1. What is chemistry?

Chemistry is the study of the composition of matter.

2. What is a chemical change?

A change, in which a new substance with different properties is formed, is

known as chemical change.

3. Give example of physical change?

Dissolving sugar in water

4. What are the forms in which matter exists?

Elements
Compounds and
Mixture of elements and compounds.

5. What is element?

Elements are the organic materials from which all substances like
solid, liquid and gas is made. It is the simplest form of matter.

6. What are the more abundant elements in the earth's crust?

O2 49.6%
Sodium 2.6%
Silicon 25.8
Aluminum 22.0
7. What are the major elements in the Human body?

Oxygen 65%
Carbon 18%
Hydrogen 10%
Nitrogen 3%
Calcium 2.4%
Phosphorus 1.0%

8. What is a compound?

Compounds are pure substances formed from the chemical reaction of elements.
They have same composition and same properties, cannot be broken down except by
chemical reactions.

9. What is an atom? What is it made up of?

Atoms are smallest particles of elements which can exist with the properties of
the element.

Different atoms of the same elements are alike in always, atoms of different
elements are unlike.

It consists of a nucleolus composed of proton and neutrons with

electrons around the nucleus, protons are positively charged,
electrons are negatively charged and neutrons are neutral.

10. What is Atomic number?

Atomic number is the number of protons in the atom of an element, which is equal
to the number of electrons.

11. What is Atomic weight?

Oxygen as a standard to the weight of the atoms of elements, which are too small to
be measured or to mean any thing. Oxygen is given a number 16 as it is a atomic
weight. Atomic weight of all other
elements is relative to this figure.

12. What is Valancy? What is the valance of carbon atom?

Valancy is combining capacity of an atom. The number of electrons, gained, lost or

shared by an atom is the valance.

Carbon atom has a valance of four.

13. What is Radical?

A radical is a group of atoms different elements are linked together in chemical

reactions. A radical behaves like a single atom.

14. What is a molecule?

Molecules are the smallest parts of compounds, some elements like

Hydrogen, Nitrogen, Oxygen, etc., exist as molecules of two atoms.

H2, N2, O2

15. What is organic compound?

Organic compounds are obtained directly or indirectly from living organisms,.

Since carbon compounds are the most important compounds of plants and animals,
organic chemistry is the
chemistry of carbons compounds.

16. What is inorganic compound?

Inorganic means 'no life' and inorganic chemistry concerns itself

with the elements and compounds other than those of carbon.

17. What is Crude oil composed of?

Crude oil is mainly a mixture of hydrocarbon compounds of carbon and hydrogen.

It also contains relatively small quantities of sulfur, oxygen and nitrogen.

18. How many different types of crude are there in the world?

There are hundreds of different crude oils, perhaps even thousands. Some crude oils
have lighter specific gravities than others, some
have lower total sulfur content than others, some can be refined to produce more
gasoline than others, and some have lower pour
points than others.

The physical properties of any specific crude oil are obtained by a

series of laboratory tests which result in what is called a "crude oil assay".

Some people classify crude oils as: paraffin base; naphthene base;
aromatic base; asphalt base; or mixed base. The general elementary
composition of crude oil falls within these approximate weight
 percent ranges: Carbon = 80 to 87, Hydrogen = 11 to 14, Nitrogen =
0.2, and Sulfur = 0 to 3.

19. What is the basis of classifying hydrocarbon?

On the basis of Chemical structure.

20. What the major hydrocarbon families’ deal within

refinery/petrochemical processing mainly?

PNAO

Paraffins,
Naphthenes,
Aromatics and
Olefins.
(Of these all but Olefins are found in natural crude)

21. How we are getting petro products?

The manufacture of petroleum product is the separation of crude oil into the main
fractions by distillation.

22. What is distillation?

Distillation is a process in which components are separated into two fractions. One
fraction is more concentrated in lights ends: one
fraction is more concentrated in heavy ends.

23. What are main fractionation products from Petroleum?

Gas
Naphtha (benzene)
Kerosene (paraffin)
Diesel
Lubricant
Fuel oil

24. What is a chemical reaction?

It is a chemical change in which elements combine to form

compounds or breaking out compounds to recombine to form new compounds.
25. What is exothermic reaction?

