Course: EAL Level 3 QET3/029 Maintenance of mechanical systems 23-24 | Grŵp NPTC Group Moodle

  • GENERAL COURSE INFORMATION

    Here you will find documents and information regarding the course overall.

    • QET3/029 Maintenance of Mechanical Systems

      This section contains useful information for the unit and covers six learning outcomes:

      LO 1 Understand the maintenance function

      LO 2 Understand lubricants and lubrication systems
      LO 3 Understand bearing operations, types, materials and causes of failure
      LO 4 Understand power transmissions, principles of operation and failure patterns
      LO 5 Understand seals and sealing principles
      LO 6 Understand and use dismantling and re-assembly techniques

      Please click on a book to read

    • Important: - Please Read!

      Please follow the link to the Ten Basic Rules of Netiquette or Internet Etiquette. Please read this as it is very important to follow the basic rules whilst commenting on a forum.

    • UPLOAD your project summary/ initial ideas here. It is important that you get some ideas down as soon as possible, fill in the summary sheet and upload it here before 22nd November. This is so we can address any problems together. 

    • Project summary proforma. Download this file and answer the short questions. This will help you get your project started.

    • Staff and Contact Details

      Unit 029 will be delivered by Ian Griffiths
       
      Email is ian.griffiths@nptcgroup.ac.uk

      Teams Phone Number is 0330 818 8345

      Ian Griffiths will be contactable during 9am to 4:30pm Mon to Friday
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    • Please find the Numeracy and Literacy Marking Code that you need to refer to when receiving feedback.


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    Aim and purpose of the unit:

    This unit enables learners to acquire the essential knowledge and skills to be able to understand and plan the maintenance of the mechanical systems that are used in modern plant and equipment Engineering.

     

    Assessment of the unit

    This unit is assessed by an internally marked multiple-choice examination that cover outcomes LO 1 to LO 6, Internal practical assessments that cover outcomes LO 3 - LO 6 and a research assessment that covers outcome LO 1 & LO 2.

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      Week 1: Lesson Objectives 

      • To read through the EAL unit descriptor 
      • To explore the Moodle page
      • To discuss the Project requirements

    • Activity 1:

      Please read through the EAL Learner Pack found below.
    • This file describes the requirements, and gives guidance for the production of a maintenance schedule for assessment of section 29.1 & 29.2.

    • You can edit this page and add some usefull images that you have found to share with your classmates. Have a go.

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    • faults

      29.1 Learning outcome Understand the maintenance function

      Lesson Objectives:

      • To identify faults using fault diagnosis including

      Six point technique, Emergent problem sequence, Half split and  Input to output technique


      • To identify fault finding aids including:
      Fault finding charts, Functional system charts, Algorithms, Maintenance records and Probability charts


    • Activity 1

      Please read through the fault finding and fault finding aid PowerPoint to help you with activity 1 and activity 2, there are some lecture notes to help you too.
    • Please read through the PowerPoint explaining the different fault finding techniques used and the fault finding aids used in industry.

    • Here are lecture notes on a Word document containing notes on various fault finding techniques.


    • Activity 2:

      Please watch the video on how to a service on a car and think about what type of maintenance this is.

    • Activity 3:

      Please watch the video on the "pre start" checks before using a forklift truck. Think about what type of maintenance this is.

    • Activity 3:

      Please complete the quiz below and think about what type of maintenance technique that is used for each task.
      Take your time as the answer may not be as straight forward as you think.

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    • prio

      29.1 Learning outcome: Understand the maintenance function

      Lesson Objectives:

      • To demonstrate an understanding of how to ensure plant and equipment is available for operation
      • To examine the maintenance function and how it impacts upon industry
      • To describe how maintenance strategies, influence the scheme adopted by industry.
      • To complete the Maintenance and Functions Exercise

      .

    • Activity 1:

      Please read through the maintenance and planning PowerPoint and complete the classroom activity within it.

    • Please read through the maintenance and planning PowerPoint and complete the classroom activity within it.
    • Activity 2:

      Please read through the PowerPoint in activity 1, along with the notes to help you complete the Maintenance Functions Exercise on maintenance types and definitions below.

    • Here are some Lecture notes on the importance of maintenance.
    • Here is a Word document summarising the main maintenance techniques.
    • Please complete the Maintenance Functions Exercise and then upload here.
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    • ewewe

      29.1 Learning outcome Understand the maintenance function

      Lesson Objectives:

      • To discover the use of condition monitoring methods

    • Activity 1:

      Please read through the PP on condition monitoring methods  and watch the videos contained within it.
    • Please read through the Condition Monitoring PowerPoint and watch the videos contained within it.
    • Activity 2:

      Please watch the video on Vibration analysis and then read through the document on using vibration analysis to detect bearing failures.
    • Vibration Analysis Video:

      Please watch the video below on vibration analysis.
    • Useful document indicating the types of bearing fault that can be detected using vibration monitoring. Good description of each type of bearing fault.

