POLYTECHNIC UNIVERSITY OF THE PHILIPPINES

College Of Engineering
DEPARTMENT OF MECHANICAL ENGINEERING

PLANT INSPECTION

QUIZ 2

Submitted by:
Abreo, Dan Vincent A.
BSME 5-1

Submitted to:
Engr. Morales, Armingol
Professor
1. Define/ Explain:

a. Blast Furnace - is a type of metallurgical furnace used for smelting to produce industrial metals,
generally pig iron, but also others such as lead or copper.
b. Steel Manufacturing - is the process of producing steel from iron ore and/or scrap.
c. Iron Ore - are rocks and minerals from which metallic iron can be economically extracted.
d. Oxidation Reaction - The process in which a substance loses an electron in a chemical reaction is
called oxidation.
e. Casting - an object made by pouring molten metal or other material into a mold.
f. Glass Production - involves two main methods – the float glass process that produces sheet glass,
and glassblowing that produces bottles and other containers. It has been done in a variety of ways
during the history of glass.
g. Annealed Glass - is also known as float or clear glass. It is a kind of glass that is not quenched after
the heating process; it is allowed to cool slowly.
h. Plastic Manufacturing - is the process of making plastic into semi-products or products with practical
value. Plastics manufacturing usually includes primary processing and secondary processing of
plastics.
i. Semiconductor - has an electrical conductivity value falling between that of a conductor, such as
metallic copper, and an insulator, such as glass. Its resistivity falls as its temperature rises; metals
behave in the opposite way.
j. Compressed Air System - consist of a number of major subsystems and components. Air filters and
air dryers remove moisture, oil and contaminants from the compressed air. Compressed air storage
(wet and dry receivers) can also be used to improve system efficiency and stability.

2. Give and discuss the types of methods used in plastic manufacturing process.

 3D PRINTING. 3D printers create three-dimensional parts directly from CAD models by building material
layer by layer until a complete physical part is formed.
 CNC Machining. CNC machining includes mills, lathes, and other computer-controlled subtractive
processes. These processes start with solid blocks, bars, or rods of metal, or plastic that is shaped by
removing material through cutting, boring, drilling, and grinding. Unlike most other plastic manufacturing
processes, CNC machining is a subtractive process where material is removed by either a spinning tool
and fixed part (milling) or a spinning part with a fixed tool (lathe).
 Polymer Casting. In polymer casting, a reactive liquid resin or rubber fills a mold which reacts chemically
and solidifies. Typical polymers for casting include polyurethane, epoxy, silicone, and acrylic.
 Rotational Molding. Rotational molding (also called rotomolding) is a process that involves heating a
hollow mold filled with powdered thermoplastic and rotated around two axes to produce mainly large
hollow objects. Processes for rotomolding thermoset plastics are available as well, however less common.
 Vacuum Forming. Vacuum forming is a manufacturing method where a plastic is heated and formed,
typically using a mold. Vacuum forming machines vary in size and complexity from low-cost desktop
devices to automated industrial machinery. The steps below describe the typical process for industrial
vacuum forming.
 Injection Molding. Injection molding (IM) works by injecting molten thermoplastic into a mold. It is the
most widely used process for mass manufacturing of plastic parts.
 Extrusion. Extrusion molding works by pushing plastic through a die. The shape of the die is a cross-
section of the final part.
 Blow Molding. Blow molding is a manufacturing technique used to create hollow plastic parts by inflating
a heated plastic tube inside a mold until it forms into the desired shape.
3. Discuss/ Explain the operational process and show flow diagram including major equipment of
the following:

HYDROPOWER PLANT

Operational Process:
At the plant level, water flows through a pipe—also known as a penstock—and then spins the blades in a
turbine, which, in turn, spins a generator that ultimately produces electricity.
Hydropower relies on the endless, constantly recharging system of the water cycle to produce electricity,
using a fuel—water—that is not reduced or eliminated in the process. There are many types of
hydropower facilities, though they are all powered by the kinetic energy of flowing water as it moves
downstream. Hydropower utilizes turbines and generators to convert that kinetic energy into electricity,
which is then fed into the electrical grid to power homes, businesses, and industries.

