Built on real plant situations
A belt running to one side, a gearbox running hot, a crusher starting to vibrate, a hydraulic system slowly losing pressure. Each question is anchored in something you'll actually see.
Industrial Engineering Series · 2026 Edition
Master CHP & RMHS Engineering with 10,000 Practical Questions
Your Complete Engineering Question Bank for Mechanical, Electrical, Instrumentation, Maintenance and Troubleshooting Professionals.
▶ Click play: why this book matters for your career
10,000Questions
100Chapters
9Technical Parts
1,178Full-colour pages
Practical Engineering KnowledgeWritten around real plant situations – what to do, and why.
Meet the book
Everything in one complete question bank
10,000 practical questions across wagon tipplers, belt conveyors, apron feeders, crushers, stackers, reclaimers, pipe conveyors and ship loaders, in 1,178 full-colour pages.
- ✓Real plant troubleshooting
- ✓Engineering calculations
- ✓Maintenance checklists
- ✓OEM technologies
38 troubleshooting tables
30 worked calculations
Why this book is different
Not a theory book. A shift-floor companion.
Most of the knowledge that keeps coal and raw material handling plants running lives in the heads of experienced people. This book puts it in one structured question bank.
Explains the "why", not just the "what"
Answers cover the working principle, the failure mechanism, the inspection that confirms it, and the action that stops it coming back.
Five reader levels in one book
Every chapter is graded L1 to L5, from ITI and diploma technicians up to maintenance heads and plant heads. One book from your first day to the day you lead the plant.
Safety is part of the engineering
Every procedure assumes a valid permit-to-work, proper LOTO isolation and approved methods. Safety questions close every chapter.
Honest about OEM data
OEM statements are tagged [GENERIC] or [OEM – verify in manual]. No invented manufacturer settings, torques or clearances.
Same structure in every chapter
100 questions per chapter in a fixed order, so you always know where to find inspection points, breakdown causes, calculations or case studies.
What you will learn
Every chapter, 100 questions, 10 practical sections
Each of the 100 chapters follows the same layout, building from core concepts through to troubleshooting, calculations, case studies and safety.
25 Q
Core concepts, construction & working principle
The foundation: what the equipment is, how it is built and how it works.
10 Q
Daily inspection points
What to look, listen and measure for on every shift round.
10 Q
Preventive maintenance points
What to check, how often, and the acceptance criteria.
10 Q
Common breakdown reasons
Why the equipment actually fails in the field.
10 Q
Troubleshooting questions
Step-by-step diagnosis from symptom to root cause and final trial.
10 Q
Advanced interview questions
The questions that separate a good engineer from a great one.
10 Q
Engineering thumb rules & calculations
Formula, variables, units, a worked example and its limitations.
5 Q
Industrial failure case studies
Clearly labelled illustrative cases built from typical plant situations.
5 Q
Maintenance improvement ideas
Practical ways to raise reliability and cut repeat failures.
5 Q
Safety-related questions
Isolation, permits and the hazards specific to each task.
The anatomy of every answer
Each answer uses only the headings relevant to the question, always in this order:
All 9 technical parts
From fundamentals to plant head level
Nine colour-coded parts take you through fundamentals, conveyors, drives, major equipment, auxiliary systems, electrical, instrumentation and reliability, ending with real breakdown cases and safety.
A
Part A · Ch 1–10
CHP & RMHS Fundamentals
Role of the CHP and RMHS, material flow, plant layout, bulk materials and their properties, TPH calculations, chutes, equipment selection and interlocking philosophy.
B
Part B · Ch 11–30
Conveyor System
Belts, drives, gearboxes, pulleys, idlers, tracking, take-ups, splicing, cleaning, sealing, chute blockage, spillage, noise, slip and conveyor fire protection.
C
Part C · Ch 31–40
Drive and Transmission Systems
Gearbox types and damage analysis, lubrication and oil analysis, rigid, flexible and fluid couplings, chain and belt drives, and shaft, bearing and keyway failures.
D
Part D · Ch 41–70
Major CHP & RMHS Equipment
Wagon tippler, apron feeder, VGF, ring granulator, roller and mobile crushers, screens, stacker, stacker-reclaimer, side arm charger, pipe conveyor, ship loader and unloader, RBF, paddle and plough feeders.