    • Activity 3:

      Please watch the video on thermal imaging. There are notes here summarising the different types of conditioning monitoring methods.
    • Thermal Imaging Video

    • Here is a Word document summarising the main techniques used in condition monitoring and highlighting, their pros and cons.


    • Paper from the Maintenance and Engineering Journal describing how maintenance strategies should be combined to get the best outcome from any equipment.
    • Activity 4:

      Please complete 29.1B Conditioning Monitoring by using the resources contained within this section and then upload to the document to the upload point.
    • Please complete the activity. These answers will form part of your assessment for this module. Think carefully about your answers.

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    • grease

      29.2 Learning outcome: Understand lubricants and lubrication systems

      Learning Objectives:

      • To interpret and examine the effects of friction
      • To identify the different types of lubricants
      • To illustrate the methods of application
      • To discuss the safe and environmental disposal of lubricants 

    • Useful Information on Lubrication

    • Here is a booklet containing information on the Principles of Lubrication.
    • Here is a PDF containing very useful information on nearly everything you need to know on lubrication.
    • Here is a Word document detailing the basic principles of lubrication.
    • Activity 1

      Please read through PowerPoint 1 and then watch Video 1 that explains lubrication and the effects of friction and wear.
    • Please read through the PowerPoint on lubrication, the effects of friction and wear.
    • Video 1:

      Effects of Friction in an engine.
    • Please complete Activity 1 Lubrication, Friction and Wear and then upload when completed.
    • Activity 2

      Please read through PowerPoint 2 and 3 and then watch Video 2 - Video 5 that discusses the principles of lubrication, oil layer boundaries and methods of applying lubrication. Then complete Activity 2.
    • Please read through the PowerPoint on forms of film condition and lubrication selection.
    • Video 2:

      Lubrication Principles 
    • Please read through the PowerPoint on the different ways of applying a lubrication to mechanical systems.
    • Video 3:

      How oil gets around an engine using a pressurised system.
    • Video 4:

      A video on how to manually grease a bearing and also automatic greasing of a bearing.

    • Video 5:

      How ball and roller bearings are lubricated in industry.
    • Please complete Activity 2 Forms of Film Condition and Lubrication Selection and then upload when completed.
    • Activity 3

      Please read through PowerPoint 4 and then watch Video 4 that discusses the four main types of lubricant used in engineering and the criteria for measuring the properties of of oils and greases.
    • Please read through the PowerPoint on exploring the four basic types of lubricant used in industry and the criteria used in measuring the properties of oils and greases.
    • Please complete Activity 3 Characteristics and Properties of Greases and Oils and then upload when completed.
    • Activity 4

      Please read through PowerPoint 5 that looks at the different types of liquid lubrication and their applications and then PowerPoint 6 that examines greases and solid lubrication. There is also a video on why viscosity is so important whilst using grease.
    • Please read through the PowerPoint on the different types of liquid lubricants used in engineering and their typical applications.
    • Please read through the PowerPoint on grease based lubricants and their applications, solid lubricants and the advantages of using solid lubrication over oils and greases.
    • Video 6:

      Why is viscosity important in grease selection?
    • Here is a PDF on how to select the most appropriate grease for a particular application.
    • Please complete Activity 4 Liquid Lubricant, Greases and Semi Solid Lubricants and then upload when completed.
    • Activity 5

      Please read through PowerPoint that explores the different types of additives used in engineering.
    • Please read through the PowerPoint on the different types of additives used in the engineering sector.
    • Please watch the video on EN BS 14001 Regulations below and what they mean.
    •  Here is a PDF document on the guidelines of how to dispose of old lubricants from the Environment Agency.

    • Ok, so you have done the reading and watched the videos......now test how much knowledge you have gained.
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    • seal

      29.5 Learning outcome: Understand seals and sealing principles

      Learning Objectives:

      • To demonstrate an understanding of the principles and identify the types of seals and gaskets
      • To dismantle, inspect and re-assemble a mechanical system that includes inspection and replacement of seals and gaskets


    • Activity 1:

      Please look through the PowerPoint on Seals and then watch Video 1 showing the different types of seals used in industry.
    • Here is a PowerPoint on Seals and Gaskets used within the engineering sector.
    • Video 1:

      Here is a video showing the different types of seal used in industry.
    • Activity 2:

      Please watch Video 2 that shows how to install packing glands into the stuffing box of a pump and then Video 3 showing you how to make a paper gasket for a flange on a pump.
    • Video 2:

      Here is a video showing how to correctly install new packing glands into a pump.
    • Video 3:

      Here is a video showing how to make a paper gasket to fit a flange on a pump.
    • Activity 3:

      Please watch Video 4 that explains what a the lip seal is and what it does.
    • Video 4:

      A video explaining the installation of a split lip seal ring.

