higher education & training Department: Higher Education and Training REPUBLIC OF SOUTH AFRICA we N1650(E)(J5)H NONNATIONAL CERTIFICATE: ENGINEERING CERTIFICATE OF COMPETENCY PLANT ENGINEERING: FACTORIES (8190316) 5 June 2017 (X-Paper) 09:00-12:00 CLOSED.BOOK EXAMINATION ‘Only nonprogrammable calculators may be used. ‘This question paper consists of 6 pages and 1 information sheet. TANO MA PLANTENGF, Copyright reserves Please tun overi) (e1s0318) 3 NTeSO(EH5)H SECTION A (COMPULSORY) QUESTION 1 11 Give the functions of a dual Mobrey-level contol fitted to a coal-fred steam 12 13 14 generator Describe how to blow down the Mobrey controls. Name FOUR other accessories that must be installed on an evaperator for @ steam generator. . A steam generator generates 5 650 kg wet steam per hour at 820 «Pa with a ‘dryness fraction of 0,95 from supply water at 41,6 °C while using 620 kg coal with a calorific value of 32 Mug From the steam tables: y= 725 kulkg tig = 2.043 kalkg ‘Tg of water requires 2 257 kd heat to evaporate from and at 100 C. Calculate the thermal efficiency of the steam generator and the equivalent ‘evaporation from and at 100 °C. ‘QUESTION 2 2a 22 23 Copyright eserves Oil circuit breakers are not manufactured on a large scale anymore by the World's leading switchgear manufacturers. This 's mainly due to the major disadvantages outweighing the advantages. Give THREE advantages and THREE disadvantages of ol cicuit breakers. +3) A1O.KVA transformer has 400 watt on losses and 600 watt copperlosses, Determine maximum efficiency of the transformer at 0,8 power factor lagging Aso calculate the load at which the maximum efficiency occurs, Star-delta starting is used on a 45 kW, three-phase, 526 V, 1.440 rimin motor with a power factor of 0,85 and an efficiency of 92%. 231 The motor draws six times its fullload running curent and produces 2.2 times its ful-oad running torque when itis started directly onfine. Establish the current draw and starting torque when itis stared by means of the star- delta starter. 232 Determine the fulbload line and phase currents when “unning in deta ® © “ © 0} © © 6 4 20 Please tur over(e190318) + NTO50(E}5) QUESTION 3 3a ‘An organisation establishes and maintains an occupational health and safety ‘management system, The employer authorised an occupational health and ‘safety (OHS) policy that clearly states overall health and safety objectives ell as commitment to improving health and safety performance. Name SIX requirements of this policy @ 32 A project manager has been appointed as part of a project teem for the installation of a refigeration plant. Name FOUR core elements and FOUR supporting elements of project ‘management. Gra @) 3.3 Electrical fauits can be due to ether human or natural causes, Name THREE faults for each type of cause. x2) 6) 0 TOTAL SECTION 60 SECTION ‘Angwer any TWO of the following questions QUESTION 4 4.1 Name 10 visual inspections to be carried out as well as 10 tests with meaningful readingsiresuits to ensure a valid certificate of compliance ‘according to the SANS 101421 wiring code for electrical installatiors, (19) 42 You have implemented a predictive maintenance programme at the factory. Handheld test tools are used to check for abnormal conditions ‘State the key indicators to look for and the type of instrument to use to detect ‘these indicators for each of the following pieces of critical equipment: 421 Transformers 422 Distribution boards 423° Motors 424 Controls systems 425 Lighting panels (62) (10) eo) Copyright reserved Please turn over(6100816) 6. Nr8s0(6,I5}H QUESTION 5 5.1 Readings taken from an uncooled centrifugal compressor were as follows: Inet pressure 100 kPa Inlet temperature 27°C Outlet pressure 450 kPa (abs) Outlet temperature 205°C Mass flow of air Okgls Energy absorbed by motor 2 100 KW Calculate the folowing: 5.41.1. Adiabatic efficiency of the compressor © 541.2 The mechanical efficiency of the compressor ifthe motor efficiency 1s 93% 6) 52 Acentritugal pump pumps dirty water with a relative density of 1,05 up with a vertical shaft from one level to another level over a distance af 210 m, “The delivery atthe top is 9 Us while 4 Us is bled off at 120 m from the top. The friction head for a pipe can be derived from this formula y= 0,062 Q'h/(1 100) metre where Q is the quantity Us Calculate the power required for this duty if the overall combined efficiency of the motor and pump is 72%. (19) eo QUESTION 6 6.1 A three-phase 6 600 \V feeder supplies power exclusively to a pump station Consisting of a number of pumps and motor units. When all the original pump ‘and motor units operate simultaneously, the feeder caries @ load of 411000 KVA at a power factor of 0,8 lagging, ‘An additional 600 KVA-synchronous motor is installed in the pump station to ‘ive an extra pump. When run unloaded, this motor absorbs 60 KW. The ump to be powered by the synchronous motor requires 270 KW to drive it ‘When delivering 270 kW, the motor is 90% efficient. 3 Calculate, when ALL the original pumps are in operation and the synchronous a ‘motors driving Is pump: i 64.1 Theline currentin the feeder (10) 6.1.2 Thepower factor of the feeder athe pump station “ Copyright reserved Psa tum over(e100316) 6 NTBEO(E)ISIH 62 Determine when ALL original pumps are in operation and the syrchronous ‘motor is uncoupled from its pump and run unloaded: 624 The line current in the feeder 622 The power factor of the feeder at the pump station QUESTION 7 7.4 Name FOUR items to check on a steel wire rope used on a gartry crane ‘when carrying out a periodic inspection and discuss each item. (x2) 7.2 Attuckfited with an A-frame of which the legs are hinged to the truck at their lower ends and joined together at their upper ends to form an apex to which ‘one end of the cable from the winch is fixed. A load of 4 KN is suspended from the apex with an overhang of 800 mm. Each of the legs is 2,5 m long and thelr lower ends are 1,5 m apart Calculate the force in the cable and in each leg, QUESTION 8 8.1 Name FIVE types of areas that shall be classified as hazardous locaions. 82 Name FIVE explosion protection techniques used in explosive gas atmospheres. 83 A symmetrical I-section beam has the dimensions shown in the figure below. itis simply supported over a length of 2 m and carries a uniformly cistributed load of 6 000 kg/m run : . = £ is : 0omm_ J Calculate the maximum bending stress in the beam. TOTAL SECTION B: GRAND TOTAL: Copyright reseed @ a) (20) ® (12) ao) 6 6 (19) (20) 100