A chemical reaction in which heat is liberated is called exothermic reaction

Example: union fining reaction

26. What is Endothermic reaction?

A chemical reaction in which heat is absorbed is call endothermic

reaction

Example: pacol reaction

27. What is the boiling range of Kerosene?

150 - 262oC

28. What is DPK? Where Return kerosene is used?

DPK: Duel purpose kerosene. Return kerosene used as Jet A, B, JP & JPB)

29. What is paraffin?

Carbon atoms connected in a straight chain by single bond (normal) Butane C-C-C-C

30. What are iso paraffins?

Carbon atoms having branched chain, single bond arrangement is called Iso-
parafins (non-normals).

Iso-butane C- C - C
|
C

31. Why kerosene selected for Normal Paraffin production?

Normal paraffin is rich in kerosene carbon range, almost about 18.5%

with C10-13 range. Average Molecular Weight of heart cut is about
165.

32. What are the characteristics of straight chain paraffins?

Saturated compounds with a general formula CnH2n+2

 Good natural stability.
Natural high Viscosity Index (V.I) lubricating oils. Good
source of waxes.
Poor for manufacture of Gasoline. Hard
carbon deposits.
High pour point
Found particularly in paraffin crude.

33. What changes in properties occur when paraffin are isomerizes?

Boiling point is lowered.

Octane number is increased.

34. What are the properties of Naphthenic hydrocarbons?

They are cyclo paraffin

They are saturated with a genera formula CnH2n+2 Low VI
Low pour point
Better octane rating than corresponding paraffin.
Naphthenic Motor oils form sort, fluffy carbon deposits.

35. What are the properties of olefins?

They are unsaturated.

Readily react with oxygen to form sludge. Possess
good anti-knock properties.

36. What are the properties of Aromatics?

They are not very reactive in spite of the presence of double bonds. They behave
more like saturated compounds.
Excellent anti-knock properties.
Used as commercial solvents due to their high solvent power. Poor VI
components.
Produces smoky flames

37. What is cracking?

Heavier hydro carbons are cracked or broken into smaller molecules to produce more
valuable lighter products from the low priced
heavier hydrocarbons.
38. What is Alkylation?

It is the process of combing two dissimilar hydrocarbons. A catalyst

is used in this reaction of saturated compounds with unsaturated.

39. What is Polymerization?

Similar to Alkylation, except that in this case two un saturates are combined over
a catalyst.

40. What is Hydrogenation or Hydro finishing reaction?

In this reaction hydrogen combines with unsaturated hydrocarbon make them a

saturated compound over a catalyst.

41. What is Hydro De-sulfurization?

A reaction over a catalyst to remove sulfur by converting it to H2S

with addition of hydrogen.

42. What is the reaction involved in decoking of furnace & regeneration

of catalyst?

It is Oxidation. Using oxygen from the air the coke is burnt to CO2.

43. What is temperature?

It is a measure of how hot something is.

44. What is freezing point? What is the freezing point of kerosene?

The temperature at which crystals first appear when a liquid is cooled under
specified conditions.

-47oC.

45. What is Dew point?

The temp at which condensation of water vapor from the air begin the temp of the
air water vapor mixture falls.

46. What is Dry bulb temperature?

It is an indication of the sensible heat content of air water vapor mixtures

47. What is Wet bulb temperature?

It is measure of total heat content or enthalpy. It is the temperature

approached by the dry bulb and the dew point as saturation occurs.

48. What is Dew point temperature?

It is a measure of the latent heat content of air-water vapor mixtures and since latent
heat is a function of moisture content, the dew point temperature is determines by the
moisture content.

49. Write difference between density and Specific gravity?

Fuel density: mass of the fuel to the volume at specified temperature.

Specific gravity of fuel: density of fuel, relative to water is called

specific gravity. Higher the sp gravity, higher will the heating values.

50. What is Calorific value (CV)?

Energy content in an organic matter (CV) can be measured by burning it and

measuring the heat released.

The heating value of fuel is the measure of the heat released during the complete
combustion of unit weight of fuel. It is expressed as Gross Calorific Value (GCV) or
Net Calorific Value (NCV).

51. What is the difference between GCV and NCV?

The difference between GCV and NCV is the heat of vaporization of

the moisture and atomic hydrogen (conversion to water vapor) in the fuel. Typical
GCV and NCV for heavy fuel oil are 10500 kcal/kg and
9800 kcal/kg.

52. How does define a "barrel"?

The "barrel" is a volumetric unit.

1 barrel is equivalent to 42 U.S. gallons or 34.97 Imperial gallons or 158.99 liters or
5.615 Cubic feet.