    • Activity 4:

      Please watch Video 5 that looks at the Mechanical seal. After watching these please read through the PowerPoint that explains how to fit a mechanical seal.
    • Video 5:

      Here is a video showing the basics of a mechanical seal.
    • Here is a PowerPoint on Mechanical Seals used within the engineering sector.
    • Here is a PowerPoint on how to replace a mechanical seal on a 4” centrifugal effluent pump.

    • Activity 5:

      Please watch Video 6 that looks at the spiral wound gasket used primarily for flanges and then Video 7 that focuses at the different seals used in engineering, including the labyrinth seal.
    • Video 6:

      Here is a video showing the make up of a spiral wound gasket and how it is made.
    • Video 7:

      Here is a video showing the different types of seal used in industry including  how the labyrinth seal works.
    • Please use the resources available in this section to complete the seals activity to the best of your ability then upload here.

    • Extra Useful Information on Seals

    • Here is a word document explaining how to identify and measure Oil Seals.
    • Here is a link to information about the make up, advantages and applications of felt seals.
    • Here is an interesting case study from a manufacturing company that produces seals.
    • Here are notes from United Seal & Rubber Co. INC on how to design and produce a high performance gasket or seal.
    • Here is a link to show the different types of gasket used in industry

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    • bearings

      29.3 Learning outcome: Understand bearing operations, types, materials and causes of failure

      Learning Objectives:

      • To identify the types and function of bearings
      • To recognise and discuss bearing materials
      • To examine the causes of bearing failure
      • To demonstrate the methods involved in mounting and removing bearings
      • To dismantle and reassemble a mechanical system that involves bearing removal, inspection and replacement


    • Useful Documents on Bearings:

      Below are some useful documents and videos that show bearing types, how to select bearings and how to also identify bearings.
    • Here is a useful booklet that contains information on the different types of bearings, installation, dismantling, bearing failure and other information.

    • Here is a useful booklet from the SKF manufacturing catalogue.

    • Here is a video of how to use bearing designation to select a new bearing to replace an old one. 


    • Here is a guide of how to identify a bearing if it needs to be replaced.
    • Here is a PDF showing tables of how to identify bearing type, series code, bore size, shield/seal configuration and internal clearance.
    • Here is an example of how to identify a bearing.
    • Here is a video explaining the internal clearance on a rolling element type bearing.
    • Here is a video explaining how to m ount a tapered bore spherical bearing on an adapter sleeve.
    • Kahoot Quiz (Bearings)

      Please follow the instructions below to access Kahoot to complete a quiz on bearings.
    • Access to Kahoot.it to enable students to play the online Kahoot! sessions. 

      THIS IS A GROUP SESSION, WAIT FOR THE LECTURER TO TELL YOU TO START.

      Nothing can happen until you have a 'pin' which should be displayed on the lecturer's PC.

    • Activity 1:

      Please watch videos 1, 2 and 3 and then complete the Different Types of Bearing Activity.
    • Here is a word document showing some of the different types of bearing used in industry.
    • Here is a PDF on the basics of the ball and roller bearing.
    • Video 1:

      Please watch the video on what a journal bearing is and how it works.

    • Video 2:

      Here is a video explaining the different types of rolling element bearings, stating their advantages and disadvantages and also their uses.

    • Video 3:

      Here is a video showing you an SKS Roller bearing type.
    • Please watch videos 1, 2 and 3 and then complete the Different Types of Bearing Activity. Please upload when completed.
    • Activity 2:

      Please watch the video 4 & 5 on the thrust bearing and then video 6 on the linear bearing.
    • Video 4:

      Here is a video showing the removal, inspection and maintenance of a journal and thrust  bearing.
    • Video 5:

      Below is a video explaining the typical construction and uses of a plain bearing.
    • Video 6:
      A video explaining the maintenance of linear bearings.
    • Activity 3:

      Please watch video 7 on bearing failure and then look at the link to a webpage explaining causes of bearing failure then complete the Bearing Failure Activity. 
    • Video 7:
      A video showing bearing failure.
    • Taken from the Koyo bearing company, a useful chart showing images of bearings and the reason they failed.
    • Please watch video 7, look at the bearing failure link and then compete the Bearings Failure Activity. Please upload when completed.
    • Activity 4:

      Please watch the video on how to fit a bearing onto a shaft with an interference fit using an induction heater. When you have watched the video please complete the Induction Heater Activity  below.

