EAL Level 3 QET3/029 Maintenance of mechanical systems 23-24

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.

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    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

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    Ten Basic Rules of Netiquette or Internet Etiquette URL

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    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.

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    Project Summary Assignment

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    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. 

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    Project Summary File

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

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    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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  MARKING CODE

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    MARKING CODE Folder

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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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  Week 1: Course Information and Documentation

  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

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    Activity 1:

    Please read through the EAL Learner Pack found below.

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    Project Overview File

    This file describes the requirements, and gives guidance for the production of a maintenance schedule for assessment of section 29.1 & 29.2.

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    Usefull Images Wiki

    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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  Week 2:LO 1 Understand the maintenance function

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    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

    
    
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    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.

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    Fault Finding PowerPoint File

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    Please read through the PowerPoint explaining the different fault finding techniques used and the fault finding aids used in industry.

    
    
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    Fault Finding File

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

    
    

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    Activity 2:

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

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    Activity 3:

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

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    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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    Maintenance Types Multichoice Quiz HotPot

    Complete the activity
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  Week 3: LO 1 Understand the maintenance function

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    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

    .

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    Activity 1:

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

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    Maintenance and Planning PowerPoint File

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

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    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.

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    The importance of Maintenance File

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    Here are some Lecture notes on the importance of maintenance.

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    Maintenance Techniques File

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    Here is a Word document summarising the main maintenance techniques.

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    Here is a useful link to the three different types of maintenance URL

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    Maintenance Functions Exercise Assignment

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    Please complete the Maintenance Functions Exercise and then upload here.
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  Week 4&5: LO 1 Understand the maintenance function

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    29.1 Learning outcome Understand the maintenance function

    Lesson Objectives:

    • To discover the use of condition monitoring methods

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    Activity 1:

    Please read through the PP on condition monitoring methods  and watch the videos contained within it.

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    Condition Monitoring PowerPoint File

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    Please read through the Condition Monitoring PowerPoint and watch the videos contained within it.

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    Activity 2:

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

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    Vibration Analysis Video:

    Please watch the video below on vibration analysis.

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    Bearing Faults Description. File

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    Useful document indicating the types of bearing fault that can be detected using vibration monitoring. Good description of each type of bearing fault.

    
    

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    Activity 3:

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

  • Thermal Imaging Video

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    Condition Moinitoring Techniques File

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

    
    

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    Condition Monitoring is Not Enough File

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

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    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.

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    Activity 29.1B Condition Monitoring Assignment

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    Please complete the activity. These answers will form part of your assessment for this module. Think carefully about your answers.

    
    
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  Week 6-8: LO 2 Understand lubricants and lubrication systems

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    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 

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    Useful Information on Lubrication

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    Lubrication Booklet File

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    Here is a booklet containing information on the Principles of Lubrication.

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    Engineers Lubrication Manual File

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    Here is a PDF containing very useful information on nearly everything you need to know on lubrication.

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    Lubrication File

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    Here is a Word document detailing the basic principles of lubrication.

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    Activity 1

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

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    PP1 Lubrication, Friction and Wear File

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    Please read through the PowerPoint on lubrication, the effects of friction and wear.

  • Video 1:

    Effects of Friction in an engine.

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    Activity 1 Lubrication, Friction and Wear Assignment

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    Please complete Activity 1 Lubrication, Friction and Wear and then upload when completed.

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    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.

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    PP2 Forms of Film Condition and Lubrication Selection File

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    Please read through the PowerPoint on forms of film condition and lubrication selection.

  • Video 2:

    Lubrication Principles 

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    PP3 Different Methods of Applying Lubrication File

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    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.

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    Lubrication Culture URL

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  • 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.

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    Activity 2 Forms of Film Condition and Lubrication Selection Assignment

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    Please complete Activity 2 Forms of Film Condition and Lubrication Selection and then upload when completed.

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    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.

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    PP4 Types of Lubricants and How to Measure the Properties of Oil and Grease. File

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    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.

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    Activity 3 Characteristics and Properties of Greases and Oils Assignment

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    Please complete Activity 3 Characteristics and Properties of Greases and Oils and then upload when completed.

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    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.

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    PP5 Liquid Lubricants and their typical applications File

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    Please read through the PowerPoint on the different types of liquid lubricants used in engineering and their typical applications.

