ATTACHEE’S REPORT FOR THE MONTH OF SEPTEMBER 2018

NAME LUBALENKOSI

SURNAME TSHUMA

PROGRAM INSTRUMENTATION AND CONTROL

DEPARTMENT C&I
INTRODUCTION

During September the trainee was involved in the following activities:

1. Extension Lines
2. TA4 condenser level indication.
3. Belt weigher calibration.
4. Pressure gauges calibration

EXTENSION LINES

The trainee worked on a numerous extension lines during the month of September. Ext 247-
the line had a tone continuously even when the switch hook was depressed. We discovered
that the switch hook was stuck. The handset was opened and the switch hook was exercised
and it was left functioning ok. Ext 212- The stores extension line had a fault. When the line
was traced, a breakage along the extension was identified. We re-joined the cable and the
line was left ok. Ext 232- The clinic extension line handset was faulty. Most of the buttons on
the handset when not responsive when depressed. The mother board of the handset was
cleaned and the buttons aligned properly and the problem was rectified. We also installed a
new extension line at the risk office, extension 256.

KEY LEARNING POINTS

The trainee had the opportunity to be part of a team that was installing a new line at the risk
office. The trainee learnt how to install a new extension line.

TA4 CONDENSER LEVEL INDICATION

The trainee also worked on TA4 condenser level indication. The panel indication was not
tallying with the level shown on the magnetic sight glass. We equalised the transmitter and
did a dynamic test and the problem was rectified.
Below is a diagram of a level indicator

KEY LEARNING POINTS

The position of the valves on the pressure gauges has an impact on the reading. There is a
procedure for isolating a transmitter from the process.

REMOVING TRANSMITTER FROM SERVICE

1. Close the low-pressure block valve.

2. Open equalising valve.
3. Close the high-pressure block valve.

The transmitter will be out of service.

BELT WEIGHER

Purpose is to determine how much coal is being consumed. The flow rate of coal per unit
time needs to be known. Therefore the belt weigher consists of the :

1) Weigh frame - Mass measurement consists of load cells.

2) Integrator/ totalizer- Combine the mass and speed, then computes the flowrate which
is tonnes per hour.

3) Tachometer-Tachometer is an instrument used for measuring the rotation or

revolution speed of objects.

Below is a diagram of a totaliser

The weigher is used to measure mass or flow of the material travelling over a conveyor belt.
The belt weigher consists of a weigh frame that has the speed sensor, load cells and
integrator. The load cells are used to determine the weight of coal. A speed sensor called
tachometer is connected also to the rollers of the conveyor. An integrator displays mass and
speed tonnage\hr that is from the weigh frame and tachometer. The trainee did a quick
calibration procedure on the integrator and reset the totalizer.
 ● The mass zero check- check when belt is stationary
● The mass span check- checked when belt is moving
● Speed zero check- check when stationary
● Speed span check- checked when belt is moving

Quick Calibration Procedure

Speed zero check:

Press F4 on the UNIPRO IV to access the main menu.

2. Select option 2=CAL. CHECKS in the menu.
3. Enter the access code for this menu 3947 and then press ENT button.
4. Select option 3=SPEED ZERO CHECK.
5. The belt speed (m/min) will be displayed.
6. Press ENT to start the test.
7. Press ENT again to stop the test after a while.
8. With the belt standing the speed should be 0 m/min.
9. Accept or reject correction

Speed span check:

Run the belt EMPTY at maximum speed with the test weight in the ZERO (normal)
position.
2. Select 4.SPEED SPAN CHECK under the CAL CHECKS MENU.
3. With the belt running empty at full speed, press ENT to start the test. Allow the belt
to run for at least three minutes.
4. Press ENT again to stop the test. The UNIPRO IV will display the average indicated
speed and will request that the actual speed be entered.
5. Enter the actual speed (see the certificate for the actual belt speed) the UNIPRO IV
will display the speed error to be considered for correction.
6. The correction can now be accepted or rejected by pressing F1 or F2.
Mass Zero check:
1. Run the empty belt with the test weight in the zero position.
2. Select 1=MASS ZERO CHECK, under the CAL CHECKS MENU.
3. The UNIPRO IV will now display the belt loading (kg/m) and the calibration length
(m).
4. Press ENT to start the zero calibration check, the calibration length will count down
to zero after which the percentage error will be displayed.
5. Accept or reject correction by pressing F1 or F2.

Mass span check :( on board test weight)

1. Stop the belt and move the test weight to the SPAN position.
2. Select MASS SPAN CHECK.
3. With the belt running empty at full speed, wait for the belt loading to stabilise and
press ENT to start the test. The UNIPRO IV counts down the calibration belt length
as the test duration.

4. The resultant span check percentage error will be displayed the correction can be
accepted or rejected by pressing F1 or F2.

N.B****MOVE THE TEST WEIGHT BACK TO THE ZERO POSITION.

PRESSURE GAUGE

The trainee also calibrated superheater outlet, leak off pressure and the steam drum pressure
gauges.

Using a dead weight tester, pressure gauges are calibrated through the application of known
weights to the DWT’s piston, the cross-sectional area of which is also known. This creates a
sample of known pressure, which is then introduced to the pressure gauge being tested to
observe its response
Below is a diagram of a dead weight tester

1. Check whether the test device is reading zero, by connecting it to the test port on the
DWT. If it isn’t, correct the error before moving on to the next step.

2. Note the cross-sectional area of the piston and rotate the handle of the adjusting piston
until its rod comes out fully. Fill oil into the reservoir up to its halfway level.

3. Open the oil reservoir’s shutoff valve and let the DWT fill completely with oil by
manually lifting the vertical piston to its maximum position. Do this gently to avoid air
bubbles.

4. Close the shutoff valve and place the first known weight on the platform of the vertical
piston.

5. Turn the handle of the adjusting piston to ensure that both it and the sample weight are
supported by the oil in the chamber.
6. Spin the vertical piston to make sure it is floating freely and allow the system to stabilize
for a few moments.

7. After the system has stabilized, make note of the sample weight, DWT reading and
reading on the pressure gauge being tested, as well as error.

8. To check the full range of the pressure gauge, repeat these steps with increasing sample
weights, till you reach the test device’s maximum pressure. Then, reverse the order of
weights and record the downscale readings till the test device reaches 0 again.

RECOMMENNDATIONS

● The telephone extension cables should be arranged orderly.

● A calibration bench should be availed to enable easy testing of hydraulic pumps.
Attachee : Lubalenkosi Tshuma

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Date : ……………………………………………..

Senior Foreman : B Mataka

Signature : ……………………………………………..

Date : …………………………………………….

Training Office : A Gumbie

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Date : …………………………………………..