wi y higher education & training Department: iC )) Higher Education and Training REPUBLIC OF SOUTH AFRICA sseLLIzL0e 11370(E)(N12)T NOVEMBER 2012 NON-NATIONAL CERTIFICATE: ENGINEERING CERTIFICATE OF COMPETENCY PLANT ENGINEERING: FACTORIES (8190316) 12 November (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 6 pages. Copyright reserved Nov 2012 Please turn over(8190316) 2 T1370(E)(N12)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 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 a SECTION A is COMPULSORY. 2. Answer any TWO questions in SECTION B. 3. Read ALL the questions carefully. 4. Number the answers correctly according to the numbering system used in this, question paper. 5. ALL calculations must be shown. 6. NO marks will be given for calculations in which the steps cannot be clearly followed or for work completed in pencil. 7. Candidates are expected to make reasonable assumptions where necessary and these, together with any formulae used, must be clearly stated. 8. Rule off on completion of each question before starting the answer to a new question. 9. This is NOT an OPEN-BOOK EXAMINATION. Candidates are NOT allowed to use any notes, textbooks or reference books during the examination. 10. Candidates who were NOT accepted by the Commission of Examiners, will be disqualified. 11. NO candidates may enter the examination room more than half an hour after the start of the examination and NO candidate may leave the examination room before one hour has elapsed 12, Cellphones are NOT allowed in the examination room. 13. Write neatly and legibly. Copyright reserved nov 2012 Please tun over(8190316) * TAS7O(E\NIZ)T SECTION A: COMPULSORY QUESTION 14 1.4 A steam generator with a heat transfer efficiency of 30% generates 15 tons/h of dry saturated steam from and at 100 °C. Coal of calorific value of 25 MJ/kg is laid 100 mm deep on a 1,2 m wide by 2 m long chain grate. If the ash contains 2% unbumt coal, determine the required speed of the chain grate. Assume the density of coal as 1 350 kg/m’. A farm truck travelled at 50 km/h on a service road to a farm site. The driver Suddenly stopped to avoid a collision with a goods train at the level crossing. The skid marks were 25 m long. The truck's wheelbase was 7,5 m and centre of gravity was 4 m behind the front axle and 3 m above the road. The Coefficient of friction between the tyres and the road was 0,4 whilst skidding. Calculate the effect on the following: Front brakes Rear brakes All four brakes, if they had been effective in preventing the accident that claimed the lives of twenty four people in the Nkomazi Municipality area around Malalane. 1.2. 1.2.3 1.2. one QUESTION 2 24 22 Copyright reserved nov 2012 Give FOUR advantages and FOUR disadvantages of earthing the neutral. A plant requires the installation of a 25 KW induction motor which will be supplied with energy on a two-part tariff of RO per kVA of maximum demand Per annum plus 0,45 cents per kWh. Two motors are available. Motor A has an efficiency of 89% and a power factor of 0,83. Motor B with an efficiency of 90% and @ power factor of 0,91 costs R20,00 more. With motor A the power factor would be raised to 0,91 lagging by installing a capacitor at a cost of R8,00 per kVAR. If the service required from the motor is 2 280 hours per annum at full load, compare the annual charges in the two cases. Assume interest and depreciation at 12,5% per annum for the motor and 8% per annum for the capacitors. Determine which motor is more expensive and provide the reason for your answer. Also determine which motor would be a better proposition if the plant is to be in operation for a period exceeding the breakeven point and show the breakeven point by means of calculations. Please turn over (4) (16) [20] (4) (16) [20](8190316) 4 TASTO(E\N12)T QUESTION 3 3.4 3.2 33 Behavioural safety depends on basic principles. Name EIGHT of these principles that will ensure effective implementation of a system. A tisk assessment must be done before the replacement of a pole mounted transformer with minimum interruption to customers. Name SIX hazards associated with this type of work and discuss precautionary measures for each of these hazards. State 12 relevant records that should be kept and are used to demonstrate conformance to the requirements of the legislation based on safety. TOTAL SECTION A: SECTION B Answer any TWO of the following FOUR questions. QUESTION 4 41 42 An air receiver in fair condition, 6 m long and 1,5 m in diameter, is salvaged from a scrapyard. Make a preliminary calculation whether the vessel is suitable for pressure of 1,8 MPa. Vessel material is 16 mm thick and has an ultimate tensile strength of 400 MPa converted from the Brunnel hardness test known as NHN. 4.1.1 Motivate your choice of safety factor. 41.2 Determine the safety factor if the welds are rated as 75% efficient. An electrode steam generator has an outside diameter of 850 mm and operates at a pressure of 1,5 MPa. Calculate the percentage of its safety factor if the circumferential plate with an original thickness of 28 mm has wasted to a thickness of 21 mm. Assume an ultimate tensile stress of 200 MPa. Copyright reserved Nov 2012 Please turn over 8) (6) (6) [20] 60 4) 4) (12) [20](8190316) oe TASTO(EMN12)T QUESTION 5 5.4 A 100 kVA 8600/50 V transformer has a delta-connected primary and star- connected secondary winding, with resistances of 1,2 ohms and 0,022 ohms per phase respectively. The iron loss is 675 watts. Calculate the efficiency of the transformer at full load if the power factor of the load is 0,9. (10) 5.2 ‘Two three-phase transformers connected in star are joined in parallel. Both transformers have a secondary no-load voltage of 380 V and a rating of 150 kVA. Short-circuit tests gave the following results: Transformer no. 1 Short-circuit volts measured in the secondary: Vis = 10-V; current = 228 A Input power = 2 100 watts. Transformer no. 2 Short-circuit volts measured in the secondary: Vas = 12 V; current = 228 A Input power = 1 800 watts Determine the distribution of load with a total load of 300 kVA at a power factor of 0,8. (10) [20] QUESTION 6 64 Calculate the power required to overcome the internal losses in an electrically driven turbo compressor operating under the following conditions: ‘Suction volume 2 1140 m/min Temperature 1 27°C Pressure : 0,85 bar (abs) Deliver temperature 104°C Pressure : 6,5 bar (abs) Motor load : 5850W Work done = Sen. PY) (12) 62 Draw up a code of practice for the maintenance of an air compressor for both reciprocating and turbo compressor. (8) [20] Copyright reserved nov 2012 Please tum over(8190316) o T1370(E\(N12)T QUESTION 7 7A Name TEN visual inspection items in a hazardous location. ) 7.2 What are the FIVE requirements that will satisfy the measurements and tests of a medical location? 6) 7.3. An elevator is designed to carry 12 passengers each weighing 70 kg at a maximum speed of 2,5 m/s. The other relevant details are as follows: Mass of the car + 800 kg Mass of ropes (including balance ropes): 300 kg Mass of counterpoise 2 4140 kg Diameter of driving sheave : 1,25m Friction torque acting on sheave : 1000 Nm Calculate the following: 7.34 The power required for uniform acceleration of a full load to full speed within 3 seconds from the lowest landing. ) 7.3.2 The torque on the sheave driving shaft to bring this load to rest with a retardation of 1,1 mis’. (6) {20} TOTAL SECTION B: 40 GRAND TOTAL: 100 ‘Copyright reserved nov 2012