com een mma eS ES higher education & training Department: Higher Education and Training REPUBLIC OF SOUTH AFRICA T30(E)(J3)T JUNE 2011 NON-NATIONAL CERTIFICATE: ENGINEERING CERTIFICATE OF COMPETENCY PLANT ENGINEERING: FACTORIES (8190316) 3 June (X-Paper) 09:00 - 12:00 CLOSED-BOOK EXAMINATION Alpha-numerical or programmable calculators may NOT be used. Only non-programmable calculators may be used. This question paper consists of 8 pages and a 1 page-formula sheet. useMoraer sh eee 2 T3O(E\3)T DEPARTMENT OF HIGHER EDUCATION AND TRAINING + REPUBLIC OF SOUTH AFRICA NON-NATIONAL CERTIFICATE: ENGINEERING CERTIFICATE OF COMPETENCY PLANT ENGINEERING: FACTORIES TIME: 3 HOURS MARKS: 100 Gs ee NOTE: if you answer more than the required number of questions, only the required number of questions will be marked. All work you do not want to be marked, must be clearly crossed out. INSTRUCTIONS AND INFORMATION 1 40. v1 12. ‘Answer QUESTION 1, QUESTION 2 and QUESTION 3 In SECTION A and any TWO questions in SECTION B, Read ALL the questions carefully. ALL the calculations must be shown. NO marks will be allocated for calculations in whlch the steps cannot be clearly followed or for work completed in a pencil Candidates aro expected to make reasonable assumptions where necessary and these, together with any formulae used, must be clearly stated. Rule off across the page on completion of each question This ig NOT an OPEN-BOOK EXAMINATION. Candidates are NOT allowed fo use any notes, textbooks, reference books or cell phones during examination. Cell phones are NOT allowed in the examination room. Candidates who were NOT accepted by the Commission, will be disqualified NO candidates may enter examination room more than half an hour after te Sart of the examination and NO candidate may leave the examination room before one hour has elapsed. Number the anewers correctly according to the numbering system used in this question paper Write neatly and legibly. PTOfax sent by meee Boreer ih eee FG eS T3O(E)(U3)T SECTION A (COMPULSORY) QUESTION 1 1 12 Name the FOUR processes in a demineralisation plant for the steam generator plant fo remove scale-forming impurities and explain each process. (8) In 2 test on a water-tube steam generator the following average readings were obtained: oisture [3.500 kg/h | [Coal fired, inclusive of 4% surface TWiass ss of dry, saturate rated steam raised_ 22 150 kg/h ure of steam ai steam-generator stop valve [3000 KPa Feedwater temperature 150°C) ‘Temperature of flue gasses at base of stack 160°C. _| | Steam-generator house temporature 15°C [Caiorfic value of coal 26 Muikg 1 [Analysis ofcoal_ [Carbon 68% | [Hydrogen 12% ‘Oxygen 35% i Ash 16,5 % Atmospheric pressure 85 kPa [Excess airused | 55% [Spe fic heat at constar eat at constant pressure fordry air 4,005 kJ/kg. K_ FOxygen by mass contained in air 123% Assume that ALL the carbon is burnt to form carbon dioxide. Calculate the fallowing 4.21 The mass of the flue gas per kg of dry coal burned 1.2.2 The heat to the flue gases per hour 1.2.3 The steam generator efficiency (12) [20] PTO=e eee mera ee T3Q(E\I3)T QUESTION 2 2.1 A 100 KW, 460 V shunt generator was run as a motor on no load at its rated voltage and speed. The total current taken was 9,4 A, including a shunt current of 2,7 A. The resistance of the armature circuit (including compoles) at normal working temperature was 0,11 2. Calculate the efficiency at the following: 24.1 Fullioad 21.2 Half load 2.2 Name TWO common applications of a DG series motor and give ONE risk of these motors. 23 An employee was complaining about a two-phase welding machine that shocked him when touching it. Name FOUR tests that you would carry out to locate the problem and give @ reason why you would carry out each test. QUESTION 3 3.1 An occupational health and safety management system (OHSMS) prescribed by chief inspector in Government Notice R.859 of 2 September 2005 requires that you must establish an occupational health and safety policy for your factory. Name FIVE elements of the occupational health and safety system. 