    • Please can you complete the Induction Heater Activity below then upload when finished.
    • Activity 5:

      After watching all of the videos and reading through the content in this section, please complete the bearing  quiz and upload when completed.

      Good luck!

    • Please carry out some research and using the videos above, complete the bearings quiz and upload here when completed.
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    belt

    29.4 Understand power transmissions, principles of operation and failure patterns of 

    BELT DRIVES

    Lesson Objectives

    • To discover the principles of operation: arc of contact and speed ratio formulae
    • To identify the different types and arrangements of belts: single, multiple and banded
    • To explore the maintenance requirements of belts: condition, tension, storage, alignment, correctly matched and change as set
    • To examine the operating symptoms: breakage, slapping, turn over, slippage and whipping
    • To recognise symptoms of belt failure: burns, stretching, worn sheaves, cracking, swelling, wear and fraying
    • To determine the causes of failure: damaged pulleys, interference, overheating, dirt, misalignment, overloading and incorrect tension




    • Belt Drive Video:

      The video below shows the different types of belt arrangements. Please take note of the term Angle or Arc of Contact that refers to the larger the arc or angle of contact the more power it can transmit. 


    • Here are some notes on using an idler for belt tensioning and also the arc of contact.
    • Information on calculating tensions, power transmission, belt slip. Higher level equations for those with a thirst for knowledge. These notes were developed Mr Kharagpurfor.
    • Belt and Pulley Transmission Booklet

      Please read through and use this resources that explains the different types of belts used, troubleshooting and maintenance procedures.

    • Here is information on all you need to know for belt drives that covers the criteria for the unit.
    • Please read through the PowerPoint on the different types of belt drive
    • Activity 2

      Please complete the compound flat belt worksheet below.
    • Please complete the 10 questions on how to work out the driven pulley of a compound flat belt drive. When done upload here.
    • Activity 3

      Please complete the open belt pulley worksheet below.
    • Please complete the 10 questions on the open belt pulley calculations. When done upload here.
    • Activity 4

      Please complete the Complete the crossed belt worksheet below.
    • Please complete the 10 questions on the crossed belt Calculations. When done upload here.
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    chain

    29.4 Understand power transmissions, principles of operation and failure patterns of 

    CHAIN DRIVES

    Lesson Objectives

    • To discover the principles of operation: chain, pitch, width and roller diameter, sprocket, pitch circle diameter, width and number of teeth, speed of driven sprocket in relation to speed of driver
    • To identify the Types and arrangements of chains: even pitch on chain/uneven number of teeth on sprocket, double pitch chains, tensioners
    • To explore the maintenance requirements of chains: alignment, installation, removal, condition, lubrication, storage and tension
    • To examine the operating symptoms: breakage, noise, whipping, jumping and overheating
    • To recognise the symptoms of chain failure: corrosion, link seizure, wear and galling
    • To determine the causes of failure: adjustment, lubrication, vibration, dirt, overload and worn sprockets




    • Video 1:

      Here is a video showing chain drive installations and maintenance of the drives

    • Here is information on all you need to know for chain drives that covers the criteria for the unit.

    • Activity 1

      Please read through the PowerPoint on the different types of chain drives

    • Please read through the PowerPoint on the different types of chain drives

    • Activity 2

      Using the previous PowerPoint on the different types of chain drives, please complete the Chain drives worksheet and upload when completed.

    • Here is a good resources on a trouble shooting guide for chain transmission and fault finding.

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    chain

    29.4 Understand power transmissions, principles of operation and failure patterns of 

    GEAR DRIVES

    Lesson Objectives

    • To discover the principles of operation: tooth profiles, cross-sectional shape, number of teeth, generation of the involute form, the geometry of gears, pressure angles, terms of circular gear geometry, backlash, diametrical pitch and speed relationship between two mating gears
    • To identify the Types and arrangements of gears: bevel gears, plain, spiral, hypoid, helical, spur, worm
    • To explore the maintenance requirements of gears: alignment, lubrication and condition
    • To examine the operating symptoms: noise, overheating and vibration
    • To recognise the symptoms of gear failure: corrosion, link seizure, wear and galling
    • To determine the causes of failure: out of alignment, out of parallel, out of plane and contamination
    • To look at the lubrication of gears: moisture, out of mesh and overload




    • Video 1:
      Here is a video showing the different types of gears widely used in industry.