53. What is specific gravity?

Specific gravity is used to measure liquid density

54. What is the relation between Sp. Gravity and API gravity?

Heavier hydrocarbons will have higher specific gravity and low API
gravity.

55. How do you calculate API Gravity?

API gravity = 141.5 -131.5

Sp. Gravity

56. How do you convert Sp. Gravity (0.8020) to API gravity?

API = 141.5 - 131.5 = 44.993

0.8020

57. How do you calculate Sp.gravity of a crude oil at a given API 45?

141.5/131.5 + 45 = 0.8017

58. What is density?

Density is mass per unit volume Mass

Volume

Select the Answer:

59. What is the purpose of relief valve in reciprocating pump?

Protect the pump against developing excessive pressure Facilitate

unidirectional flow of fluid
Increase the discharge pressure

60. When an electrical motor will tip?

It runs on over load

Any processes interlock actuates Short
circuit occurred
All of the above
61. Pump priming is done for

Removal of non condensate from pump suction and casing Arrest

cavitations in pump
Filling liquid in pump casing
All of the above

62. Refrigeration cycle means

Expansion → evaporation → condensation → compression

Evaporation → compression → condensation → expansion

63. Start centrifugal pump only when

Suction valve full open

Kick back valve partial open
Discharge valve fully close
All of the above

64. An insulator should have

Low thermal conductivity

High thermal conductivity
Less resistance to heat flow
A porous structure

65. Which of the following has the highest thermal conductivity?

Brick
Air
Water
Silver

66. Thermo siphoning in re-boiler is

Movement of fluids due to density difference Re boiling

the fluids at highest temperature Reducing the re boiling
of process fluids To control re boiling of fluids

67. Normal safe position of flare control valve in case of instrument air
failure is

Fail to open
Fail to close
Manually operated to bring in safe position
 Non of the above

68. MSDS of any chemical is

Material safety data sheet

Material safety design sheet
Material safety documentation sheet Material
separation data sheet

69. Pump symbols. Give names of the types of pumps against each
pump symbol.

Centrifugal pump
Rotary pump
Positive displacement pump

70. Throttling (joule-Thomson effect) process is a constant

Enthalpy process
Entropy process
Pressure process
None of these

71. With the increase the flow of any centrifugal pump

The discharge pressure will decrease

Motor current will increase
Both of the above

72. Multi pass heat exchangers are used because of

Simplicity of fabrication
For low heat load
To obtain higher heat transfer co efficient and shorter tube To reduce the
pressure drop

73. Finned tube heat exchangers

Give larger area per tube

Use metal fins of low thermal conductivity
Facilitate very large temperature drop through tube wall Used for
smaller heat load

74. Steam trap is used to

Condense the steam flowing in pipeline

 Remove water resulting from partial condensation of steam Stop the
supply of steam
None of these

75. Flooding in a column result due to

High pressure drop

Low pressure drop
Low velocity of the liquid
High temperature

76. What are the four types of devices commonly used to measure
temperature?

Mercury thermometer
Filled system temperature indicator
Bimetallic thermometer, Thermocouple
Resistance temperature detector RTD

77. Isotropic distillation is employed to separate

Constant boiling mixture

High boiling mixture
Mixture with very high relative volatility Heat
sensitive materials

78. In an adiabatic process

Heat transfer is zero

Temperature change is zero
Work done is a path function
Enthalpy remains constant

79. Entropy is measure of

Disorder of system
Orderly behavior of a system
Only temperature changes of the system None of
these

80. Stainless steel is used at place as MOC where operating temperature

may go below

-40oC
-73 oC
-0 oC
 -23 oC

81. H2SO4 to be dosed in cooling water system

For the pH control

For the SO4 control
For the bio growth control
None of the above

82. For the measurement of corrosion in CW system

Corrosion coupon is installed

Annual inspection of CW line is being carried out Cathodic
protection is tube checked
All of the above.

83. Find the even of abnormal pressure rise in the boiler, one of the
drum safety valves will lift first to release the pressure immediately and to save the
pressure part of the boiler

True
False

84. Scale in the boiler tube cannot be allowed because

Its acts as insulators

It conducts high amount of heat It causes
corrosion
All the above

85. Dry bulb temperature of the gas is

Less than the wet-bulb temperature More

than the wet-bulb temperature Equal to the
wet-bulb temperature None of these

86. LPG stands for

Liquid petroleum Gel

Liquid petrol gas
Liquefied petroleum gas

87. Location of any pipe line vent is always

At the highest point

 At the lowest point
At the isolation valve

88. Why do we treat lowers API gravity crude to meet product

specification?