E
Part E · Ch 71–80
Other Material Handling Equipment
Scraper and chain conveyors, transfer towers, magnetic separators, metal detectors, feeders, dust suppression and extraction, bag filters, fans, hydraulic power packs, pumps, valves and accumulators.
F
Part F · Ch 81–85
Electrical Engineering
Motor selection and protection, electrical faults, MCC, PCC, VFD and soft starters, conveyor drive control, cables, earthing and electrical interlocks.
G
Part G · Ch 86–90
Instrumentation and Automation
Industrial sensors, belt sway, zero speed and pull cord switches, belt weighers and weigh feeders, PLC, SCADA and DCS, loop checking and calibration.
H
Part H · Ch 91–95
Maintenance and Reliability
Preventive, predictive and breakdown maintenance, RCA, MTBF, MTTR and OEE, bearing failure and lubrication management, alignment, balancing and vibration analysis.
I
Part I · Ch 96–100
Practical Engineering & Troubleshooting
Real-life breakdown cases, thumb rules and quick calculations, inspection checklists and SOPs, safety, LOTO and permit-to-work, and plant head-level interview questions.
Book contents
100 chapters overview
Question numbering is continuous from Q0001 to Q10000. Chapter n always holds Q(100n − 99) to Q(100n), so any question number tells you its chapter instantly.
100 chapters
ACHP & RMHS Fundamentals
- Ch 1Introduction to Coal Handling PlantQ0001–Q0100
- Ch 2Raw Material Handling System FundamentalsQ0101–Q0200
- Ch 3Complete Material Flow ProcessQ0201–Q0300
- Ch 4CHP and RMHS Plant Layout and Equipment IdentificationQ0301–Q0400
- Ch 5Coal, Iron Ore, Limestone, Dolomite and Other Bulk MaterialsQ0401–Q0500
- Ch 6Material Properties, Bulk Density, Moisture and Particle SizeQ0501–Q0600
- Ch 7Plant Capacity, TPH and Material Handling CalculationsQ0601–Q0700
- Ch 8Material Flow, Transfer Points and Chute DesignQ0701–Q0800
- Ch 9Equipment Selection and Engineering FundamentalsQ0801–Q0900
- Ch 10Plant Operation Philosophy and InterlockingQ0901–Q1000
BConveyor System
- Ch 11Belt Conveyor FundamentalsQ1001–Q1100
- Ch 12Conveyor Belt Construction and SelectionQ1101–Q1200
- Ch 13Conveyor Belt Types and ApplicationsQ1201–Q1300
- Ch 14Belt Conveyor Drive SystemsQ1301–Q1400
- Ch 15Conveyor Gearboxes and Motor CouplingsQ1401–Q1500
- Ch 16Conveyor Pulley and Drum AssembliesQ1501–Q1600
- Ch 17Head Pulley, Tail Pulley and Snub PulleyQ1601–Q1700
- Ch 18Carrying Idlers and Return IdlersQ1701–Q1800
- Ch 19Impact Idlers and Self-Aligning IdlersQ1801–Q1900
- Ch 20Belt Tracking and MisalignmentQ1901–Q2000
- Ch 21Belt Tensioning and Take-Up SystemsQ2001–Q2100
- Ch 22Belt Splicing and VulcanizingQ2101–Q2200
- Ch 23Belt Joint Failures and RepairQ2201–Q2300
- Ch 24Conveyor Scraper and Belt Cleaning SystemsQ2301–Q2400
- Ch 25Conveyor Skirt Rubber and Sealing SystemsQ2401–Q2500
- Ch 26Conveyor Chute Blockage and Chute DesignQ2501–Q2600
- Ch 27Conveyor Spillage and Material CarrybackQ2601–Q2700
- Ch 28Conveyor Abnormal Noise and VibrationQ2701–Q2800
- Ch 29Conveyor Belt Slip and Belt SlippageQ2801–Q2900
- Ch 30Conveyor Belt Fire and Emergency ProtectionQ2901–Q3000
CDrive and Transmission Systems
- Ch 31Industrial Gearbox FundamentalsQ3001–Q3100
- Ch 32Helical, Bevel, Worm and Planetary GearboxesQ3101–Q3200
- Ch 33Gear Tooth Damage and Failure AnalysisQ3201–Q3300
