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PLANT MAINTENANCE AND
FREE PDF
3341906
Code: 3341906
Credits: 5
Semester 4
Production
Plant Maintenance And Safety
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Plant Maintenance And Safety Syllabus — Unit-wise Content
The official GTU curriculum for Plant Maintenance And Safety (subject code 3341906) as prescribed for Production · Semester 4 divides the course into 7 units, covering 73 listed topics. The unit-wise breakdown below is read from the GTU syllabus document for this subject code, so you can check what the course actually covers before deciding which papers to attempt.
Download the official syllabus PDF (3341906)Unit 1 Fundamentals of maintenance engineering
- 1.1. Definition and aim of maintenance engineering.
- 1.2. Primary and secondary functions and responsibility of maintenance department.
- 1.3. Types of maintenance.
- 1.4. Types and applications of tools used for maintenance.
- 1.5. Maintenance cost & its relation with replacement economy.
- 1.6. Service life of equipment.
Unit 2 Wear and Corrosion and their prevention
- 2.1. Wear- types, causes , effects
- 2.2. Wear reduction methods
- 2.3. Lubricants-types and applications.
- 2.4. Lubrication methods –General sketch, working and applications. i. Screw down grease cup. ii. Pressure grease gun. iii. Splash lubrication. iv. Gravity lubrication. v. Wick feed lubrication. vi. Side feed lubrication. vii. Ring lubrication.
- 2.5. Definition, principle and factors affecting the corrosion.
- 2.6. Types of corrosion.
- 2.7. Corrosion prevention methods.
Unit 3 Fault tracing
- 3.1. Fault tracing-concept and importance.
- 3.2. Decision tree-concept, need and applications.
- 3.3. Sequence of fault finding activities, show as decision tree.
- 3.4. Draw decision tree for problems in machine tools, hydraulic, pneumatic, automotive, thermal and electrical equipments like: i. Any one machine tool. ii. Pump iii. Air compressor. iv. Internal Combustion engine. v. Boiler. vi. Electrical motors.
- 3.5. Types of faults in machine tools and Plant Maintenance and Safety Course code: 3341906 GTU/NITTTR/Bhopal/13-14 Gujarat State 3 Unit Major Learning Outcomes Topics and Sub-topics their general causes.
Unit 4 Periodic and preventive maintenance
- 4.1. Periodic inspection-concept and need.
- 4.2. Degreasing, cleaning and repairing schemes.
- 4.3. Overhauling of mechanical components.
- 4.4. Overhauling of electrical motor.
- 4.5. Common troubles and remedies of Electric motor.
- 4.6. Repair complexities and its use.
- 4.7. Definition, need, steps and advantages of preventive maintenance.
- 4.8. Steps/procedure for periodic and preventive maintenance of: i. Machine tools. ii. Pumps. iii. Air compressors. iv. Diesel generating (DG) sets.
- 4.9. Program and schedule of preventive maintenance of mechanical and electrical equipments.
- 4.10. Advantages of Preventive maintenance.
- 4.11. Repair cycle-concept and importance.
Unit 5 Industrial safety
- 5.1. Accident - causes, types, results and control.
- 5.2. Mechanical and electrical hazards- types, causes and preventive steps/procedure.
- 5.3. Describe salient points of Factories act 1948.for health and safety-, wash rooms, drinking water layouts, light, cleanliness, fire, guarding, pressure vessels, etc.
- 5.4. Safety colour codes.
- 5.5. Fire prevention and fire fighting, equipment and methods.
Unit 6 Recovery, reconditioning and
- 6.1. Definition of recovery, reconditioning and retrofitting.
- 6.2. Methods of recovery and their applications.
- 6.3. Selection criteria of recovery methods. Plant Maintenance and Safety Course code: 3341906 GTU/NITTTR/Bhopal/13-14 Gujarat State 4 Unit Major Learning Outcomes Topics and Sub-topics retrofitting 6b. Explain reconditioning and retrofitting process.