Lower API crude requires high temperature and longer retention time to meet proper
oil product specification.

89. What is heat?

It is an energy associated with the motion of molecules in a substance.

90. What is the basic principle of heat transfer?

Heat transfer is the transfer of heat from hot place to cold place.

91. What is temperature?

It is a measure of how hot something is.

92. How do you convert - 10o F into oC?.

(-10 - 32) / 1.8 = - 23.3 oC

93. What are the four types of devices commonly used to measure
temperature?

Mercury thermometer
Filled system temperature indicator
Bimetallic thermometer, Thermocouple
Resistance temperature detector RTD

94. How do you convert 108 oF into oC?

(108 - 32) / 1.8 = 42.2 oC

95. How do you convert 210 oC into oF?

(210 * 1.8) + 32 = 410 oF.

96. What is a sensible heat?

Sensible heat is that which is used for increasing liquid temperature to Boiling Point.
97. What is latent heat?

Latent heat is the amount of heat required to change the state of liquid at its
boiling point

98. How gas volume is is calculated?

Gas volume is normally calculated at standard temperature (60 oF) * Standard

pressure 14.7 Psi.

99. What is a boiling point?

It is a temperature at which a liquid turns into vapor state.

100. What is the effect of boiling point in relation with pressure?

Boiling point increases at high pressure and decreases at low pressure.

101. What happens to vapor pressure when it reaches to boiling point?

At boiling point vapor pressure of a liquid equalizes to the pressure

of the surrounding atmosphere.

102. Shell and tube heat exchanger. Identify main parts of a shell and
Tube heat exchanger:

1. Shell,
2. Baffles
3. Tube
4. Tube sheet
5. Tube head

103. Identify the parts of a 'U' Tube kettle re boiler and fill the blanks with
correct answer.

1. Steam inlet
2. Vapor outlet
3. Condensate outlet
4. Crude oil
5. Hot oil

104. What is a vapor pressure?

When molecules start to leave the liquid as vapor, it will create vapor Pressure.
105. What happens to the temperature, pressure and volume of gas when
it is compressed?

When gas is compressed the pressure and temperature will increase and
volume decreases.

106. What is vaporization?

It is a quick change from the state of liquid to gas (vapor) due to boiling.

107. What is an atom?

An atom is the smallest part of an element.

108. What does an atom consists of?

An atom consists of Electrons, Protons and Neutrons.

109. What is a compound?

A compound is a new product by the bonding two or more elements by chemical

reaction having new physical properties.

110. Give two examples of compounds?

H2O, CO2

111. What is the specific gravity of water?

Specific gravity of water is considered as 1. (One)

112. What is an inert gas?

An inert gas is that which do not react chemically or non-flammable.

113. Give two examples of Inert gases?

Nitrogen and Carbon dioxide.

114. What does molecule contain?

Molecule contains two or more atoms from the same kind by chemically
bonded together.
115. Give examples molecules.

O2
N2
H2

116. What is the purpose of a hazardous area classification drawing?

Hazardous areas are classified as

Zone 0 (Class 0)
Zone 1 (Class 1)
Zone 2 (Class 2)

117. Give examples of Zone 0, Zone 1 and Zone 2

Zone 0 = Always air fuel mixture is continuously present.

Example: Tank vents, Sump vents, Drains etc.

Zone 1 = Air fuel mixture is present during normal operations.

Example: Pipe line flanges, Inlet manifold areas. (Flange joints are the weaker
areas in a process system that may cause leak during abnormal Operation).

Zone 2 = Air fuel mixture is may present during abnormal operations.

Example: Welded pipelines where there are no flange joints. This area reduces the
chances of leaks. Flare lines, welded hydrocarbon pipelines where there are no
flanges.

118. What is a natural gas?

Natural gas is produced from organic compounds or hydrocarbons during the

process of crude oil / gas production operations from an oil reservoir.

119. Why do we consider methane is the lightest gas?

Methane has only one carbon atom.

120. What is viscosity?

Viscosity is the resistance of a liquid to flow.

121. What is pressure?

Pressure is the measure of force applied to a unit area.

Force.
Area

122. How do you calculate pressure of 100 pound block measuring 25

Square inches on each side?

100/25 = 4 psi.