- Ch 34Gearbox Lubrication and Oil AnalysisQ3301–Q3400
- Ch 35Industrial Couplings and Their ComponentsQ3401–Q3500
- Ch 36Fluid Couplings and Variable Speed DrivesQ3501–Q3600
- Ch 37Grid, Gear, Tyre and Jaw CouplingsQ3601–Q3700
- Ch 38Chain Drive and Sprocket SystemsQ3701–Q3800
- Ch 39Belt Drive and Pulley SystemsQ3801–Q3900
- Ch 40Shaft, Bearing and Keyway FailuresQ3901–Q4000
DMajor CHP & RMHS Equipment
- Ch 41Wagon Tippler – Construction and OperationQ4001–Q4100
- Ch 42Wagon Tippler – Mechanical and Hydraulic SystemsQ4101–Q4200
- Ch 43Wagon Tippler – Electrical and Interlocking SystemsQ4201–Q4300
- Ch 44Wagon Tippler – Troubleshooting and MaintenanceQ4301–Q4400
- Ch 45Apron Feeder – Design and Working PrincipleQ4401–Q4500
- Ch 46Apron Feeder – Chain, Pan and Sprocket MaintenanceQ4501–Q4600
- Ch 47Apron Feeder – Drive and Hydraulic SystemQ4601–Q4700
- Ch 48Apron Feeder – Common Failures and TroubleshootingQ4701–Q4800
- Ch 49Vibrating Grizzly Feeder (VGF)Q4801–Q4900
- Ch 50VGF – Exciter, Bearings, Springs and VibrationQ4901–Q5000
- Ch 51Primary Crusher and Crusher FundamentalsQ5001–Q5100
- Ch 52Ring Granulator – Construction and OperationQ5101–Q5200
- Ch 53Ring Granulator – Rotor, Hammers and Breaker PlatesQ5201–Q5300
- Ch 54Ring Granulator – Failure Analysis and TroubleshootingQ5301–Q5400
- Ch 55Secondary Roller CrusherQ5401–Q5500
- Ch 56Roller Crusher – Rollers, Bearings and DriveQ5501–Q5600
- Ch 57Mobile Crusher and Mobile Screening SystemsQ5601–Q5700
- Ch 58Mobile Screen and Vibrating ScreenQ5701–Q5800
- Ch 59Stacker – Boom Conveyor and Slewing MechanismQ5801–Q5900
- Ch 60Stacker – Luffing, Hydraulic and Travel SystemsQ5901–Q6000
- Ch 61Stacker Cum ReclaimerQ6001–Q6100
- Ch 62Stacker Cum Reclaimer – Slewing and Luffing SystemsQ6101–Q6200
- Ch 63Stacker Cum Reclaimer – Bucket Wheel and ReclaimingQ6201–Q6300
- Ch 64Side Arm ChargerQ6301–Q6400
- Ch 65Pipe Conveyor – Construction and OperationQ6401–Q6500
- Ch 66Pipe Conveyor – Belt Folding and Belt TrackingQ6501–Q6600
- Ch 67Ship LoaderQ6601–Q6700
- Ch 68Ship UnloaderQ6701–Q6800
- Ch 69Reclaimer Breaker FeederQ6801–Q6900
- Ch 70Paddle Feeder and Plow FeederQ6901–Q7000
EOther Material Handling Equipment
- Ch 71Scraper Conveyor and Drag Chain ConveyorQ7001–Q7100
- Ch 72Chain Conveyor and Flight ConveyorQ7101–Q7200
- Ch 73Transfer Towers and Transfer ChutesQ7201–Q7300
- Ch 74Magnetic Separator and Metal DetectorQ7301–Q7400
- Ch 75Vibrating Feeder and Belt FeederQ7401–Q7500
- Ch 76Dust Extraction and Dust Suppression SystemsQ7501–Q7600
- Ch 77Dust Separation and Bag Filter SystemsQ7601–Q7700
- Ch 78Industrial Fans, Blowers and Exhaust SystemsQ7701–Q7800
- Ch 79Hydraulic Power Packs and Hydraulic CylindersQ7801–Q7900
- Ch 80Pumps, Valves, Filters and AccumulatorsQ7901–Q8000
FElectrical Engineering
- Ch 81Industrial Motors and Motor SelectionQ8001–Q8100
- Ch 82Motor Protection, Overload and Electrical FaultsQ8101–Q8200
- Ch 83MCC, PCC, VFD and Soft StarterQ8201–Q8300
- Ch 84Electrical Drives and Conveyor Control SystemsQ8301–Q8400
- Ch 85Cable, Earthing, Electrical Interlocks and ProtectionQ8401–Q8500
GInstrumentation and Automation
- Ch 86Industrial Sensors and Limit SwitchesQ8501–Q8600
- Ch 87Belt Sway, Zero Speed and Pull Cord SwitchesQ8601–Q8700
