ALAGAPPA UNIVERSITY, KARAIKKUDI
MAINTENANCE PRACTICES LAB – PRACTICAL
[Link] KALANITHI
REMO INTERNATIONAL COLLEGE
CHENNAI
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List of Practical:
1. Identification of CO2 and DCP fire extinguisher
2. Riveting by Lap Joint
3. Riveting by Butt Joint
4. Bending and Flaring of Aluminum pipes.
5. Engineering Drawing practices
6. Sheet Metal Bending and Forming
7. Swaging of Cables
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EX NO : 1
IDENTIFICATION OF CO2 AND DCP FIRE
DATE: EXTINGUISHER
AIM:
To identify and differentiate between CO₂ (Carbon Dioxide) and DCP (Dry Chemical Powder)
fire extinguishers based on their physical characteristics, components, and usage.
APPARATUS REQUIRED:
1. CO₂ fire extinguisher
2. DCP fire extinguisher
3. Safety gloves and goggles
4. Labeling materials (marker, chart, tape)
PROCEDURE:
Step 1: Physical Inspection
Observe the body color and band marking of both fire extinguishers.
CO₂ extinguisher: Red body with a black band (in many countries).
DCP extinguisher: Red body with a blue band (in some standards).
Step 2: Nozzle and Discharge Mechanism
Inspect the nozzle type.
CO₂ extinguisher: Equipped with a horn-shaped nozzle to prevent freezing injuries.
DCP extinguisher: Has a standard hose or nozzle for powder discharge.
Step 3: Weight and Pressure Check
Lift both extinguishers and note the weight difference.
CO₂ extinguisher: Heavier due to high-pressure CO₂ gas storage.
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DCP extinguisher: Lighter as it contains dry powder.
Check the pressure gauge (if present).
CO₂ extinguisher: Usually does not have a pressure gauge.
DCP extinguisher: Has a pressure gauge indicating operational readiness.
Step 4: Label and Instruction Examination
Read the label instructions on both extinguishers.
Identify the fire classes they are designed for.
CO₂ extinguisher: Suitable for Class B (flammable liquids) and Class E (electrical) fires.
DCP extinguisher: Suitable for Class A (solids), Class B (liquids), and Class C (gases).
Step 5: Discharge Test (Optional, under supervision)
CO₂ extinguisher: Discharges a white mist of CO₂ gas and quickly evaporates.
DCP extinguisher: Releases a cloud of dry powder, leaving residue.
RESULT:
By following the identification steps, we can distinguish between CO₂ and DCP fire extinguishers based on their
color coding, nozzle type, pressure gauge, fire class suitability, and discharge characteristics.
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DCP FIRE EXTINGUISHER
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EX NO : 2
RIVETING BY LAP JOINT
DATE:
AIM To join two given metal plates by a LAP joint using arc welding.
MATERIAL SUPPLIED Mild Steel Plate of Size 75x50x6 mm
TOOLS REQUIRED
Power supply, (AC /DC), earthing clamp, welding electrode, welding torch, tongs,
bench vice, wire brush, gloves, shield, apron, safety goggles, steel rule, flat file,
chipping hammer
WORKING STEPS
1. The given metal plates are cleaned to remove rust and scale formation, by using
a wire brush. Then edge preparation is done to the required dimensions, with the
aid of bench vice.
2. Based on the thickness of the metal plates to be welded the amperage and correct
voltage is selected. Two metal plates are placed in the over lapped position using a
support piece and tag weld is done on the ends to avoid the movement of the plates
while welding.
3. Then welding is started from one end of the plates and is continued till the other
end by maintaining 3 mm gap between the welding rod and the plates to be welded.
While welding goggles, gloves and shield are used for the safety of eyes and hand.
The electric arc produced by the transformer melts the electrode and joins the two
metal plates. Then cool the welded metal plates finally the welded portion is
chipped to remove slag using chipping hammer and wire brush.
RESULT
Hence the two given metal plates are joined by lap joint using arc welding.