123. Why do we use vacuum scale?

Vacuum scale is used to measure pressure in vessels which are

below atmospheric (Absolute).

124. What reading on a mercury vacuum gauge corresponds with the

Atmospheric pressure?

Zero in Vacuum gauge is equal to the atmospheric pressure.

125. What is a perfect vacuum?

Zero pressure absolute Psia equals the pressure in a perfect vacuum.

126. What is RTD?

RTD is resistance Temperature Detector. (Heat creates by

Electrical Resistance). Increase the heat means increases the resistance.

127. What is the unit of electrical resistance?

Unit of electrical resistance is Ohms at 0 oC 128. Why

do we use Centrifugal pumps?

Centrifugal pumps are used when large volumes of fluids to be moved.

129. Which part of the centrifugal pump move liquid?

In a centrifugal pump the impeller moves liquid

130. Which part of centrifugal pump is giving power to pump liquid?

A centrifugal pump is powered by a driver to pump liquid.

131. Write the start up procedure of a typical centrifugal pump

The following minimum precautions an operator should observe before starting

a centrifugal pump:

Ensure area is safe to start the pump.

Open suction valve full and discharge must be in cracked open position.

Prime the pump to remove vapor or gas.

Check for any leak and ensure there is no abnormal alarm on the pump panel.

Inform control room. Then start the pump. Open the discharge valve
full.

Check pressure, flow and Ampere. Seal flush line temperature and check for any
abnormal noise.

132. Pumps. Identify the parts of a pump.

Upstream side
Down stream side
Suction inlet
Discharge outlet
Housing
Shaft
Impeller

133. What action should an operator takes, if a pump is having any

abnormalities?

Inform to control room.

Stop the pump.
Investigate and take proper corrective action.

134. Why do we use lubricating oil system in a centrifugal pump?

Lubricating oil system is to remove heat from pump bearings

135. What are the safe guarding systems of a centrifugal pump?

Pre-warning alarms (Unit Alarms) Trip

switches
Safety relief valves
Seal pot level high low alarms

136. What is the difference between single stage pump and multistage
pump?

Single stage pump has only one impeller and multistage pump has two or more
impellers

137. What types of bearings are used in a pump?

Sleeve bearings and ball bearings are used in pump.

138. What will happen to bearing, if it is too hot?

If the bearings are too hot they can seize the shaft.

139. Identify main parts of a multistage centrifugal pump and write correct
names.

1. Upper casing,
2. Mechanical seal.
3. Bearing housing,
4. Suction
5. Discharge,
6. Lower casing.

140. How do we remove heat from an operating pump?

Excessive heat can be removed from pump by ambient air

temperature or by circulating cooling water through water jackets.

141. What is a centrifugal force?

A force, which tends to move an object away from the center of rotation, is
called centrifugal force.

142. How a pump driver is connected to pump?

Pump driver is connected to a pump by coupling.

143. What is the function of bearing?

Pump bearings control the side to side movement or radial

movement of the Shaft. It also controls the forward and backward movement or
thrust of the Shaft.

144. What is the largest part of a centrifugal pump?

Pump casing is the largest part of a centrifugal pump.

145. Which part of a centrifugal pump prevents leakage?

Pump packing is used to prevent leakage from a pump.

146. Label the parts of the closed lubricating system.

1. Sight glass
2. Pump
3. Lube oil cooler
4. Temp. control valve TCV
5. Filter
6. PCV
7. Reservoir.

147. Where do we use reciprocating pumps in our process system?

Reciprocating pumps are commonly used in Chemical injection

where we require high pressure pumping.

148. What should be the position of suction and discharge valves while
starting a reciprocating pump?

Suction and discharge valves must be in full opened position and remove air / gas
completely from the pump before starting a
reciprocating pump.

149. Which part of the reciprocating pump actually moves liquid?

Piston and cylinder helps to move liquid in a reciprocating pump.

150. Reciprocating pumps can not increase the pumping capacity and it
can pump only fixed quantity. Why?

Cylinders and pistons are designed to pump fixed quantity. So Reciprocating

pumps can not increase amount of flow.
151. What is a pump cavitation?

When there is no enough (low) suction head pressure, liquid, which

is in the eye of the impeller, will move faster causing high
temperature to produce vapor. This vapor lock will produce knocking
sound to escape. This will cause pressure surging and loose the
efficiency .It can damage the pump. This is called cavitation.