- Ch 88Weigh Feeders and Belt Weigh ScalesQ8701–Q8800
- Ch 89PLC, SCADA, DCS and AutomationQ8801–Q8900
- Ch 90Instrumentation Troubleshooting and CalibrationQ8901–Q9000
HMaintenance and Reliability
- Ch 91Preventive, Predictive and Breakdown MaintenanceQ9001–Q9100
- Ch 92Mechanical Failure Analysis and Root Cause AnalysisQ9101–Q9200
- Ch 93MTBF, MTTR, OEE and Equipment ReliabilityQ9201–Q9300
- Ch 94Bearing Failure and Lubrication ManagementQ9301–Q9400
- Ch 95Alignment, Balancing and Vibration AnalysisQ9401–Q9500
IPractical Engineering & Troubleshooting
- Ch 96Real-Life CHP and RMHS Breakdown CasesQ9501–Q9600
- Ch 97Engineering Thumb Rules and Quick CalculationsQ9601–Q9700
- Ch 98Maintenance Inspection Checklists and SOPsQ9701–Q9800
- Ch 99Industrial Safety, LOTO and Permit-to-WorkQ9801–Q9900
- Ch 100Advanced Technical Interviews and Plant Head-Level QuestionsQ9901–Q10000
No chapter title matches that word. Try a broader term like "conveyor", "hydraulic" or "motor".
Plus the complete back matter
Who should buy this book?
Written for the people who keep the plant running every shift
Technicians, operators, engineers, supervisors and managers. Every chapter carries questions for all five levels.
L1
ITI & Diploma Technicians
20 questions per chapter
L2
Junior / Graduate Engineers
25 questions per chapter
L3
Senior Engineers & Supervisors
25 questions per chapter
L4
Assistant Managers & Managers
15 questions per chapter
L5
Maintenance & Plant Heads
15 questions per chapter
Thermal & captive power plants
Coal receipt, crushing, stacking, reclaiming and bunker feeding.
Integrated steel plants
RMHS for ore, coal and fluxes, bed blending and delivery to sinter, BF and coke ovens.
Ports
Ship loaders, ship unloaders, pipe conveyors and stockyard machines.
Mines & interview candidates
Mobile crushers and screens, plus an interview preparation section.
Practical engineering benefits
Tools you'll use on the job, not just in exams
38 full troubleshooting tables
Each real plant problem gets a table: Problem, Possible Cause, Inspection, Corrective Action and Preventive Action, plus a diagnostic sequence. Examples include:
- Conveyor belt running towards one side
- Belt slip during heavy loading
- Conveyor gearbox overheating
- Apron feeder chain jumping
- Ring granulator rotor vibration
- Hydraulic pressure dropping
- Reclaimer breaker feeder tail-end jumping
- VFD trip & motor overload trip
30 worked engineering calculations
Each one gives the formula, the meaning and units of every variable, a worked numerical example, the engineering interpretation, and its limitations.
v = πDN / 60Q = 3600·A·v·ρT = 9550·P / NT1/T2 = e^μθ
L10 = (C/P)^pF = p·AI = P / (√3·V·cosφ·η)OEE = A × P × Q
25 original colour schematics
Numbered component callouts, a legend, the working principle and maintenance points, covering the belt conveyor system, gearbox internals, wagon tippler hydraulic circuit, ring granulator, stacker-reclaimer, pipe conveyor, bag filter, MCC/VFD and more.
Checklists, SOPs & OEM references
Daily, weekly and monthly inspection checklists, SOP structure, shift handover and start-up/shutdown checks. OEM coverage spans hydraulics, bulk handling equipment, gearboxes and drives, and electrical and instrumentation makers.
