DEPARTMENT OF EDUCATION EXAMINER: Commission of Examiners MODERATOR: (Commission of Examiners T2180(E)(N22)T NOVEMBER 2001 ENGINEERING CERTIFICATE OF COMPETENCY PLANT ENGINEERING: FACTORIES (6190316) 22 November (X-Paper) 09:00 ‘Alphanumerical or programmable calcula- ‘tors may NOT be used. Only non-programmable calculators may bo ueed. (CLOSED-BOOK EXAMINATION NOTE: _fyouanswer more than the required number of questions, ony the required ‘umber of questions willbe marked, All work you do not want to be marked must be clearly crossed out INSTRUCTIONS 4. Answer QUESTIONS 1, 2 and 3 and any TWO other questions. 2 Ab. caleulations are tobe shown, 3. NO crest willbe given for calculations in which the steps cannot be clearly followed or for work completed in pencil 4. Candidates ara axpcied to make raasonabla assumptions where necessary ‘and these, topether with any formulae used, must be Cleary stated 5. Rule of n completion ofeach answer beers staring the answer to new question, 6. Answers must be clearly and correctly numbered. Write neally and legibly. 7. Megible answers will not be marked. PTO.2 T2180 )(N22)T ‘This is NOT an open-book examination. Candidates are not allowed to use ary’ notes, textbook or reference works during the examination. Candidates who have not been accepted by the Commission will be disqualified. No candidate may enter the examination roc more than half an hour ster the ‘commencement ofthe examination and no candidate may leave the examination room before one hour has elapsed, SECTION A COMPULSORY QUESTION + @) © ‘Among the candidates applying to be trained as Boller Attendants are the following: Y + Aman with tunnel vision |= Aman who is eolour-blind ‘+ Aman who was bom completely deat ‘+ Aman who has had one hand amputated atthe wrist ‘State, giving reasons, which ofthe ebove candidates you would reject and how you would accommodate the others, bearing the requirements for employment equity in mind! ® Determine the complete mass balance for a combustion process, on the basis (of 1 kg of coal burt, given the folowing data Fuel composition (ractons by mass) oes HO03 © 0K NOM HU OND AHOIS Dry exhaust gas analysis (rations by volume) ©0,0,148 00920 0,0055 N,079 Refuse analyse (rastons by mass) C040 Ashogo Where C= Carbon, iydrogen, O = Oxygen, N= Nitrogen Airs dry-bulb temperature 22,8°C, wet-bulb temperature 15,5°C. 02) (0),T2180(E)(N22)T ‘QUESTION 2 (2) Anelectric motor is used to chive @ harmonic vibrating screen. Due to extensive ‘opairs, mass was added and thus the natural frequency changed. ‘The shaft rive speed ofthe rotating mass has to be decreased from the present 970 rnin to 810 min. The vibrating shaf is directly cannacted t the motor. The power input to the 415 V, S-phase, 6-pole, 60 Hz induction motor is 60 KW when ‘running at 970 rlmin. The stator losses are 2 KW and the friction and windage losses are 1,5kW. Calculate the folowing: ® Rotor 'R loss (i) Gross torque in Nm (ii) Power output of the motor (iv) Rotor resistance per phase if the rator phase current is 110 A, (¥) Resistance to be added to each phase to achieve the reduced speed ifthe motor torque is to remain constant, (©) Explain what is meant by @ condition-based maintenance programme for large «electric motors and discuss the equipment, instruments end stills needed, QUESTIONS ‘Annew process requires small quantities ofa sodium cyanide (NaCN) solution to be added {othe production stream, The process operator in tne area will be expected to work alone ‘or much of his her shift, only meeting others during hisiner tea breaks or when there is naintanance work being done, ‘The proposed method isto pour a meaturad amount of cry cyanide powder iniu ws open 20 ire bucket of water on the floor, dissolve it by stirring wth a stick, then carrying the ‘open bucket to an open mixing tank, cimb three steps onto @ platform, it the bucket to ‘shoulder height and pour the contents ofthe bucket into a holding tank, from where the cyaninde solution is pumped into the production stream using a metering pump. The following information is extracted from a Material Safety Data Sheet for sodium oyanice: ‘Appearance and odour: White granules, flakes or eggs; deliquescent (absorbs ‘moisture from the air and forms a wet solid or solution); douriess when dry slight odour ‘of HCN when damp; HCN smells lke biter almonds. ‘Odour threshold: NaCN is odouriess, HCN odour threshold 0.25 ppm, PTO (14) ©) 20)