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Double pipe heat exchangers are used when the heat transfer area is small say up to 14 m2. If we
connect them in series to increase the heat transfer area it will require much space as well the
pressure drop will be higher due to more fittings. Also we can’t increase no of passes for either
side fluids. The double pipe HE can’t be used for dirty fluids due to choking and cleaning is
tougher. The advantage is it is simple to construct and easy to operate.But in shell and tube HE,
we can pack a large heat transfer area within a small volume. As the numbers of tubes are more
in a shell and tube HE, we can expect a higher turbulence which will result in higher heat
transfer rates. Dirty fluids also can be handled owing to easy cleaning.
2) What is Biot No?
Biot No is a dimensionless No defined as Bi= hL/kb (No unit). h= convective heat transfer co
efficient (unit is W/m2 K)
L= characteristic length (Volume of the body/ surface area of the body” unit is metre)
kb= thermal conductivity of the body(W/mK)
It is the ratio between conductive heat transfer within a body to that of convective heat transfer
away from the body. If it is above one means convection is more and less than one means
conduction is more.
3) What should be the pressure to be taken for pipe and reactor before put in service?
For pipes the test pressure should be double the proposed application pressure and for reactors
test pressure should be 1.5 times the reaction pressure. It means if we wish to subject a pipe to 10
bar we have to do pressure testing at 20 bars whereas for the reactor it would be 15 bars.
4) Which liquid should be on shell side of a shell and tube HE and why?
Even though there are no strict conditions on this the following points are taken into
consideration normally. 1)The corrosive fluid shall pass through the tube side as the
replacement of tubes is easier and cheaper than shell side 2) The toxic, hazardous fluid shall
pass through tube side. Because in case of any leakage it won’t get exposed to atmosphere.
5) How we can find leakage in any tube in shell and tube HE?
We have to remove the bonnets of left and right side of the HE. We have to force a liquid thro’
the shell side with high pressure. It will penetrate the leaked tube and come out via the same
tube. Thus we can find the leakage.
18) Why we use LMTD to calculate overall heat transfer co efficient in shell and tube than
arithmetic average?
In a heat exchanger the heat being lost by the hot fluid as well as the heat gained by the
cold fluid is not linear. So we need to use logarithmic average than arithmetic average to
calculate correct value of overall heat transfer co efficient.
19) What should be the packing size in packed columns?
The size of packing should be approximately 1/8th of the internal diameter of packed column for
optimum pressure drop
20) When to use absorption factor method to calculate no of plates?
If the operating data line and equilibrium line in the Mccabe thiele method runs parallel the no of
theoretical plates would be infinite. So it would be impossible to find the no of plates as the both
won’t touch at any point. So we need absorption factor method wherein no of theoretical plates
can be found by Fenske equation.
21) How to convert ppm in to percentage?
We have to divide by 104 to for the ppm to get converted to percentage. To convert percentage to
ppm we have to multiply by 104.
How to calculate?
ppm(parts per million) means out of million i.e. out of 106 Percentage means out of 100 ie out
of 102
Let us assume we have to convert X ppm into percentage
106 parts of substance is having x parts of a component 102 parts of the substance would have
(102 * X) / 106 = X/104
22) What is TLV (threshold limit value)?
The threshold limit value was set by American Conference of Governmental industrial
Hygienists, Inc (ACGIH) which is defined as the level of concentration of a chemical substance
in which a worker can work without an unreasonable risk of disease or injury. It can be
expressed in ppm or mg/m3.
For example the TLV of chlorine for an 8 hrs work day is 0.5ppm or 1.5 mg/m3. Which
indicates a worker can work without any unreasonable risk of disease or injury for 8 hours if and
only the chlorine concentration in his/her vicinity is within 0.5ppm.
23) What is critical insulation thickness for pipes?
We know that by adding more insulation to a wall always decreases heat transfer. The thicker the
insulation, the lower the heat transfer rate. This is expected, since the heat transfer area A is
constant, and adding insulation always increases the thermal resistance of the wall without
affecting the convection resistance.
Adding insulation to a cylindrical piece or a spherical shell, however, is a different matter. The
additional insulation increases the conduction resistance of the insulation layer but decreases the
convection resistance of the surface because of the increase in the outer surface area for
convection. The heat transfer from the pipe may increase or decrease, depending on which effect
dominates.
