ESE 2018

UPSC ENGINEERING SERVICES EXAMINATION

Preliminary Examination

Paper General Studies and

I Engineering Aptitude

Vol. 1
General Principles of Design, Drawing and Importance of Safety
Standards and Quality Practices in Production, Construction,
Maintenance and Services
Basics of Energy and Environment

Comprehensive Theory with Practice Questions

and ESE Solved Questions

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ESE 2018 Prelims : General Studies and Engineering Aptitude : Vol.-1

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Preface
The compilation of this book General Studies and
Engineering Aptitude (Vol. 1) was motivated by the
desire to provide a concise book which can benefit
students to understand the concepts of General Studies
and Engineering Aptitude topics.

This textbook General Studies and Engineering

Aptitude (Vol. 1) provides all the requirements of
the students, i.e. comprehensive coverage of theory,
fundamental concepts and objective type questions articulated in a lucid language. The concise
presentation will help the readers grasp the theory of this subject with clarity and apply them with
ease to solve objective questions quickly. This book not only covers the syllabus of ESE in a holistic
manner but is also useful for many other competitive examinations. All the topics are given the
emphasis they deserve so that mere reading of the book clarifies all the concepts.

We have put in our sincere efforts to present detailed theory and MCQs without compromising the
accuracy of answers. For the interest of the readers, some notes, do you know and interesting facts
are given in the comprehensive manner. At the end of each chapter, sets of practice question are
given with their keys, that will allow the readers to evaluate their understanding of the topics and
sharpen their question solving skills.

Our team has made their best efforts to remove all possible errors of any kind. Nonetheless, we would
highly appreciate and acknowledge if you find and share with us any printing and conceptual errors.

It is impossible to thank all the individuals who helped us, but we would like to sincerely thank all
the authors, editors and reviewers for putting in their efforts to publish this book.

With Best Wishes

B. Singh
CMD, MADE EASY
 General Studies and
Engineering Aptitude Vol. 1 Contents

General Principles of Design, Drawing and Importance of Safety

4.5 EVAD (Design EVAluation) Method....................33

General Principles of Design
4.6 Weighted Decision Matrix.....................................34
Chapter 1 4.7 Analytic Hierarchy Process (AHP)........................34
Engineering Design Process......................1 Objective Brain Teasers............................................35
1.1 Introduction.................................................................. 1
1.2 Engineering Design Process......................................
Chapter 5
1.3 Design Method versus Scientific Method.......... 3
Embodiment Design & Detail Design .... 36
5.1 Introduction................................................................36
1.4 Steps in Engineering Design process.................. 3
5.2 Product Architecture...............................................36
1.5 Description of Design Process............................... 4
5.3 Configuration Design..............................................37
1.6 Sequential and Concurrent Engineering........... 7
5.4 Parametric Design....................................................38
Objective Brain Teasers.............................................. 8
5.5 Industrial Design.......................................................42
Chapter 2 5.6 Prototyping.................................................................45
Problem Definition and Information 5.7 Testing..........................................................................47
Gathering................................................. 10 5.8 Detail Design..............................................................47
2.1 Introduction................................................................10 Objective Brain Teasers............................................49
2.2 Preliminary Research on Customer Needs......10
2.3 Customer Requirement..........................................11
Chapter 6
2.4 Establishing the Engineering Characteristics.13
Design of Machine Elements.................. 50
6.1 Chain Drive..................................................................50
2.5 Quality Function Deployment (QFD).................14
6.2 Belt Drive......................................................................52
2.6 Product Design Specification...............................16
6.3 Clutches........................................................................59
2.7 Gathering Information............................................16
Objective Brain Teasers............................................66
2.8 Information Gathering for a Particular PDS.....17
Objective Brain Teasers............................................20
General Principles of Drawing
Chapter 3
Generate Multiple Solutions................... 21
Chapter 7
Basics of Engineering Drawing............... 69
3.1 Introduction................................................................21
7.1 What is Engineering Drawing?.............................69
3.2 Introduction to Creative Thinking......................21
7.2 Classification of Engineering Drawing..............69
3.3 Creativity and Problem Solving...........................23
7.3 Drawing Instruments...............................................69
3.4 Concept Generation Methods.............................26
7.4 Engineering Scales...................................................73
Objective Brain Teasers............................................30
7.5 Drawing Standards...................................................77
Chapter 4 7.6 Layout of a Drawing Sheet....................................77
Analyse and Select a Solution................ 31 7.7 Lines...............................................................................78
4.1 Introduction................................................................31 7.8 Lettering.......................................................................79
4.2 Decision Making........................................................31 7.9 Dimensioning.............................................................81
4.3 Evaluation Process....................................................32 7.10 Geometric Constructions and Curves...............87
4.4 Pugh Chart (Datum Method)................................33 Objective Brain Teasers............................................95