152. Types of pumps

Write the names of the pump and label the following parts against each pump. (1.
Lobe pump, 2. Rotary gear pump, 3. Screw pump 4. Vane pump)

1. Suction inlet
2. Discharge
3. Pumping element
4. Drive shaft
5. Pump housing.

153. Expand the P&ID abbreviations?

FSH Flow switch high,

FR Flow recorder
FRC Flow recorder Controller
FIC Flow indicating Controller
PR Pressure recorder
PRV Pressure Relief Valve
TSV Temperature safety valve
ESD Emergency Shut Down
PDIC Pressure differential indicating controller
PCV Pressure control valve
FCV Flow control valve
TCV Temperature control valve
LCV Level control valve
PSHH Pressure switch high high
FSHH Flow switch high high
TSHH Temp. Switch high high
PSLL Pressure switch low low
LO Lock open
LC Lock closed
TIC Temperature indicating controller
CSO Car Seal Open (valve sealed and kept in OPEN position)
CSC Car Seal Closed (valve sealed and kept in CLOSED
condition)
154. What is a mixture? Give two examples.

Mixture is a composition of two or more molecules of an element that

are not chemically bonded and can be physically separated.

155. How many liters and Gallons in a US barrel of crude oil?

159 Liters, 42 Gallons

156. Find the following from P&ID?

Pipe line specifications

Fail open valves
Fail closed valves
Restricted orifice plates
Lock open valve
Lock closed valves
Piping insulation
Pneumatic inst. Signal lines
Level controller
Level relay switch
Pressure control valves
Reducers
Shutdown valves
Spectacle blinds
Reciprocating pump
Pulsation damper

157. Where is the globe valves mainly used for in a process system?

Globe valves are used to control flow, mainly as control valves.

158. Where are ball valves mainly used for in a process system?

Ball valves are used in high pressure lines as an isolation valve.

159. Where are butterfly valves commonly used in a process system?

Butterfly valves are commonly used in low pressure pipelines.

160. Find the Valve symbols in P & ID.

Gate valve, Globe valve, Check valve, Butterfly valve, Closed gate
valve, Closed globe valve, Control valve, AOV(S/D valve) , MOV, HOV
161. Identify valve parts:

1. Hand wheel nut

2. Hand wheel
3. Bonnet
4. Packing gland
5. Packing
6. Stem
7. Opening element
8. Valve seat
9. Valve body.

162. Write names of the valve actuators:

1. MOV
2. Pneumatic Actuator
3. Solenoid actuator,
4. Hydraulic actuator

163. What happens to the volume of gas from one stage to the next
stage?

Volume reduces when compressed gas move out from one stage to
the next stage.

164. Why do centrifugal compressors need to operate at higher speed

than centrifugal pumps?

Centrifugal compressors use gas to compress. Gas is lighter than

liquid. So centrifugal compressors need high speed than pumps.

165. What is the function of a un loader switch of a reciprocating

compressor?

An un loader switch of a reciprocating compressor prevent over

loading of compressor by keeping suction valve open, in case of pressure above
set limit, till it reaches below normal operating
pressure.

166. What is the purpose of an inter cooler of a compressor?

Inter cooler will help to cool discharge gas / air between one stage to another stage.
167. What is the purpose of an after cooler of a compressor?

After cooler is used to reduce the temperature of a compressed gas /

air from the final stage of compression.

168. What are the functions of pre-filters and after filters of an instrument
air system?

Pre- filter before drier is used to remove oil mist and liquid from compressed air
and after filter is used to remove any suspended particles from the drier unit to
supply a high quality clean air for instrument system

169. What type of desiccant those generally use in instrument drier

system?

Activated alumna or silica gel.

170. What electrical value can be measured across the copper and zinc
rods?

Voltage.

171. What is alternating current (AC)?

Alternating current changes direction. (50 Hz Supply)

172. What is Direct Current (DC)?

Does not change direction.

173. What does a fuse protect against in a circuit?

High current.

174. What unit is used to measure an electrical resistance?

Ohms.

175. What are the major parts of an electrical motor?

1. Motor enclosure
2. Stator
3. Rotor
4. Shaft
5. Bearings
 6. End fan cover.

176. Furnace. Explain the following terms:

1. Natural draft
2. Induced draft
3. Forced draft
4. Balanced draft.

Natural draft: The air flow and the flue gas flow are maintained without fan or
blower.

Induced draft: The hot flue gas flow the stack is maintained by a fan or blower
located downstream of flue gas outlet.