- 6.4. Reconditioning - process, features and advantages.
- 6.5. Retrofitting - concept, need and applications.
Unit 7 Installation, erection and commissioning of equipments
- 7.1. Design and planning of foundation.
- 7.2. Erection and commissioning of equipment.
- 7.3. Alignment and testing of equipment.
- 6. SUGGESTED SPECIFICATION TABLE WITH HOURS & MARKS (THEORY) Unit Unit Title Teaching Hours Distribution of Theory Marks R Level U Level A Level Total Marks I Fundamentals of maintenance engineering 4 3 4 0 7 II Wear and Corrosion and their prevention. 8 4 4 6 14 III Fault tracing 6 2 2 6 10 IV Periodic and preventive maintenance 10 3 3 8 14 V Industrial safety 5 3 3 3 9 VI Recovery, reconditioning and retrofitting 5 2 3 4 9 VII Installation, erection and commissioning of equipments 4 2 3 2 7 Total 42 19 22 29 70 Note: This specification table shall be treated as a general guideline for students and teachers. The actual distribution of marks in the question paper may vary slightly from above table. General Notes: a. If mid semester test is part of continuous evaluation, unit numbers I, II, III, and IV (Up to point number 4.6 only) are to be considered. b. Ask the questions from each topic as per marks weightage. Numerical questions are to be asked only if it is specified. Optional questions must be asked from the same topic.
- 7. SUGGESTED LIST OF EXERCISES/PRACTICALS. The practical/exercises should be properly designed and implemented with an attempt to develop different types of skills (outcomes in psychomotor and affective domain) so that students are able to acquire the competencies/programme outcomes. Following is the list of practical exercises for guidance. Plant Maintenance and Safety Course code: 3341906 GTU/NITTTR/Bhopal/13-14 Gujarat State 5 Note: Here only outcomes in psychomotor domain are listed as practical/exercises. However, if these practical/exercises are completed appropriately, they would also lead to development of certain outcomes in affective domain which would in turn lead to development of Course Outcomes related to affective domain. Thus over all development of Programme Outcomes (as given in a common list at the beginning of curriculum document for this programme) would be assured. Faculty should refer to that common list and should ensure that students also acquire outcomes in affective domain which are required for overall achievement of Programme Outcomes/Course Outcomes. S. No. Unit Number Practical Exercises (Outcomes’ in Psychomotor Domain) Hrs. required
- 1. I Preparatory Activity: Study and demonstrate use of various types of tools. (Fix spanners, box spanners, ring spanners, allen keys, types of pliers, screw drivers, bearing puller, etc.). 02
- 2. II Measurement of Wear: Measure wears of anyone of the following. a. Machine guide ways. b. Shaft –sleeve. c. Piston –cylinder. d. Bearing. 02
- 3. II Corrosion: Each student will collect corroded component from field and identify the types of corrosion and possible causes. Student will also suggest prevention methods. 02
- 4. III Fault Tracing and Decision Tree: Develop decision tree for location of fault for any two items from following- a. Internal combustion (IC) engine. b. Boiler. c. Pump. d. Machine tool. e. Air compressor. f. Electric motor. 04
- 5. IV Maintenance of Mechanical Based Equipment/Device/Machine. Maintenance of any two from following. Batch may be divided in to two groups and each group may be given one case. a. Head stock. b. Tail stock. c. Feed box. d. Indexing head. g. Internal combustion (IC) engine. h. Pump. (Dismantle of given case, observe rules, follow sequence of dismantling operations, cleaning, inspection, measuring deviations , recovery methods, testing and assembling). 08 Plant Maintenance and Safety Course code: 3341906 GTU/NITTTR/Bhopal/13-14 Gujarat State 6
- 6. IV Preventive Maintenance: Prepare a preventive maintenance schedule of any workshop having- air compressors, car washing pumps, tyre changer, lifts, welding machines, and wheel alignment. 02