Consider a cylindrical pipe of outer radius r1 whose outer surface temperature T1 is maintained
constant. The pipe is now insulated with a material whose thermal conductivity is k and outer
radius is r2 .Heat is lost from the pipe to the surrounding medium at temperature T∞ with a
convection heat transfer coefficient h. The rate of heat transfer from the insulated pipe to the
surrounding air can be expressed as
The value of r2 at which heat transfer rate reaches maximum is determined from the requirement
that (zero slope). Performing the differentiation and solving for r2 yields the critical radius of
insulation for a cylindrical body to be
rcr,cylinder = k/h Note that the critical radius of insulation depends on the thermal conductivity of
the insulation k and the external convection heat transfer coefficient h.The rate of heat transfer
from the cylinder increases with the addition of insulation for r2< rcr, reaches a maximum when
r2= rcr, and starts to decrease for r2> rcr. Thus, insulating the pipe may actually increase the rate
of heat transfer from the pipe instead of decreasing it when r2< rcr.
46) What are the color codes for cylinders of Oxygen, Carbon di oxide, and Chlorine?
Oxygen – White
Carbon di oxide – Grey
Chlorine – Yellow
47) Please provide the color coding of pipe lines in process industries.
Please refer the following file
http://www.scribd.com/doc/40068469/Color-Codes-for-Pipe-Lines
Petroleum
For same octane number which of the following has higher octane number? Paraffin, Olefins,
Aromatics, all have same.
Hydrocracking takes place at ? Low temp-Low pressure, High temp. High pressure, Low T high
P, High T Low
Question 1. Define Heat Transfer?
Answer :Heat transfer can be defined as the transmission of energy from one region to another
due to temperature difference.
Question 2. What Are The Modes Of Heat Transfer?
Answer :
Conduction
Convection
Radiation.
Question 3. What Is Conduction?
Answer :Heat conduction is a mechanism of heat transfer from a region of high temperature to a
region of low temperature within a medium [solid, liquid or gases] or different medium in direct
physical contact.
Question 4. State Fourier’s Law Of Conduction?
Answer :The rate of heat conduction is proportional to the area measured normal to the direction
of heat flow and to the temperature gradient in that direction. Q α – A dT / dx Q = -kA dT /dx
Where, A – Area in m2 dT / dx – Temperature gradient, K/m k – Thermal conductivity, W/mK.
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Question 5. Define Thermal Conductivity?
Answer :Thermal conductivity is defined as the ability of a substance to conduct heat.
Mechanical Interview Questions
Question 6. What Are The Factors Affecting The Thermal Conductivity?
Answer :
Moisture
Density of material
Pressure
Temperature e. Structure of material.
Question 7. What Is Meant By Free Or Natural Convection?
Answer :
It is fluid motion is produced due to change in density resulting from temperature gradients, the
mode of heat transfer is said to be free or natural convection.
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Question 8. Define Grashof Number [gr].?
Answer :
It is defined as the ratio of product of inertia force and buoyancy force to the square of viscous
force.
Gr = Inertia force x Buoyancy force / [Viscous force]2
Question 9. Define Stanton Number [st].?
Answer :
It is the ratio of Nusselt number to the product of Reynolds number andPrandtl number.
St = Nu / Re x Pr.
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Question 10. What Is Meant By Newtonian And Non-newtonian Fluids?
Answer :
The fluids which obey the Newton’s law of viscosity are called Newtonian fluids and those
which do not obey are called no-newtonian fluids.
Question 11. What Is Meant By Laminar Flow ?
Answer :
Laminar flow: Laminar flow is sometimes called stream line flow. In this type of flow, the fluid
moves in layers and each fluid particle follows a smooth continuous path. The fluid particles in
each layer remain in an orderly sequence without mixing with each other.
Mechanical Engineering Interview Questions
Question 12. What Are The Dimensionless Parameters Used In Forced Convection?
Answer :
Reynolds number [Re].
Nusselt number [Nu].
Prandtl number [Pr].
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Question 13. Define Reynolds Number [re]?
Answer :
It is defined as the ratio of inertia force to viscous force.
Re = Inertia force / Viscous force
Question 14. State Newton’s Law Of Convection?
