higher education

& training
Department:
Higher Education and Training
REPUBLIC OF SOUTH AFRICA

NONNATIONAL CERTIFICATE: ENGINEERING CERTIFICATE OF

COMPETENCY

PLANT ENGINEERING: FACTORIES

(8190316)

31 May 2021 (X-paper)

09:00-12:00
CLOSED-BOOK EXAMINATION

Alpha-numerical or programmable calculators may not be used.

Nonprogrammable calculators may be used.

This question paper consists of 7 pages.

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 -2- 30701 J2131000532
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DEPARTMENT OF HIGHER EDUCATION AND TRAINING

REPUBLIC OF SOUTH AFRICA
NONNATIONAL 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 will be marked. Clearly cross out all work you do not want to be marked .

INSTRUCTIONS AND INFORMATION

1. SECTION A is compulsory.

2. Answer any TWO questions in SECTION B.

3. Read all the questions carefully.

4. Number the answers according to the numbering system used in this

question paper.

5. Show all calculations.

6. Make reasonable assumptions where necessary and clearly state these,

together with any formulae used.

7. Rule off across the page on completion of each question.

8. Candidates who were not accepted by the Commission will be disqualified .

9. Candidates will not be allowed into the examination venue more than half an
hour after the start of the examination . No candidate may leave the examination
venue before one hour has elapsed.

1O. No cellphones may be taken into the examination venue.

11. Write neatly and legibly.

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SECTION A (COMPULSORY)

QUESTION 1
Of
800 kPa wit h a
steam at a pre ssu ~e lori fic val ue of
1.1 A ste am gen era tor pro duc es
of 6 t/h . Fuel hav ing a ca
is 48 oc
0,98 dry nes s fraction at a rate re ·
kg/h. The feed wa ter tem per atu
30,3 MJ/kg is used at a rate of 680

ST EA M PR OP ER TIE S ~
ht9 kJ/k
ht kJ/k h 9 kJ/ k
P kPa ts °C 2 768
721 2 047
800 170 ,4

De term ine each of the following :

1. 1 . 1 Efficiency
at 100 °C (10 )
1.1 .2 Equivalent evaporation from and

a~ av~ rag e
which is rated at 5 Uh del ive rs
1.2 An eco nom ic steam generator sol ids in the
acity. The num ber of dis sol ved
dem and of 80% of its rated cap ~
fee dw ate r is 125 mg/f.
ma inta in a
down in kg/h be in ord er to
Wh at should the rate of blow we en 2 000
solids in this ste am gen era tor bet
rec om me nde d level of dissolved (6)
and 3 000 mg ll?
ply ing wa ter
l water treatment pro gra mm e sup
1.3 Wh at is the purpose of an interna (4)
to a steam generator? [20 ]

QUESTION 2
ns rati o of
ase 100 kVA tran sfo rme r supplied with 2,2 kV has a tur
2.1 A sin gle -ph
resistances are 0,3 O and 0,01
res pec tive ly n
400:80. Primary an? secondary res pec tive ly. n
ctances are 1, 1 O and 0,0 35
and the corresponding leakage rea
~
De term ine each of the following:
the prim ary circ uit
2.1.1 Equivalent imp eda nce referred to (4)
d
ary term ina l vol tag e for full loa
2.1 .2 Voltage regulation and sec ond
the foll ow ing :
having a pow er fac tor of each of

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·rr- _
-

12? ~\
x3
0,8 lead-in_g_ _ _ --------
(b} - - ~--::J.. @L

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2.2 (5)
Prepare 8 checklist for maintaining a suburban electrical substation .
2 .3
liS t th e_checks to be carried out prior to using a phasing stick on an overhead
power hne . ~ (5)
[20]

QUESTION J: SANS/ISO 45001: 2018

Occupational health and safety management systems - Requirements with guidance for
use (replaced OHSAS 18001 and 18002) is a health and safety management system .

3.1
An organisation shall establish processes for the implementation and cont~ol of
planned temporary and permanent changes that impact on the occupational
health and safety performance.

Name FIVE scenarios in which case you will implement manage of change. (5)

3 -2 The organisation shall also establish, implement and maintain processes

needed to prepare for and respond to potential emergency situations, as
identified.

Name FIVE matters that shall be included in the emergency preparedness and
response . - (5)

3.3 A confined space may include, but not be limited to, underground vaults, tanks,
storage bins, pits, vessels, sewers and silos. Before any employee enters a
confined space, the employer shall ensure that an assessment of the hazards
related to the confined space has been carried out.

Name TEN hazards associated with confined spaces (10)

[20]

TOTAL SECTION A: 60

SECTION B

Answer any TWO of the following five questions.

