cone clutch transfers a higher torque than plate or disk clutches of the same size due to the wedging action and increased surface area. Cone clutches are generally now only used in low encircling(prenominal) speed applications although they were once common in automobiles and other electrocution engine transmissions.Two different kinds of breaks disc brakes are made of cast iron or ceramic composites. The use of these types of breaks ate to throw in or slow the rotation of a wheel.Hydraulic brakes use brake fluid, and normally containing ethene glycol the reason for this is because to transfer pressure from the controlling unit and also to brake mechanism which is normally near the wheel.(P8) Describe with the aid of diagrams the general layout operation of a pneumatic actuation systemPneumatic systems provide a softer action and are also not able to deliver such large forces. Besides the disadvantages pneumatic systems have some advantages which areSimplicity of Design and ControlMachines are easily designed using standard cylinders other components. Control is as easy as it is simple ON OFF type control.ReliabilityPneumatic systems tend to have l ong operating lives and require very little maintenance. Because gas is compressible, the equipment is less likely to be damaged by shock. The gas in pneumatics absorbs excessive force, whereas the fluid of hydraulics directly transfers force.StorageCompressed Gas can be stored, allowing the use of machines when galvanising power is lost.SafetyVery low chance of fire (compared to hydraulic oil). Machines can be designed to be overload safe.The process of the pneumatic system that is shown aboveThe compressor receives filtered air form air filter and delivers through an after-cooler to the crocked air receiver. Then the air is distributed to different applications as well as the pneumatic cylinder. Pneumatic systems employ gas that is compressed under extremely high pressure. For some applications where the air must be perfectly dry, the system also contains a moisture separator. The practical use of pneumatics comes in position that compressed gas to use, at its most basic level a pneumatic system holds compressed gas in a specially designed armoured combat vehicle and then we smother some of that gas into an expandable chamber. The expandable part of the chamber has a rod attached to it so that as it expands the rod moves outward.Hydraulic actuation systemsAir has a low density and is compressible at the same time as hydraulic oil has a much higher density and is almost incompressible. Therefore, hydraulic systems are capable to function at much advanced pressure and deliver the very huge positive forces which are necessary in applications such as hydraulic presses and lifts. Hydraulic actuation system has advantages which are listed belowAdvantages of hydraulicsLiquid (as a gas is also a fluid) does not absorb any of the supplied free zero.Capable of moving much higher loads and providing much higher forces due to the incompressibility.The hydraulic operative fluid is basically incompressible, leading to a minimum ofspringaction. When hydraulic fluid flow is stopped, the slightest motion of the load releases the pressure on the load there is no need to bleed off pressurized air to release the pressure on the load.The process of the Hydraulic actuation systems that is shown aboveThe system has motor-driven pump which draws filtered oil from the tank and distributes it through a pressure regulator to the positions where it is necessary. The pump runs constantly and the excess oil which is not necessary for procedures is diverted back to the tank by the pressure regulator. It must be noted that the organization generally supplies a relatively little work area in the locality of the pump and tank. It is not virtual(prenominal) to provide oil under pressure over large distances for the reason that of pressure drop and the need for a return pipe. A manual or automatic control valve supplies oil to the actuation cylinder and directs return oil to the reservoir.A mechanical handling systemThe transfer of material, components and assem blies through the manufacturing stages often takes position on roller or belt conveyors.Mechanical handling has a broad variety of handling. Lifting gear used in developing business is broad and in some cases it is extremely meticulous.The roller conveyer belt is most expected the easiest form where manufactured goods are passed among work stations along a track having rollers. Materials are regularly shifted through a motor-driven belts conveyer. The belts are from frequently maintained on concave roller so that is falls in the center.(P9) Describe with the aid of diagrams the general layout and operation ofSteam power generation plant Though the main process in locomote power station is the conversion of estrus energy into electrical energy, it comprises of many steps for its proper workss and good cleverness. The whole arrangement of a steam power station could be divided into following steps The steam generating plant consist of boiler and its auxiliary equipments for the u tilisation of flue gases.Boiler The come alive produced by the burning of coal in the boiler is used to produce steam at high temperature and pressure. The flue gases produced at the time of burn is passed through the super heater, economiser, air- preheater and finally exhausted into the atmosphere through chimney.Super Heater The steam produced in the boiler has got moisture content so it is dried and superheated (i.e. steam temperature is increased above boiling turn on of irrigate)by the flue gases on the way to chimney. Super heating ensures two benefits at first the overall efficiency of the system is increased and secondly the corrosion to the turbine blades due to condensation in later stages is prevented. The superheated steam from superheater is fed to steam turbine by means of a main valve.Air preheater Air preheater increases the temperature of the air supplied to coal for combustion using flue gases. Air is drawn in using a forced draught lover and is passed through preheater before supplying it to the boiler. This