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LAPP JOINT
ALL DIMENSIONS ARE IN MM
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EX NO : 3
RIVETING BY BUTT JOINT
DATE:
AIM To join two given metal plates by a BUTT joint using arc welding.
MATERIAL SUPPLIED Mild Steel Plate of Size 75x50x6 mm
TOOLS REQUIRED
Power supply, (AC /DC), earthing clamp, welding electrode, welding torch,
tongs, bench vice, wire brush, gloves, shield, apron, safety goggles, steel rule, flat
file, chipping hammer
WORKING STEPS
1. The given metal plates are cleaned to remove rust and scale
formation by using a wire brush. Then edge preparation is done to the required
dimensions with the aid of bench vice and a file for a butt joint.
2. Based on the thickness of the metal plates to be welded, the amperage
and correct voltage is selected.
3. Two metal plates are placed as shown in the figure with a suitable gap
of 2mm between them and tag weld is done on the ends to avoid the movement of
the plates while welding. Then welding is started from one end of the plates
and is continued till the other end by maintaining 3 mm gap between the welding
rod and the plates to be welded.
4. While welding goggles, gloves and shield are used for the safety of
eyes and hand. The electric arc produced by the transformer melts the electrode
and joins the two metal plates. Then cool the welded metal plates. Finally the
welded portion is chipped to remove slag using chipping hammer and wire brush.
RESULT
Hence the two given metal plates are joined by BUTT joint using arc welding.
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BUTT JOINT
ALL DIMENSIONS ARE IN MM
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EX NO : 4
BENDING AND FLARING OF ALUMINIUM PIPES.
DATE:
AIM To connect the Aluminium pipe with pipe fittings like valves bends and tap.
FITTINGS AND COMPONENTS REQUIRED
1. Pipes of different length 2. Gate valve [Link]
4. Elbows 5. Reducer
TOOLS REQUIRED
Pipe wrench, Hack saw, Hammer, Screw driver, measuring tape.
WORKING STEPS
1. The required pipe connection layout is drawn.
2. The gate valve which is internally threaded is connected between two pipes. The
other end of the pipe is connected with the elbow which is also internally
threaded.
3. A third pipe, with external threads is connected to the elbow for vertical
extension. To this pipe another elbow is attached at the free end.
4. The free end of the second elbow is connected with another pipe for horizontal
extension.
5. A reducer coupling with internal threads is connected to the horizontal pipe.
6. A tap is connected properly to the end of the reducer coupling.
RESULT
Hence the required connection is obtained using required pipes and pipe fittings.
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LINE DIAGRAM
PIPE CONNECTIONS FOR WASH BASIN
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EX NO : 5
ENGINEERING DRAWING PRACTICES
DATE:
Aim:
To Construct a Diagram with given dimensions
Apparatus Required:
1. Pencil Sharpener
2. Scale
3. Compass
4. Eraser
5. Mini drafter
6. Divider
7. French Curve
8. Protractor
9. Set Square
[Link] Board
[Link] Sheet
Procedure:
Steps: Projection of Points
[Link] reference line XY and mark VP and HP
[Link] the Projector and mark the points as per dimension
[Link] all dimensions
[Link] only visible
Steps 1: Projection of Straight Line
1. Draw XY line
2. Mark the point c’20mm above XY line and c 30mm below XY.
3. From e’ draw a line inclined at 300 to HP and mark (d1 length 80mm)
4. Draw the locus line d’
5. Draw the top view of c’d1’ which is cd1
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Steps 2: Projection of Straight Line
1. From e draw a line inclined at 450 to VP and mark (cd2 length 80mm)
2. Draw the locus line d
3. Draw the front view of cd2 which is c’d2’
Step 3: Draw Final Front View and Top View
Exercise:
1. Draw the projections of following points on the same reference line, keeping the projectors 30 mm apart.
a) Point A, 40 mm above the H.P. and 25 mm in front of the V.P.
b) Point B, in the H.P. and 20 mm behind the V.P.
c) Point C, in the V.P. and 40 mm above the H.P.
d) Point D, 25 mm below the H.P. and 25 mm behind the V.P.
e) Point E, 15 mm above the H.P. and 40 mm behind the V.P.
f) Point F, 40 mm below the H.P. and 25 mm in front of the V.P.
g) Point G , in the H.P. and V.P.