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    PP6 Grease based Lubricants and Solid Lubricants File

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    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?

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    How to Select a Grease for a Particular Job File

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    Here is a PDF on how to select the most appropriate grease for a particular application.

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    Activity 4 Liquid Lubricant, Greases and Semi Solid Lubricants Assignment

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    Please complete Activity 4 Liquid Lubricant, Greases and Semi Solid Lubricants and then upload when completed.

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    Activity 5

    Please read through PowerPoint that explores the different types of additives used in engineering.

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    PP7 Different Types of Additives Used in Engineering File

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    Please read through the PowerPoint on the different types of additives used in the engineering sector.

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    Please watch the video on EN BS 14001 Regulations below and what they mean.

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    Disposal of Oil File

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     Here is a PDF document on the guidelines of how to dispose of old lubricants from the Environment Agency.

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    Lubrication Quiz File

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    Ok, so you have done the reading and watched the videos......now test how much knowledge you have gained.
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  Week 9: Project Review
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  Week 10-12: LO 5 Understand seals and sealing principles

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    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

    
    

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    Activity 1:

    Please look through the PowerPoint on Seals and then watch Video 1 showing the different types of seals used in industry.

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    Seals and Gaskets PP File

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    Here is a PowerPoint on Seals and Gaskets used within the engineering sector.

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    Video 1:

    Here is a video showing the different types of seal used in industry.

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    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.

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    Video 2:

    Here is a video showing how to correctly install new packing glands into a pump.

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    Video 3:

    Here is a video showing how to make a paper gasket to fit a flange on a pump.

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    Activity 3:

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

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    Video 4:

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

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    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.

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    Video 5:

    Here is a video showing the basics of a mechanical seal.

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    Mechanical Seals PP File

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    Here is a PowerPoint on Mechanical Seals used within the engineering sector.

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    How to Install Mechanical Seals PP File

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    Here is a PowerPoint on how to replace a mechanical seal on a 4” centrifugal effluent pump.

    
    
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    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.

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    Video 6:

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

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    Video 7:

    Here is a video showing the different types of seal used in industry including  how the labyrinth seal works.

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    Seals Activity Assignment

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    Please use the resources available in this section to complete the seals activity to the best of your ability then upload here.

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    Extra Useful Information on Seals

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    How to identify and Measure Oil Seals File

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    Here is a word document explaining how to identify and measure Oil Seals.

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    Felt Seals URL

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    Here is a link to information about the make up, advantages and applications of felt seals.

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    United Seal Case Study File

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    Here is an interesting case study from a manufacturing company that produces seals.

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    Information on Designing and Producing a High Performance Gasket or Seal File

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    Here are notes from United Seal & Rubber Co. INC on how to design and produce a high performance gasket or seal.

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    Different Types of Gasket Materials URL

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    Here is a link to show the different types of gasket used in industry
• 9

  Week 13 - 16: LO 3 Understand bearing operations, types, materials and causes of failure

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    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

    
    

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    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.

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    Bearing Booklet File

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    Here is a useful booklet that contains information on the different types of bearings, installation, dismantling, bearing failure and other information.

    
    

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    SKF Bearing Manual File

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    Here is a useful booklet from the SKF manufacturing catalogue.

    
    

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

    
    

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    How to Identify a Bearing File

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    Here is a guide of how to identify a bearing if it needs to be replaced.

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    Bearing Identification Table File

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    Here is a PDF showing tables of how to identify bearing type, series code, bore size, shield/seal configuration and internal clearance.

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    An Example of how to Identify a Bearing File

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    Here is an example of how to identify a bearing.

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    Here is a video explaining the internal clearance on a rolling element type bearing.

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    Here is a video explaining how to m ount a tapered bore spherical bearing on an adapter sleeve.

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    Kahoot Quiz (Bearings)

    Please follow the instructions below to access Kahoot to complete a quiz on bearings.

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    Kahoot! for students URL

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    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.

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    Activity 1:

    Please watch videos 1, 2 and 3 and then complete the Different Types of Bearing Activity.

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    Different Types of Bearing File

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    Here is a word document showing some of the different types of bearing used in industry.

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    Bearing Basics File

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    Here is a PDF on the basics of the ball and roller bearing.