Forced draft: A fan is located upstream of the burners to force the air into the
heater.

Balanced draft: Two fans are used simultaneously, one for forcing the air into the
furnace and the other for sucking the hot flue gas out of the furnace to the stack.

177. What is unit of measurement electrical load?

Ampere (Amps)

178. What is pH reading of normal fresh water?

pH reading 7. If it is below 7 is acidic and above 8 is alkali or base.

179. At what temperature the movement of molecules completely stops?

At absolute zero temperature.

180. What are the four major parts of a process control loop?

1. Sensing element
2. Transmitter
3. Controller
4. Control valve.

181. What is the function of a ratio controller?

A ratio control is where a pre determined ratio is maintained between two variables.
182. What is pyrophoric iron sulphide? How it is formed?

Pyrophoric iron sulfide is normally found in process lines by the Chemical

reaction of iron and sulfur from hydrogen sulfide.

183. How Pilot Gas pressure is controlled in furnace?

A Pilot gas pressure is controlled by pressure control valve (PCV) by

the help of a pressure control loop.

184. What could happen if the level controls failed and the separator
vessel became empty?

Gas will escape from the vessel through liquid out let line causing
extensive damage to downstream equipments due to high gas
pressure.

185. Select the parameters that could cause a FGC to trip or shut down?

PALL PAHH LALL LAHH

186. How is the discharge pressure of a centrifugal pump controlled and

maintained?

Discharge pressure of a centrifugal pump is controlled and

maintained by pressure control valve and recycle (spill back) valve.

187. Why do we check three phase motors backward run after certain
electrical maintenance repairs?

If the phase sequence is reversed while connecting power cable,

motor will run backward which may cause serious damage to
equipment.

188. What must be done to crude oil before it is placed in floating roof
storage Tank?

Oil must be stabilized to remove all easily separated gas, before storing into
floating roof tank.

189. Label the auxiliaries of Tank in P & ID?

1. Mixer
2. Level float or level measuring tape
3. Vent
4. Gauging platform
 5. Gauging well
6. PVRV
7. ERV
8. Foam pourer
9. Pump out suction

190. Why do we use vacuum relief valves on a doomed roof tank or fixed
roof tank?

Vacuum relief valve prevent forming vacuum in side tank when

product is being removed. This valve open automatically if the
pressure in the tank falls below 0.2 psig. Then this valve allows air flow into dome
of the tank.

191. What are the fire / explosive protection provided on a storage tank?

To prevent fire and explosion protection vent pipes are fitted with flame or spark
arrestor.

192. What is the function of a diesel fire water pump?

Diesel fire water pump provides to stand by during power failure.

193. What is the purpose of EMDG?

It’s used to give the emergency power supply during power failure to
important pumps

194. What are the primary parts of a closed lubrication system in Screw
compressor 400 C 01?

Lube oil rundown tank

Lube oil reservoir
Lube oil pump
Lube oil filter
Pressure control valve
Temperature control valve
Coolers

195. How does the compressor trip if the lube oil filters is dirty?

Low pressure indicator alarm after the filter will trip the compressor to prevent any
damages.
196. What is the function of a lube oil pressure control valve?

Lube oil pressure control valve of lube oil system is controlling to adjust and
maintain lube oil system pressure.

197. Which part of process pipes line is a source of potential leak?

Flanges and joints.

198. What is the function and purpose of pipe line insulation?

Pipeline insulation protects person from very hot and very cold pipes.

199. Oil is called Petroleum. Why?

They are found in rock. Petra means Rock and Oleum means Oil. So it is called
Petroleum.

200. What is Organic theory?

Oil and gas comes from the remains of plants and animals by heat and pressure.

201. What do you understand by light crude and heavy crude?

Light crude contains the lowest number of Carbon atoms per unit volume.

Heavy crude contains highest number of carbon atoms.

202. What is 'Solution gas' and 'Bubble point'?

Gas which is inside a solution and is coming out is called solution

gas.

The point at which all gas comes out from a solution , we call bubble point.

203. Why the under ground lines should not be steam flushed?

Under ground lines have a protective coating of asphalt which will melt and spoil
if subjected to high temperature.
204. What is the meaning of "warming up of a pump"?

Warming up of pump means opening the warm up line, which by

passes the NRV in pump discharge. This allows the stand by pump to remain warm
as hot liquid passes from discharge line to suction of the stand by pump.