2. A line CD measuring 80mm is inclined at an angle of 30 0 to HP and 450 to VP. The point C is 20mm above HP and
30mm infront of VP. Draw the projection of the straight line
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EX NO : 6
SHEET METAL BENDING AND FORMING
DATE:
AIM
To make the rectangular tray from the given sheet metal.
MATERIAL REQUIRED
26 or 30 gauge Galvanized Iron (G.I) Sheet [150x110mm]
TOOLS REQUIRED
1. Steel Rule [Link] 3. Mallet [Link] Snip
WORKING STEPS
The given GI sheet is marked as per the given dimensions shown in the
drawing.
The unwanted portion of the sheet is cut by using the straight snip along the
marked lines.
Then the sheet is leveled for the perfect flatness using the mallet.
The position of the hemming operation is marked at the edges with the help
of the steel rule and a scriber.
By holding the sheet in the bench vice the hemming operation is done on
four sides of the tray using ball peen hammer.
The sides of the tray are bent to 90 degrees as per the given sketch by using
the required stacks, anvil and mallet.
Finally, all the corners of the tray are joined by riveting and finishing
operations.
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RESULT
Hence the rectangular tray is made on the given GI sheet to the required size.
RECTANGULAR TRAY
DEVELOPMENT OF RECTANGULAR TRAY
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EX NO : 7
SWAGING OF CABLES
DATE:
Aim:
To demonstrate the principles of operation and the use of a dial test indicator
for measuring small linear variations or deviations in a work piece.
Apparatus Required:
1. Dial test indicator (with a magnetic base or holder)
2. Work piece with features to be measured
3. Surface plate or flat reference surface
4. Height gauge or surface height comparator (optional)
5. Measuring instruments (e.g., Vernier caliper, micrometer)
6. Safety equipment (e.g., goggles, gloves)
Procedure:
1. Introduction to Dial Test Indicator:
a. Provide an overview of the components of the dial test indicator,
including the dial face, needle, and contact point.
b. Explain the basic principles of operation, including how the indicator
measures linear variations or deviations in the surface of a work piece.
2. Setup and Calibration:
a. Attach the dial test indicator to its magnetic base or holder.
b. Place the magnetic base on a flat reference surface, such as a surface
plate or machine table.
c. Adjust the position of the dial test indicator so that the contact point
is aligned with the surface of the work piece to be measured.
d. Zero the dial indicator by rotating the dial face until the needle points
to the zero mark.
3. Measurement Procedure:
a. Position the work piece on the surface plate or machine table.
b. Bring the dial test indicator into contact with the surface of the
work piece at the desired measurement location.
c. Gently move the indicator along the surface while observing the
movement of the needle on the dial face.
d. Record the readings indicated by the dial test indicator at various
points on the work piece surface.
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4. Comparison with Reference Standards (Optional):
a. Use a height gauge or surface height comparator to establish reference
standards for comparison.
b. Compare the measurements obtained with the dial test indicator to the
reference standards to assess the accuracy and precision of the measurements.
5. Analysis and Interpretation:
a. Analyze the recorded measurements to identify any deviations or
irregularities in the surface of the work piece.
b. Interpret the results to determine the extent of variation from the
desired dimensions or specifications.
Tabulation:
Measurement Point Dial Reading (mm)
Point 1
Point 2
Point 3
Results:
- The tabulated data will include the measurement points on the work
piece and the corresponding dial readings obtained with the dial test
indicator.
- The results will demonstrate the capability of the dial test indicator to
accurately measure small linear variations or deviations in the surface of
a work piece.
- Any deviations from reference standards can be identified and analyzed
to assess the quality of the work piece surface.
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