Answer :
Heat transfer from the moving fluid to solid surface is given by the equation.
Q = h A = [Tw – T∞]
This equation is referred to as Newton’s law of cooling.
Where h = Local heat transfer coefficient in W/m2K.
A = Surface area in m2
Tw = Surface [or] Wall temperature in K.
T∞ = Temperature of fluid in K.
Question 15. Mention Stefan Boltzmann Constant?
Answer : σ = Stefan Boltzmann constant = 5.6697 x 10-8 W/ (m² K4).
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Question 16. What Is Meant By Absorptivity?
Answer : Absorptivity is defined as the ratio between radiation absorbed and incident radiation.
Absorptivity, α = Radiation absorbed / Incident radiation.
Question 17. What Is Meant By Direct Heat Exchanger [or] Open Heat Exchanger?
Answer : In direct contact heat exchanger, the heat exchange takes place by direct mixing of hot
and cold fluids.
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Question 18. What Is Meant By Indirect Contact Heat Exchanger?
Answer :In this type of heat exchangers, the transfer of heat between two fluids could be carried
out by transmission through a wall which separates the two fluids.
Mechanical Interview Questions
Question 19. What Is Meant By Parallel Flow Heat Exchanger?
Answer :
In this type of heat exchanger, hot and cold fluids move in the same direction.
Question 20. What Is Meant By Lmtd?
Answer :
We know that the temperature difference between the hot and cold fluids in the heat exchanger
varies from point to point. In addition various modes of heat transfer are involved. Therefore
based on concept of appropriate mean temperature difference, also called logarithmic mean
temperature difference, the total heat transfer rate in the heat exchanger is expressed as
Q = U A [∆T]m
Where, U=Overall heat transfer co-coefficient [W/m2K], A=Area, m2
[∆T]m = Logarithmic mean temperature difference.
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Question 21. What Is Meant By Effectiveness?
Answer :
The heat exchanger effectiveness is defined as the ratio of actual heat transfer to the maximum
possible heat transfer.
Effectiveness ε = Actual heat transfer / Maximum possible heat transfer = Q / Qmax
Question 22. What Is The Difference Between Air Conditioning And Refrigeration?
Answer :
Refrigeration is the process of providing and maintaining the temperature in space below
atmospheric temperature. Air conditioning is the process of supplying sufficient volume of clean
aircontaining a specific amount of water vapour and maintaining the predeterminedatmospheric
condition with in a selected enclosure.
Question 23. What Are The Advantages And Disadvantages Of Air Refrigeration System?
Answer : Advantages:
1. The refrigerant used namely air is cheap and easily available.
2. There is no danger of fire or toxic effects due to leakages.
3. The weight to tonne of refrigeration ratio is less as compared to other systems.
Disadvantages:
1. The quantity of refrigerant used per tonne of refrigeration is high as compared to other system.
2. The COP of the system is very low. Therefore running cost is high.
3. The danger of frosting at the expander valves is more as the air contains moisture content.
Question 24. What Is Net Refrigeration Effect Of The Refrigeration?
Answer : Refrigeration effect is the total heat removed from the refrigerant in the evaporator.
COP = Refrigeration effect / Work done.
Refrigeration effect = COP x Work done.
AutoCAD Interview Questions
Question 25. What Is Meant By Transmissivity?
Answer :
Transmissivity is defined as the ratio of radiation transmitted to the incident radiation.
Transmissivity, τ = Radiation transmitted / Incident radiation.
Why is a pressure cooker effective in cooking?
Why are the wet and dry bulb temperatures different? When will these be equal?
Apply Le Chatelier's principle to the reversible gas-phase reaction A+B → C, and explain how
the equilibrium conversion will vary with pressure?
What is a Newtonian fluid? How does it differ from a Bingham plastic fluid?
What is the velocity profile for flow of a Newtonian fluid in a cylindrical tube. What is it for a
Bingham plastic fluid?
Why does water freeze on a cold night even when the ambient temperature is not sub-zero?
If there are no constraints, how would you conduct a stage-wise distillation column so as to bring
its efficiency closer to unity?
Consider a sphere and a cube of the same volume and having the same initial temperature T0. If
both are exposed to the same external temperature Te ( > T0), which would gain heat faster?