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Chapter 8
Orthographic Projections....................... 97
8.1 Introduction................................................................97
8.2 Methods of Projection............................................97
8.3 Planes of Projection.................................................98
8.4 Types of Orthographics..........................................99
Objective Brain Teasers......................................... 103
Chapter 9
Projection of Points............................... 108
9.1 Introduction............................................................. 108
9.2 Projections of a Point in the First Quadrant. 108
9.3 Projections of a Point in Second Quadrant.. 109
9.4 Projections of a Point in Third Quadrant....... 109
9.5 Projections of a Point in Fourth Quadrant.... 110
9.6 Projections of Points Lying on Horizontal ............
Projection Plane..................................................... 111
9.7 Projections of Points Lying on Vertical ..................
Projection Plane..................................................... 111
Objective Brain Teasers......................................... 112
Chapter 10
Projection of Lines................................. 114
10.1 Introduction............................................................. 114
10.2 Positions of a Line with Respect to HP and VP.......114
10.3 Projection of a Line Parallel to Both HP and VP
but Contained in Neither................................... 114
10.4 Projection of a Line Contained in HP and
Parallel to VP............................................................ 115
10.5 Projection of a Line Contained in VP and
Parallel to HP........................................................... 116
10.6 Projection of a Line Perpendicular to the HP
and Parallel to VP................................................... 116
10.7 Projection of a Straight Line Perpendicular to
the VP and Parallel to the HP............................. 117
10.8 Projection of a Line Contained in the HP and
Inclined to the VP................................................... 117
10.9 Projection of a Line Contained in the VP and
Inclined to the HP.................................................. 118
10.10 Projection of a Line Contained in both the HP
and the VP................................................................ 119
10.11 Projection of a Line Inclined to the HP and
Parallel to the VP.................................................... 119
10.12 Projection of a Line Inclined to the VP and
Parallel to the HP.................................................... 120
10.13 Projection of a Line inclined to both the VP and
the HP......................................................................... 121
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10.14 Determining True Length and True inclinations
of a Line..................................................................... 122
10.15 Different Positions of a Line for its Traces wrt
the HP and the VP.................................................. 123
Objective Brain Teasers......................................... 125
Chapter 11
Projections of Planes............................. 127
11.1 Introduction............................................................. 127
11.2 Traces of Planes...................................................... 127
11.3 Types of Planes....................................................... 127
11.4 Projection of Planes.............................................. 127
Objective Brain Teasers......................................... 129
Chapter 12
Projections of Solids.............................. 131
12.1 Introduction............................................................. 131
12.2 Types of Solids........................................................ 131
12.3 Projection of Solids............................................... 134
Objective Brain Teasers......................................... 140
Chapter 13
Sections, Development and Intersection
of Solids................................................. 141
13.1 Section of Solids..................................................... 141
13.2 Intersection of Solids............................................ 154
13.3 Development of Surfaces................................... 157
Objective Brain Teasers......................................... 159
Importance of Safety
Chapter 14
Safety and its Importance..................... 161
14.1 Introduction............................................................. 161
14.2 Need for Safety....................................................... 161
14.3 OSHA Safety and Health Program
Management Guidelines..................................... 165
14.4 Occupational Health and Safety (OHS).......... 167
14.5 Fire Safety Engineering........................................ 169
14.6 Safety in Construction.......................................... 174
14.7 Safety in Demolition
(Construction in Reverse).................................... 184
14.8 Hazardous Waste Management....................... 185
14.9 Electrical Safety...................................................... 189
14.10 Safety in Engineering Industry......................... 191
14.11 Safety in Agriculture............................................. 195
14.12 Occupational Health and Safety in India....... 196
Objective Brain Teasers......................................... 203
 Standards and Quality Practices in Production,
Construction,Maintenance and Services
Chapter 1
Quality...................................................................206
1.1 What is Quality?...................................................... 206
1.2 Cost of Quality......................................................... 208
1.3 Methods for Generating Solution to
Improve Quality...................................................... 210
1.4 Quality Process ....................................................... 210
1.5 Contribution of Quality Gurus........................... 211
Objective Brain Teasers......................................... 213
Chapter 2
Quality Control Tools............................................214
2.1 Introduction............................................................. 214
Objective Brain Teasers......................................... 225
Chapter 3
Sampling...............................................................226
3.1 Sampling................................................................... 226
3.2 Acceptance Sampling........................................... 226
3.3 Sampling Plan.......................................................... 227
3.4 Sampling Terms...................................................... 230
3.5 Operating Characteristic Curve (OC Curve).. 231
Objective Brain Teasers......................................... 234