Real samples from the book
See exactly how the answers read
Q0007L1 · ITI & Diploma Technician
Why must coal be crushed in a CHP?
Coal mills (pulverisers) are designed to accept coal only up to a certain size — commonly around 20–25 mm in many Indian stations. Larger lumps reduce mill output, increase mill wear and power, and can choke feeders. Crushing gives a uniform feed size for stable milling and combustion.
Thumb rule: Typical target in many stations is 'minus 20 mm', but the actual value must be taken from the mill and plant design specification.
Chapter 1 · Introduction to Coal Handling Plant
Q0008L1 · ITI & Diploma Technician
What is a 'stream' in a CHP and why are two streams provided?
A stream is one complete chain of conveyors, feeders and crushers able to carry coal along a route. Most CHPs provide two parallel streams (for example 'A' and 'B'), each of full rated capacity, so that one can run while the other is under maintenance or breakdown. This redundancy protects bunker feeding.
Chapter 1 · Introduction to Coal Handling Plant
Q1958L3 · Senior Engineer & Supervisor
Belt mistracks only at the loading point. Diagnose.
Troubleshooting / findings: Off-centre loading, chute deflectors, build-up in chute.
Also in this chapter: belt runs off along the entire conveyor (Q1956), at one idler section (Q1957), with a particular belt section (Q1959) and only in windy weather (Q1960).
Chapter 20 · Belt Tracking and Misalignment
About the author
Written by an engineer who has kept these plants running
P. L. Majhi
15 years hands-on experienceP. L. Majhi is a mechanical engineer with 15 years of hands-on experience in bulk raw material handling. His career has been spent in coal handling plants (CHP), raw material handling systems (RMHS), port material handling and RMPP operations. Across these plants he has kept conveyors, crushers, feeders, yard machines and hydraulic systems running safely and reliably.
He has worked with leading organisations in the port, power, steel, aluminium and mining sectors.
Qualifications
- B.Tech in Mechanical Engineering
- Certificate courses in industrial hydraulicsBosch Rexroth (India) Private Limited · Yuken India Limited
"If the conveyors stop, the boilers starve and the blast furnace slows down."
— from the Preface
Frequently asked questions
Questions before you buy
What exactly do I get?
The complete CHP & RMHS Engineering Question Bank eBook (2026 Edition): 10,000 questions with practical answers across 100 chapters and 9 parts, in 1,178 full-colour A4 pages. It includes 38 troubleshooting tables, 30 worked calculations, 25 original schematics and the full back matter: formula handbook, inspection checklists, troubleshooting master tables, OEM reference section, interview preparation section and index.
What format is the eBook?
It's a full-colour PDF eBook. It opens in any standard PDF reader on a laptop, desktop, tablet or phone. The A4 layout reads most comfortably on a tablet or computer screen.
How will I receive the book after payment?
After payment, follow the download / delivery instructions shown on the payment confirmation page and in your payment receipt email.
Is it useful if I'm a fresher or ITI technician?
Yes. Every chapter has 20 L1 questions written for ITI and diploma technicians and 25 L2 questions for junior and graduate engineers, so you can start from the basics and grow into the senior-level questions.
Will it help with job interviews?
Every chapter includes 10 advanced interview questions. Chapter 100 is dedicated to advanced technical interviews and plant head-level questions, and the back matter includes an Interview Preparation Section.
Does it cover electrical and instrumentation, or only mechanical?
All of them. Part F (Chapters 81–85) covers electrical engineering, Part G (Chapters 86–90) covers instrumentation and automation, and the major equipment chapters include electrical, interlocking and hydraulic aspects as well.
Can I use it in place of OEM manuals or site SOPs?
No. The book is an educational and reference work. Model-specific values such as settings, clearances, torques, oil grades and intervals must always come from the current OEM manual, and all work must follow your site's approved procedures, permits and LOTO.
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Offer ends in
- ✓10,000 practical questions & answers
- ✓100 chapters across 9 technical parts
- ✓1,178 full-colour pages · 2026 Edition
- ✓38 troubleshooting tables · 30 worked calculations · 25 schematics
- ✓Formula handbook, checklists, interview section & index
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