        
    • Here is very useful information on all you need to know for gear drives that covers the criteria for the unit.

    • Here is a PowerPoint on an introduction to gears and the engineering formulas associated with them

    • Here is a gear ratio worked example number 1
    • Here is a gear ratio worked example number 2
    • Please complete examples 1 to 6
    • Activity 2

      Please watch the video 2 on how to work out gear ratios and velocities that will help you further on to answer the worksheet. Please complete the Compound Gear worksheet.
    • Video 2:
      Here is a video showing you how to work out the velocity and gear ratios of compound gear trains
       
    • Please complete the Compound Gears Worksheet.
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    couplings

    29.4 Understand power transmissions, principles of operation and failure patterns of 

    COUPLINGS

    Lesson Objectives

    • To discover the principles of operation: direct drive, driver to driven
    • To identify the different types and applications of couplings: rigid, flexible, alignment
    • To explore the operating symptoms: noise, overheating, vibration 
    • To inspect the symptoms of coupling wear: breakage, wear, cracking
    • To determine the causes of failure: wear, out of alignment, vibration, contamination, overload




    • Activity 1

      Please look through the PowerPoint on the different types of couplings used in engineering. Then take a look at video1.

    • Please read through the PowerPoint on the different types of couplings used in industry.

    • Video 1:

      Here is a video on the different types of coupling used in industry

    • Activity 2

      Please look through the notes on how to align couplings correctly along with the video 2. This will help you with MIG 101 assessment.
    • Video 2

      Here is a video showing how to check and rectify angular, parallel and side to side misalignment.

    • A Practical guide along with diagrams on how to align two shafts with a solid coupling.

    • Extra Resources

      Here are some useful resources on couplings.

    • Here is a very useful link to the different types of couplings that can be used in industry.

    • Here is extra information on shafts and couplings.
    • Activity 3

      Please split into groups of 3-4. Using the learning materials and videos above, I want you as a group, to produce a PowerPoint on how to align a solid coupling up. The slide needs to be a maximum of 10 slides and must contain images and text size of at least 24. This needs to be explained in a way that someone with none or little experience in engineering can successfully align two couplings together. Don't forget to include tools and equipment needed. You have 30 mins to do this as a group and then present for no more than 5 mins.

    • Please upload your finished PowerPoints here.

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    This section includes details of the practical activities, guideline notes and also useful video links to complete the written tasks.

    • Please find the job report templates for :

      1. MIG 101 Alignment Rig
      2. MIG 102 Dismantling and Reassembly of a Compressor 
      3. MIG 103 Power Transmission Rig
      4. MIG 104 Strip and Rebuild of a Hydraulic Cylinder
      5. MIG 105 Dismantling and Reassembly of a Split ‘Cooper’ Bearing
      OR 
      6. MIG 106 Dismantling and Reassembly of a Split ‘Cooper’ Bearing with Housing
      7. MIG 108 Strip and Rebuild of a Plummer Block


    • Here is a link to the Bright Hub Engineering website, and information on reciprocating compressors. You made need to follow a few links but there is a lot of good information here.

    • Here you will find a PowerPoint showing the different parts of the compressor in the form of an exploded diagram.

    • Video 2: 

      Here is a video on V belt drive alignment and tensioning.

    • Here are some useful notes on the Cooper bearing activity.

    • Video 3:

      A short video on how a diaphragm pump works.


    • Here you will find some useful information on the bearing type used for the Plummer block assessment.

    • PDF manual on how to maintain and strip a diaphragm pump. This document includes performance curves to help you select the correct pump for a given duty.

    • Here is a simple video on explaining how bearings work.

    • Here is a video on how to use a piston compression tool.

    • Here is a word document containing information on some common bearing types that you may find useful.

    • Here is a word document containing information on some common bearing types that you may find useful.

    • Here is a torque setting sheet that gives you the torque values needed to tighten the nuts/bolts to their correct setting when using a torque wrench.

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    In this section, you need to  upload all your written work for the assessment tasks.

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    • This file includes suggestions on a maintenance task for those of you who have failed to find your own. It involves taking measurements of shafts and bearings to determine wear.
    • Here is an example of what a completed maintenance project should look like. You can read this to assist you but DO NOT copy and paste as it is plagiarism.
    • comp

      Link to a suggested maintenance schedule for a reciprocating compressor. This is very useful information.
    • A few suggestions on how to work safely with air compressors.
    • Tips on how to track down problems with air compressors. A very good FAULT FINDING guide

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    • Here is the criteria that you must include in your projects.