Chapter 4
Total Quality Management..................................236
4.1 Introduction............................................................. 236
4.2 Principles of TQM.................................................... 238
4.3 Taguchi Approaches in TQM............................. 241
4.4 Quality Function Deployment (QFD).............. 243
4.5 Other Methods Utilizes along TQM to Increase
Efficiency................................................................... 245
4.6 Benefits of TQM....................................................... 247
Objective Brain Teasers......................................... 247
Chapter 5
Six Sigma...............................................................249
5.1 Historical View......................................................... 249
5.2 Six Sigma Methodology....................................... 251
5.3 Different Levels in Six Sigma.............................. 253
Objective Brain Teasers......................................... 255
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Chapter 6
ISO Standards.......................................................257
6.1 Introduction............................................................. 257
6.2 ISO 9000..................................................................... 257
6.3 ISO 14000.................................................................. 260
6.4 OHSAS 18000........................................................... 262
6.5 Emission Norms...................................................... 263
Objective Brain Teasers......................................... 266
Chapter 7
Inventory Control.................................................268
7.1 Inventory................................................................... 268
7.2 Types of Models...................................................... 270
7.3 Selective Inventory Management.................... 279
7.5 Line Balancing......................................................... 280
Objective Brain Teasers......................................... 284
Chapter 8
Quality in Construction and Services..................290
8.1 Introduction............................................................. 290
8.2 Methodology to Improve Quality in
Construction............................................................ 292
8.3 Service Quality........................................................ 292
Objective Brain Teasers......................................... 294
Chapter 9
Maintenance.........................................................296
9.1 Reliability................................................................... 296
9.2 Maintainability........................................................ 298
9.3 Different Types of Maintenance........................ 300
9.4 Reliability Centered Maintenance (RCM)....... 305
Objective Brain Teasers......................................... 307
Chapter 10
Non-Destructive Examination.............................310
10.1 Non-Destructive Testing...................................... 310
10.2 Non-Destructive Examination (NDE) .............. 312
10.3 PT Techniques.......................................................... 316
10.4 RT Techniques.......................................................... 318
10.5 UT Techniques......................................................... 319
10.6 ET Techniques.......................................................... 321
Objective Brain Teasers......................................... 322
 Basics of Energy and Environment
Chapter 1
Energy & its Conservation....................................325
1.1 Introduction............................................................ 325
1.2 Renewable Energy Resources........................... 326
1.3 Non-renewable Energy Resources.................. 337
1.4 Chemical Sources of Energy.............................. 339
1.5 Energy Conservation............................................ 340
Objective Brain Teasers......................................... 343
Chapter 2
Environment & its Conservation.........................346
2.1 Introduction............................................................ 346
2.2 Ecology...................................................................... 349
2.3 Ecosystem................................................................ 350
2.4 Biome......................................................................... 359
2.5 Biodiversity.............................................................. 360
2.6 Environmental Degradation.............................. 371
2.7 Conservation of Environment........................... 372
2.8 Environmental Events.......................................... 376
Objective Brain Teasers......................................... 377
Chapter 3
Environmental Pollution and Degradation.......386
3.1 Introduction............................................................ 386
3.2 Classifications of Pollution................................. 386
3.3 Environmental Laws for Controlling
Pollution................................................................... 403
Objective Brain Teasers......................................... 405
nnnn
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Chapter 4
Climate Change.....................................................411
4.1 Introduction............................................................ 411
4.2 Greenhouse Gases................................................ 412
4.3 Global Warming..................................................... 414
4.4 Causes of Climate Change................................. 417
4.5 Evidences of Climate Change........................... 419
4.6 Conventions on Climate Change..................... 420
4.7 National Action Plan on Climate Change..... 424
Objective Brain Teasers......................................... 425
Chapter 5
Environmental Impact Assessment (EIA)............428
5.1 Introduction............................................................ 428
5.2 EIA Regulations...................................................... 429
5.3 Steps in Environmental Impact Assessment
Process...................................................................... 430
5.4 Roles of Parties in EIA Process .......................... 432
5.5 Forms of Impact Assessment............................ 433
5.6 Benefits of EIA......................................................... 433
5.7 Limitations of EIA.................................................. 434
5.8 Environmental Considerations......................... 434
5.9 Ecological Considerations.................................. 434
5.10 Green Public Procurement (GPP)..................... 434
Objective Brain Teasers......................................... 435
 Section A
General Principles of Design,
Drawing and Importance of
Safety