ABB Maintenance Engineer Interview Questions and Answers

Q1. What are the methods for measuring with a micrometer and a vernier caliper?
Ans. 
Methods for measuring with a micrometer and a vernier caliper
• For micrometer: Close the jaws gently around the object being measured, read the measurement from the scale, and add any additional measurements from the thimble.

• For vernier caliper: Close the jaws around the object, read the main scale measurement where the zero mark on the vernier scale aligns, then add the vernier scale measurement for precision.

• Ensure the...read more
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Q2. What is the process of casting?
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Casting is a manufacturing process in which a liquid material is poured into a mold, where it solidifies into the desired shape.
• Melted material is poured into a mold

• The material solidifies and takes the shape of the mold

• The mold is then removed to reveal the final product
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Q3. What are cope and drag in the context of casting processes?
Ans. 
Cope and drag are the two halves of a mold used in casting processes to create a cavity for the molten metal.
• Cope is the top half of the mold, while drag is the bottom half.

• The cope and drag are typically made from sand and are used to create a cavity in which the molten metal is poured.

• After the metal has solidified, the cope and drag are separated to reveal the casting.
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Q4. What are the different types of cylinders?
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Different types of cylinders include single-acting, double-acting, telescopic, and impact cylinders.
• Single-acting cylinders: Operate in one direction using fluid pressure to extend or retract the piston.

• Double-acting cylinders: Use fluid pressure to extend and retract the piston in both directions.

• Telescopic cylinders: Consist of multiple nested stages that allow for a longer stroke length in a compact design.

• Impact cy...read more
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Q5. What is the difference between pneumatic and hydraulic systems?
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Pneumatic systems use compressed air to transmit power, while hydraulic systems use fluid (usually oil) to transmit power.
• Pneumatic systems use air as the working fluid, while hydraulic systems use oil or other fluids.

• Pneumatic systems are generally cleaner and easier to maintain than hydraulic systems.

• Hydraulic systems can handle higher loads and pressures compared to pneumatic systems.

• Pneumatic systems are often used...read more
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Q6. What are the different types of heat exchangers?
Ans. 
Heat exchangers are devices used to transfer heat between two or more fluids, without mixing them together.
• Shell and tube heat exchanger

• Plate heat exchanger

• Double pipe heat exchanger

• Finned tube heat exchanger

• Spiral heat exchanger
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Q7. What are the different types of bearings and their applications?
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Different types of bearings include ball bearings, roller bearings, plain bearings, and fluid bearings.
• Ball bearings are used in applications requiring low friction and high speed, such as in wheels and conveyor belts.

• Roller bearings are suitable for heavy radial loads, such as in automotive transmissions and industrial machinery.

• Plain bearings, also known as bushings, are used in applications where lubrication is diff...read more
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Q8. What is the heat treatment process?
Ans. 
Heat treatment is a process used to alter the physical and sometimes chemical properties of a material through heating and cooling.
• Heat treatment involves heating a material to a specific temperature, holding it at that temperature for a certain amount of time, and then cooling it at a controlled rate.

• The process can be used to increase the hardness, strength, toughness, and ductility of a material.

• Common heat treatmen...read more
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Q9. What are the defects associated with the casting process?
Ans. 
Defects in casting process include porosity, shrinkage, cold shuts, misruns, and inclusions.
• Porosity: air or gas trapped in the casting

• Shrinkage: volume reduction during solidification

• Cold shuts: incomplete fusion of molten metal

• Misruns: incomplete filling of the mold cavity

• Inclusions: foreign materials trapped in the casting
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Q10. What are the types of sand used in casting?
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Types of sand used in casting include green sand, resin sand, shell mold sand, and sodium silicate sand.
• Green sand: most commonly used type, made of silica sand mixed with clay and water

• Resin sand: mixed with resin and hardener for better surface finish and dimensional accuracy

• Shell mold sand: uses a resin-coated sand that is heated to form a shell around the pattern

• Sodium silicate sand: uses sodium silicate as a binde...read more
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Q1. DIFTER MAINTEANCE
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Q2. SMART ROCK T40 OPERATION
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Q3. MANPOWER HANDLING
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Q1. How to calculate Boiler direct & indirect efficiency ?
Ans. 
Boiler efficiency can be calculated by measuring the heat input and heat output of the boiler.
• Calculate the heat input by measuring the fuel flow rate, fuel calorific value, and fuel consumption.

• Calculate the heat output by measuring the steam flow rate and steam enthalpy.

• Direct efficiency = (Heat output / Heat input) * 100%

• Indirect efficiency = Direct efficiency * Boiler efficiency of other components (like economizer
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Q2. What is the monthly maintenance cost of your section ?
Ans. 
The monthly maintenance cost of my section is approximately $10,000.
• The monthly maintenance cost includes expenses for spare parts, labor, equipment rental, and utilities.

• Regular maintenance tasks such as lubrication, inspections, and repairs contribute to the overall cost.

• Cost may vary depending on the size of the section, age of equipment, and frequency of maintenance activities.
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Q1. How induction motor started
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An induction motor starts when a rotating magnetic field is created by the stator winding, inducing current in the rotor.
• Induction motors start by using the principle of electromagnetic induction.

• The stator winding is energized with a three-phase AC current, creating a rotating magnetic field.

• This rotating magnetic field induces a current in the rotor, which in turn creates a magnetic field.

• The interaction between the ...read more
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Q2. What's is your father name
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Q3. Transformer working, also induction Furnace working &basic principle
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Q1. Machines information
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Q2. All machines and all problems.. solve the maintenance manager
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Q1. Tell me about yourself
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Q2. Where have you worked before this
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Q3. What information do you have?
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Q4. What work did you do in the other company before this?
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Information about the project

Q1. Information about machines
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Q2. Axis of the machine
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