4. DIESEL POWER PLANT

OPERATIONAL PROCESS:

The diesel power uses a diesel engine to rotate alternators and produce electrical energy. The diesel
engine is used as a prime mover and this power plant is known as a diesel power plant. Due to the
combustion of diesel, rotational energy is generated. The alternator is connected with the same shaft of
the diesel engine. And the alternator is used to convert the rotational energy of the diesel engine into
electrical energy. In most cases, the diesel power plant is used to generate electrical energy for small-
 scale production and at the load end. When the grid power is not available, the diesel engine is used to
supply load in emergency conditions. Generally, the capacity of diesel power plants is between 2 to 50
MW is used in central power plants to meet peak demand in steam power plants and hydroelectric power
plants. But nowadays, due to the high cost of fuel, diesel engines are not used for such applications.

5. NUCLEAR POWER PLANT

OPERATIONAL PROCESS:

A nuclear reactor produces electricity in much the same way other power plants do. The chain reaction
produces the energy, which turns water into steam. The pressure of the steam turns a generator, which
produces electricity.

The difference is in how the heat is created. Power plants run on fossil fuels burn coal, oil or natural gas to
generate heat. In a nuclear energy plant, heat is produced from splitting atoms – a process called nuclear
fission.

 Nuclear reactor creates heat that is used to make steam

 The steam turns a turbine connected to an electromagnet, called a generator
 The generator produces electricity

6. COMPRESSED AIR SYSTEMS

Operational Process:
 Compressed air systems consist of a number of major subsystems and components. Compressed air
systems can be subsided into the Supply and Demand side.

The Supply side includes compressors, air treatment and primary storage. A properly managed supply side
will result in clean, dry, stable air being delivered at the appropriate pressure in a dependable, cost
effective manner. Major compressed air supply subsystems typically include the air intake, air compressor
(fixed speed and/or variable speed), aftercooler, motor, controls, treatment equipment and accessories.

Controls serve to adjust the amount of compressed air being produced to maintain constant system
pressure and manage the interaction between system components. Air filters and air dryers remove
moisture, oil and contaminants from the compressed air. Compressed air storage (wet and dry receivers)
can also be used to improve system efficiency and stability. Accumulated water is manually or
automatically discharged through drains. Optional pressure controllers are used to maintain a constant
pressure at an end use device.

The Demand side includes distribution piping, secondary storage and end use equipment. A properly
managed demand side minimizes pressure differentials, reduces wasted air from leakage and drainage
and utilizes compressed air for appropriate applications. Distribution piping systems transport
compressed air from the air compressor to the end use point where it is required. Compressed air storage
receivers on the demand side can also be used to improve system pressure stability.

7. REFRIGERATION AND AIR CONDITIONING

OPERATIONAL PROCESS:

An air conditioner works using a thermodynamic cycle called the refrigeration cycle. It does this by
changing the pressure and state of the refrigerant to absorb or release heat.
The refrigerant (aka coolant) absorbs heat from inside of your home and then pumps it outside.
Most air conditioners are air-source, split systems. What this means is that there is one unit inside and
one unit outside, which is why it is called a split system.
The air-source part refers to the place where the thermal energy is dumped, the outside air. There are
other potential places where the heat can be transferred, such as water or ground, known as water-
 source, or ground-source systems. The inside unit is normally inside the house somewhere, in the attic,
basement, closet or crawl space. The outside unit is normally located on the side or back of the building.
Other kinds of air conditioning systems, such as ground-source and water-source, follow the refrigeration
cycle, but some of the specifics, such as location and parts may differ.

8. OCEAN WAVE POWER PLANT

OPERATIONAL PROCESS:
Wave power, also called ocean wave energy, electrical energy generated by harnessing the up-and-down
motion of ocean waves. Wave power is typically produced by floating turbine platforms or buoys that rise
and fall with the swells. However, wave power can be generated by exploiting the changes in air pressure
occurring in wave capture chambers that face the sea or changes in wave pressure on the ocean floor.

The areas of greatest potential for wave energy development are in the latitudes with the highest winds
(latitudes 40°–60° N and S) on the eastern shores of the world’s oceans (which border the western edges
of the continents).