QUESTION 4

4.1 Name SIX electrical checks to be done on a medium voltage circuit breaker
during maintenance. ~ (6)

4.2 Name FOUR acceptable manners how fuses may be used when not installed
in a distribution board. (4)

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4.3
A feeder cable 317 1 1
The fault is
localised by the foll n , ong develops a fault to earth on o_ne phase. one end
of the fault owrng resistance measurements obtained between
y conductor and earth :

D~stant end insulated == 7 01 ohms ~

g,stant end solidly earth~d == 1 85 ohms
onductor resistance == 7,192 ~hms/1 000 m

Calculate th e distance of the fault from the test end . (10)

[20]

AND/OR
QUESTION 5

5.1
A tripod comprises three 75 mm bore pipes 5 m long and is used to raise a
tr~nsformer having a mass of 5 t. The wall thickness of the pipes is 5 mm. The
trr_pod is designed to be used in symmetrical arrangement with its legs at 60°
with the horizontal.

Determine the safety factor of the system when it supports the full load of the
transformer. It is assumed that the pipes are straight and pin-jointed. The
modulus of elasticity for the steel pipes is 207 GPa.

El 2
CTI
Given : Per= - - (Euler)
L2

cr.A
Per=
1+-
1 (L)
. -K
2 (Rankine)
c.a (16)

5.2 Briefly describe the construction, advantages and applications of the following
types of steel ropes:

5.2.1 Lang's lay

5.2.2 Ordinary (regular) lay

(2 X 2) (4)
AND/OR

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QUE STIO N1V

moto r draw s a full-l oad curre nt

6.1 A 6600 V, 3-ph ase, star conn ected sync hron ous
0 ~ 80 A at a powe r facto r of 0,8 leadi ng . The arma ture resis tance
is 2 ,2 ohm s
e. If the stray losse s of the
with ~ sync hron ous resis tance of 22 ohm s per phas
ing:
mac hine are 3200 W , dete rmin e each of the follow
(5)
6.1.1 EMF indu ced
(5)
6 .1.2 Outp ut powe r
(2)
6 .1.3 Effic iency

a resu lt of fault s of elect rical

6 -2 A num ber of fires in facto ries and build ings start as
cabl es and cable joints.
neer mus t chec k to prev ent
Desc ribe thos e items you as the responsible engi (8)
such fires. [20]

AND/OR

QUE STIO N 7
betw een the tens ionin g
7 .1 A mon o-rop e conv eyor has a total length of 400 m
ing place .
pulle y and is used to trans port material to the work
are trans porte d to the top
The bund les of material have a mass of 100 kg and
. The bund les are conv eyed
of a 5 in 1 incline, 310 m from the loading station
at 20 m inter vals at a velocity of 0,8 mis.
coeff icien t of fricti on betw een
The rolling resis tance coeff icien t is 0, 15 and the
rope pass es two turns roun d
the drivin g whee l and rope is 0,065. The driving
the drivin g wheel.

Dete rmin e each of the following:

7.1.1 Tigh t side tensi on of rope

7.1.2 Minim um slack side tensi on in rope

7.1.3 Minim um initial tensi on in rope ~

7. 1.4 Pow er to drive loade d rope
(10)

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7.2 .
S e Iect a suitable . f t of safety of 6.
rope from below for the Installation with a ac or

outer wire
Nominal rope Estimated Estimated breaking
diameter
diameter mass (kg/m) force (k/N)
(mm)
(mm) 1600 MPa 1800 MPa
57,0 0,69
9,5 0,360 51, 1
107,4 0,96
13 0,673 96,3
160,7 1,20
16 1,006 144, 1
227,9 1,40
19 1,420 204,3
305,9 1,64
22 1,911 274,4
1,92 (5)
26 2,649 381,9 425,9

7.3 Sketch a tensioning arrangement for the system .

(5)
[20]

AND/OR

QUESTION©

8.1 A centrifugal pump in an underground chamber of a high-security facility

delivers 50 litres/s through a vertical column against a static head of 400 m and
it needs 330 kW to drive it.

A leak of 25 litres/s develops exactly halfway up the delivery column. As a

result, the quantity delivered at the top of the column drops to 29 litres/s.

Friction head loss in the delivery column is 0,005 Q 2m per 100 m, where Q is
the flow in litres/s.

Calculate the power required to drive the pump under the new conditions if the
efficiency remains constant. ( 10)

8.2 A three-phase motor takes a constant input of 1,25 MVA at a power factor of
0,8 lagging. In order to reduce the kVA demand, it is proposed to install
correction equipment to improve the power factor.

The annual cost per kVA demand is R1 100 and the capital cost of the
correction equipment is R3 000 per kVAR with an interest and depreciation of
12% per year.

Calculate each of the following :

8.2.1 Most economical power factor

(4)
8.2.2 Annual saving when correction is made to the economic limit
(6)
(20]

TOT AL SECTION B: 40
GRAND TOTAL: 100

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