32 The Occupational health and safety management systems (OHSAS 18002: 2000) — Guidelines for the implementation of OHSAS 18001, is a guideline for the implementation of OHSAS 18001 Name FIVE typical outputs of the planning for hazard identification, risk assessment and risk control, 33 Alarge printing machine has to be shut down for maintenance. Draw-up 2 lock out procedure for the artisans before they may work on the machine. TOTAL SECTION A: PTO *g* “as ®) (4) @) ® B20) (8) (5) (10) [20] 60fax sent by meee Borers tes FSS NS T3O(E\U3)T SECTION B Answer any TWO of the following five questions. QUESTION 4 41 A horizontal beam, with a weight of 100 KN, resis on two supports and is loaded as shown below. By what distance and in what direction should the uniformly distributed load be shified if it is required that the reaction at the supports should be equal? 1 sokn GEE Petescokat Wears Lee. A+ (10) 42 Name FIVE areas where liquid penetrarit testing cannot be used 6) 43 Name FIVE areas where liquid penetrant testing can be used. ©) [20] QUESTION 5 5.1 State FOUR requirements for the heights of a distribution board in an electrical installation @® 5.2 State FOUR requirements for the installation of a manually-operated disconnector for an electrical motor in an electrical installation. ) 5.3 Give FOUR reasons why an impregnant is used in an electric motor 4) 54 Name FOUR benefits by using thermography as part of a predictive maintenance programme on electrical machinery. 4) 5.6 Name FOUR different lamp types that are used in an industrial environment. @) [20] PTOeee fax sent by meen Sermehe ee SS 6 T3O(E\ Ua) QUESTION 6 64 The simple lifting machine shown below is used to raise a series of loads. These loads, with their corresponding required efforis, are shown in the table below: Load | 250N TS00N 750 N Effort ZN ZN 212N Determine the following: 6.1.1 The velocity ratio of the machine in the sketch 6.1.2 The formula to be used for this arrangement 643 The mechanical advantage and the efficiency of this machine when lifting the 250 N load 6.1.4 The maximum efficiency attainable by the machine 615 The maximum load that can be lifted if the maximum effort that can be applied is 700 N 62 Name FIVE items or conditions to be checked to ensure that stee! wire ropes. on cranes are properly maintained 63 You need to replace the ropes on a crane, Name SIX specifications to be given the supplier fo ensure that the correct ropes are supplied. PTO @) 6) (6) [20]fax sent by meee Serene Re FS T30(EYJ3)T QUESTION 7 7.1 The electrical portion of a plant is connected in star and is supplied from a three-phase, 50 Hz, 380 V system, from which it takes 120 kVA at a leading power factor of 0,9. ‘The plant is moved to a new facility where it is connected in delia and itis fed from a three-phase, 60 Hz, 400 V supply. it is necessary to purchase two induction motors for the 60 Hz piant. The first jp a star-connacted 80 KW motor working at a power factor of 0,8 lagging and the second is @ delia-connected 70 kW motor working at a power factor of 0.8682 lagging, both supplied form the 50 Fiz, 380 V system. Find the following, after the two motors wore added to the 50 Hz plant. 7.14 The overall power factor and the supply current of the plant and draw the complete load diagram showing alt values 7.1.2 The required capacitance in farads needed to bring the plant power factor to unity, by making use of a capacitor bank connected in delta (9) 7.2 Your new plant is supplied by an 11 kV overhead power line. The voltage is reduced to 400 V in the substation. Give 11 safety checks for the MV part of the installation on the test report that should be done before a cerlificate of compliance can be issued. (11) QUESTION 8 The data shown below is derived from a constant speed test of a centrifugal pump: Qin timin jo [200 | 400 600 [800 | 1000 H,manometicheadinm (18/1758 (165 [144/145 154 LEfficiency in% 0 T4868 7 (72/50 | Pipe friction is given as hy = (70.10%) The static head against which three of these pumps are to be used in parallel, is 12 m PTO.fax sent by meee — Ss 8 T3O(E3)T Calculate the quantity pumped and the power demand when the following number of pumps aré run at the same time: &1 One 82 Two 83 Three [20] TOTALSECTIONB: 40 GRAND TOTAL: 100