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    Video 1:

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

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    Video 2:

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

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    Video 3:

    Here is a video showing you an SKS Roller bearing type.

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    Different Types of Bearing Activity Assignment

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    Please watch videos 1, 2 and 3 and then complete the Different Types of Bearing Activity. Please upload when completed.

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    Activity 2:

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

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    Video 4:

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

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    Video 5:

    Below is a video explaining the typical construction and uses of a plain bearing.

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    Video 6:

    A video explaining the maintenance of linear bearings.

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    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. 

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    Video 7:

    A video showing bearing failure.

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    Here is a useful link to common types of bearing failure URL

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    Bearing Fault Chart File

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    Taken from the Koyo bearing company, a useful chart showing images of bearings and the reason they failed.

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    Bearings Failure Activity Assignment

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    Please watch video 7, look at the bearing failure link and then compete the Bearings Failure Activity. Please upload when completed.

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    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.

    
    

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    Induction Heater Activity Assignment

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

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    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!
    

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    Bearings Quiz Assignment

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    Please carry out some research and using the videos above, complete the bearings quiz and upload here when completed.
• 10

  Week 17 - 18: LO 4 Understand power transmissions, principles of operation and failure patterns of Belt Drives

  
  

  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

  
  
  
  

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    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. 

    
    

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    Belt Tensioning and Arc of Contact File

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    Here are some notes on using an idler for belt tensioning and also the arc of contact.

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    Belt Drive Equations File

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    Information on calculating tensions, power transmission, belt slip. Higher level equations for those with a thirst for knowledge. These notes were developed Mr Kharagpurfor.

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    Belt and Pulley Transmission Booklet

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

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    Belt Drives Booklet File

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

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    Belt Drives PowerPoint File

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    Please read through the PowerPoint on the different types of belt drive

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    Activity 2

    Please complete the compound flat belt worksheet below.

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    Compound Flat Belt Drive Calculation Worksheet Assignment

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

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    Activity 3

    Please complete the open belt pulley worksheet below.

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    Open Belt Pulley Calculation Worksheet Assignment

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    Please complete the 10 questions on the open belt pulley calculations. When done upload here.

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    Activity 4

    Please complete the Complete the crossed belt worksheet below.

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    Crossed Belt Calculation Worksheet Assignment

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    Please complete the 10 questions on the crossed belt Calculations. When done upload here.
• 11

  Week 19-20: LO 4 Understand power transmissions, principles of operation and failure patterns of CHAIN DRIVES

  
  

  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

  
  
  
  

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    Video 1:

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

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    Chain Drives Booklet File

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

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    Activity 1

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

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    Chain Drives PowerPoint File

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

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    Activity 2

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

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    Chain Drive Trouble Shooting Guide File

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    Here is a good resources on a trouble shooting guide for chain transmission and fault finding.
• 12

  Week 21-23: LO 4 Understand power transmissions, principles of operation and failure patterns of GEAR DRIVES

  
  

  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

  
  
  
  

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    Video 1:

    Here is a video showing the different types of gears widely used in industry.

    
      
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    Gear Drives Booklet File

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

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    Introduction to Gears File

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

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    Gear Ratio Worked Example 1 File

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    Here is a gear ratio worked example number 1

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    Gear Ratio Worked Example 2 File

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    Here is a gear ratio worked example number 2

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    Gear Ratio Worksheet 1 File

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    Please complete examples 1 to 6

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    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.

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    Video 2:
    Here is a video showing you how to work out the velocity and gear ratios of compound gear trains

     

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    Compound Gears Worksheet File

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    Please complete the Compound Gears Worksheet.
• 13

  Week 24-25: LO 4 Understand power transmissions, principles of operation and failure patterns of 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

  
  
  
  

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    Activity 1

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

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    Couplings PowerPoint File

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

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    Video 1:

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

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    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.

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    Video 2

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

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    Coupling Alignment Guide File

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

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    Extra Resources

    Here are some useful resources on couplings.

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    Shaft Couplings and Alignment URL

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

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    Shafts and Couplings PDF File

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    Here is extra information on shafts and couplings.

  • Mark as done

    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.