- 7. V Safety: Demonstrate use of fire fighting and safety related equipments. 02
- 8. VII Test Chart: Prepare test chart of newly installed or repaired machine tool. 02
- 9. ALL Mini Project And Presentation: a. Identify mechanical based any one equipment / device / machine at institute level which requires maintenance. b. Prepare general sketch. c. Perform fault tracing and prepare the decision tree. d. Dismantle. Write the sequence of dismantling. Also describe the steps. List the tools used for this activity. e. Attend necessary maintenance tasks. Write the tasks performed. f. Assemble, test and if necessary, modify. Write the steps. g. Prepare power point presentation. Present the project. This must include photographs / movies of group working on project. 04
- 10. ALL Industrial Visit: Arrange visit to nearby automobile workshop/machine shop. - Total Hours 28 Notes: a. Term work report must not include any photocopies, printed manual/pages, litho, etc. It must be hand written / hand drawn by student only. However photographs/movies of actual performance by batch students and photographs of device/s undertaken for maintenance may be allowed by teacher. b. Term work report content of each experience should also include following. i. The specifications of machines / equipments / devices / tools /instruments / items/ elements which is / are used to carry out and to check experience. ii. Sequence of dismantling and assembling. iii. Steps / process description to execute experience. iv. Observations. c. Mini project and presentation topic/area has to be assigned to the student in the beginning of the term by batch teacher. This may be assigned individually or in the group of maximum 4 to 6 students. e. For 20 marks ESE, students are to be assessed for competencies achieved. They should be given following tasks: Plant Maintenance and Safety Course code: 3341906 GTU/NITTTR/Bhopal/13-14 Gujarat State 7 i. Identify different tools. ii. Make decision tree for given case. iii. Assemble and dismantle parts of given device.
- 8. SUGGESTED LIST OF STUDENT ACTIVITIES Sr. No. Activity
- 1. Monitor functionality of machine element and try to judge fault in it.
- 2. Visit nearby Industry/plant/workshop/hospital and collect samples of periodic & preventive maintenance format.
- 9. SPECIAL INSTRUCTIONAL STRATEGIES (If any) Sr. No. Unit Unit Name Strategies
- 1. I Fundamentals of maintenance engineering Demonstrate and explain use of tools.
- 2. II Wear and Corrosion and their prevention Show worn out parts. Also discuss reasons. Show corroded parts. Also discuss reasons.
- 3. III Fault tracing Show movie. Demonstrate the steps.
- 4. IV Periodic and preventive maintenance Show movie. Demonstrate the steps. Show some sample formats.
- 5. V Industrial safety Demonstrate and explain use of safety equipments. Industrial visit.
- 6. VI Recovery, reconditioning and retrofitting Show movie. Demonstrate the steps. Industrial visit.
- 7. VII Installation, erection and commissioning of equipments Show movie. Demonstrate the steps. Industrial visit.
- 10. SUGGESTED LEARNING RESOURCES (A) List of Books: Sr no. Title of Books Author Publication
- 1. Maintenance Engineering Handbook Higgins & Morrow DA Information Services
- 2. Maintenance Engineering H.P.Garg S. Chand and Company.
- 3. Maintenance of Machine Tools Gilbirg & Morrow
- 4. Pump-hydraulic Compressors Audels. McGrew Hill Publication.
- 5. Foundation Engineering Handbook Winterkorn, Hans. Chapman & Hall London Plant Maintenance and Safety Course code: 3341906 GTU/NITTTR/Bhopal/13-14 Gujarat State 8
- 6. Manuals Of Machine Tool And Auto mobile Vehicles - -
- 7. Corrosion handbook - - (B) List of Software/Learning Websites: i. www.mt-online.com ii. www.pmxpert.com iii. www.nptel.iitm.ac.in iv. en.wikipedia.org v. webstore.ansi.org/preventive-maintenance vi. www.mapcon.com (C) List of equipments: i. Tool kit. ii. Fire extinguishers. iii. Lubricants. iv. Cotton waste. v. Kerosene. vi. Measuring instruments.
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