process increases the thermal efficiency and steam capacity per square meter of the boiler surface.Steam Turbine The dry and super heated steam from superheater is fed to the turbine by means of a main valve. Due to the striking or reaction impact of the steam on the blades of turbine it starts rotating i.e. heat energy is converted to mechanical energy. After giving heat energy to the turbine the steam is exhausted to a electrical condenser which condenses the exhausted steam by means of a cold water circulation.Alternator The steam turbine is coupled to an alternator the alternator converts the mechanical energy into electrical energy. The electrical output is transferred to the bus bars through transformer, circuit breaker and isolators.Feed Water The condensed water produced in the condenser is used as feed water, some amount of water may be lost in the cycle but it is compensated using an external reference and the cycle re peats and gives a better efficiency to the system.Cooling Arrangement Inorder to increase the efficiency of the plant the steam coming from the turbine is condensed using a condenser. The water circulation for cool down steam in condenser is take from a natural source like river, stream etc and the out coming hot water from condenser is fired in some lower portion of the water source. In scarcity of water the water from the condenser is cooled and reused with the help of a cooling tower.Refrigeration systemThere are several heat transfer loops in a refrigeration system as shown above. Thermal energy moves from left to right as it is extracted from the space and expelled into the outdoors through five loops of heat transferIndoor air loop. In the left loop, indoor air is driven by the supply air caramel through cooling coil, where it transfers its heat to chilled water. The cool air then cools the building space.Chilled water loop. Driven by the chilled water pump, water returns f rom the cooling coil to the chillers evaporator to be re-cooled.Refrigerant loop. Using a phase-change refrigerant, the chillers compressor pumps heat from the chilled water to the condenser water.Condenser water loop. Water absorbs heat from the chillers condenser, and the condenser water pump sends it to the cooling tower.Cooling tower loop. The cooling towers fan drives air across an open flow of the hot condenser water, transferring the heat to the outdoors.There are two fundamental types of refrigeration system. They are theVapour-compression systemThe vapour-absorption system.The two types are used for commercial purposes and domestic refrigerators and the two of them work on the standard that when a liquid vanishes, it takes in concealed heat from its surroundings. The liquids used in refrigerators and freezers are called refrigerants. They are made to evaporate at a temperature below 0 degrees Celsius and in doing so they take in latent heat and maintain the cold space at a sub-zero temperature.A refrigerant must have a low freezing point so that it does not solidify or form slush in the low temperature part of the refrigeration cycle. Also it should have a high value for its latent heat of vaporisation to maximise the transfer of heat energy during the cycle. crush refrigeration cycles take advantage of the fact that highly compressed fluids at a certain temperature tend to get colder when they are allowed to expand. If the pressure change is high enough, then the compressed gas will be hotter than our source of cooling (outside air, for instance) and the expanded gas will be cooler than our desired cold temperature. In this case, fluid is used to cool a low temperature environment and reject the heat to a high temperature environment. Vapour compression refrigeration cycles have two advantages. First, a large amount of thermal energy is required to change a liquid to a vapor, and therefore a lot of heat can be removed from the air-conditioned space. Second, the isothermal nature of the vaporization allows extraction of heat without raising the temperature of the working fluid to the temperature of whatever is being cooled. This means that the heat transfer rate remains high, because the closer the working fluid temperature approaches that of the surroundings, the lower the rate of heat transfer.An air condition system An Air-condition system is the full automatic control of the indoor atmosphere to maintain comfortable and healthy conditions. Its objective is to provide clean, mellifluous air at a temperature and humidity level that is comfortable to the occupants. The essential ingredients in an air condition system are a fan to blow air around, a cold surface to cool and dehumidify the air, a warm surface and a source of water vapour. In a large system there will also be a tangle of tubes to distribute the air and uplift it again. Notice that the cold surface has two independent jobs to do it is used to cool the air and it is also used to dehumidify, by condensing water from the air.Advantages of Pneumatic systems over Hydraulic systemsExtremely cheaper then hydraulic systems.The force transmitter, air, is freely available.Cleaner systems as air leakage do not create a mess.Due to high pressure Hydraulic oil becomes very hot after continuous use. It can cause injury/burns if someone comes in contact with it.Usually has open circuits and we dont have to beat about the return circuit.(D1) Justify the use of shell tellus oil 27 lubricant and the splash lubrication system in the lathe machines in the college machine shopShell tellus oil 27and 37 lubricantsShell Tellus Oils oil 27 are premium quality hydraulic oils generally acknowledged to be the standard-setter in the field of engineering hydraulic and fluid power lubrication. Shell tellus oil 27 has high lubrication properties and excellent low friction characteristics in hydraulic systems operating at low or high speed. Prevents stick-slip problems in critical applications enabling very fine control of machinery.Because of the reasons mentioned above shell tellus oil 27 is rated one of the best lubricant for lathe machine.Shell Tellus Oil 37 is an improved version of shell tellus oil 27. Shell Tellus Oi