  • 

    Coupling Alignment PowerPoint Upload Point Assignment

    Mark as done

    Please upload your finished PowerPoints here.
• 14

  Week 26-27: LO 4 Understand power transmissions, principles of operation and failure patterns of CLUTCHES

  
  

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

  CLUTCHES

  Lesson Objectives

  • To discover the principles of operation: torque transmission, positive, friction and wedge
  • To identify clutch actuation: electrical, hydraulic, mechanical, and pneumatic
  • To identify the different types and applications of clutches: dog tooth, single plate friction, multi-plate friction, cone, centrifugal, dry fluid and fluid
  • To look at the maintenance of clutches: alignment, assembly, lubrication 
  • To explore the operating symptoms: slippage, power loss, overheating, 
  • To inspect the symptoms of clutch wear: glazing, wear
  • To determine the causes of failure: contamination of plates, incorrect tension
  • To examine shaft alignment in a clutch: parallel and angular
  • To list the methods of alignment: straight edge and feeler gauge, face and rim and reverse indicator

  
  
  
  
• 15

  Week 28 - 31: Practical Workshop MIG 101, MIG 102, MIG 103, MIG 104, MIG,105 OR 106 & MIG 108
• 16

  29.6 Practical Assessment Job Reports and Help

   

  

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

  • 

    Usefull Industrial Images to help YOU! Add your own too! Lightbox Gallery

    Mark as done
  • 

    MIG 101 to MIG 108 Job Report Templates Folder

    Mark as done

    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

    
    

  • 

    Reciprocating Compressors URL

    Mark as done

    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.

  • 

    Compressor Exploded Diagram File

    Mark as done

    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.

  • 

    Cooper Bearing Notes File

    Mark as done

    Here are some useful notes on the Cooper bearing activity.

  • Mark as done

    Video 3:

    A short video on how a diaphragm pump works.

    
    

  • 

    Plummer Block Notes File

    Mark as done

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

  • 

    Diaphragm Pump Manual File

    Mark as done

    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.

  • Mark as done

    Here is a simple video on explaining how bearings work.

  • Mark as done

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

  • 

    Diaphragm Pump Notes on Advantages and Disadvantages File

    Mark as done

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

  • 

    Bearing Types File

    Mark as done

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

  • 

    Torque Setting Chart File

    Mark as done

    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.
• 17

  Practical Assessments & Project Upload Point

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

  • 

    MIG 101 Alignment of Two Shafts With a Rigid Coupling. Assignment

    Receive a grade

    Please upload your completed report on how to align two shafts with a rigid coupling here.

  • 

    MIG 102 Dismantling and Re-Assembly of an Air Compressor Assignment

    Receive a grade

    Please upload your completed report on the Compressor here.

  • 

    MIG 103 Power Transmission Investigation. Assignment

    Receive a grade

    Please upload your completed report on the Power Transmission Rig here.

  • 

    MIG 104 Strip and Rebuild of Hydraulic Cylinder Assignment

    Receive a grade

    Please upload your completed report on the Hydraulic Cylinder here.

  • 

    MIG 105 or MIG 106 Dismantling and Re-assembling a 'Split' Cooper Bearing. Assignment

    Receive a grade

    Please upload your completed report on the Cooper Split  Bearing here.

  • 

    MIG 107 Strip and Rebuild of a Diaphragm Pump Assignment

    Receive a grade

    Please upload your work on the Air Operated Double Diaphragm Pump here.

  • 

    MIG 108 Dismantling and Reassembly of a Plummer Block Assignment

    Receive a grade

    Please upload your work on the Dismantling and Reassembly of a Plummer Block

  • 

    Upload your Maintenance Project here Assignment

    Receive a grade

    You can upload your maintenance Project for marking here.
• 18

  Week 32: Internal Assessment
• 19

  Week 33: Internal Assessment Resit
• 20

  Project Information

  • 

    Compressor Project File

    Mark as done

    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.

  • 

    Example of Completed Maintenance Project. File

    Mark as done

    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.

  • 

    Portland Compressors URL

    Mark as done

    

    Link to a suggested maintenance schedule for a reciprocating compressor. This is very useful information.

  • 

    Air Compressor Safety Tips URL

    Mark as done

    A few suggestions on how to work safely with air compressors.

  • 

    Air Compressor Trouble Shooting URL

    Mark as done

    Tips on how to track down problems with air compressors. A very good FAULT FINDING guide
• 21

  Dave Richards Old Data

  Documents previously uploaded by Dave