205. While commissioning the exchanger which fluid should be opened

first, hot or cold? Why?

Cold fluid should be opened first to prevent uneven expansion due to overheating if
hot is opened first.

206. What is maggering?

Magger value is an indication of health of the insulation, especially in motor winding.

When a motor is kept under cold condition for long time, the insulation may become
ineffective due to moisture in
surrounding air.

207. What should be the ideal color of oil flame in heater?

Golden yellow

208. What are flame front lines?

Lines used for flame front propagation for lighting the pilot of flare.

209. What is the weathering temperature of LPG?

+2 oC

210. What is the odoring component added in Domestic LPG? Why it is

added?

Ethyl mercaptan

211. What is the difference of tracing and jacketing? Where are they
used?

Jacketing is done with double pipe type arrangement. Especially for very high
viscosity fluids which may quickly congeal upon slightest cooling.
212. What is the hot spot? How it is formed?

It is localized heating of furnace tubes, which can be seen in the form of a hot spot. It
results when heat transfer rate from tube skin to the moving fluid reduces due to coke
formation inside the tube. Hot
spots can also be created by flame impingement

213. Generally what differential pressure we maintain between steam and

fuel oil at furnace burner?

1.5 times F.O. pressure

214. Valve stem of a gate valve in flare header should face upwards or
downwards and why?

Downwards since among most frequent failures in gate valve is

falling down of gate. If stem is facing downwards, gate will remain
intact.

215. What is peep hole?

Small hole with a door to monitor furnace conditions

216. What is SO2 emission limit in HO heater?

340 ng/J

217. What is octane number?

Octane number of a fuel indicates its ant knocking characteristics

218. What is the pressure of LPG in domestic cylinders?

LPG is a mixture of propane and butane and vapor pressure of the mixture is
around 7 KG/cm2.

219. How many types of tanks are there in petrochemical industries?

Cone roof, Floating roof, Internal-floating roof, Dome roof.

Upto 0.05 RVP - Cone roof

0.05 -0 .85 - Floating roof
0.85 - 1.25 - Dome roof
Above 1.25 - pressure vessel (bullet or sphere)
220. What is supply temperature of tempered water?

60o C

221. Where is positive displacement pump required?

For less flow and high head - like chemical dosing.

222. What is TSV and where do we use it?

TSV (Thermal safety valve) is used to take care of pressure build up due to thermal
expansion. It is provided at places where a liquid can remain in blocked up state with
no room for expansion due to
temperature rise.

223. What is the difference between flammable and combustible liquids?

A flammable liquid has a closed cup flash point below 37.7oC and vapor pressure
below 2.72 ksc at 37.7oC.

A combustible liquid has a closed cup flash point at or above 37.7oC. 224. What is the

difference in flash point and fire point?

Flash point is the lowest temperature at which application of test flame causes
vapor above the Hydrocarbon liquid to ignite.

Fire point is the lowest temperature at which application of test flame causes vapor
above hydrocarbon liquid to ignite and continue to
burn for 5 seconds

225. Why does a glass bottle crack when it is filled with water and frozen?

Water has lowest volume at 4oC, below this it again expands which exerts pressure
on the walls.

226. What is the concentration of salt in seawater

Approx 3.5 %

227. How do we control TDS (total dissolved solids) in boilers?

By regular blow down.

228. What is Aniline point?

Aniline point is the lowest temperature at which the oil is completely

miscible with an equal volume of aniline - high aniline point
indicates presence of paraffinic components and hence better diesel
index

229. What is

LNG
CNG
NGL

i. LNG - Liquefied natural gas - which is 87%-

99%methane, remaining C2, C3 etc.

ii. CNG - Compressed natural gas - the non-condensable

components of the gas (C1, C2) which is sold in gaseous
phase.

iii. NGL - Natural gas liquid - similar to naphtha - the light

H/C liquid remaining after removal of LNG and CNG.

230. A warning is written on most air compressors “Do not use

compressed air for blowing dust etc. from the body or clothes….” What is the
reason?

Compressed air may enter the body through small nicks and cuts, if any, and cause
stoppage of blood flow, clotting etc - which may have serious consequences

231. Where do we use screw pump and gear pump?

For high viscosity fluid service

232. What is upper and lower explosive limits of LPG?

9.6% & 1.8%

233. What is the flue gas temp at the stack outlet of Furnace?

>180oC; to prevent Dew point corrosion

234. Which is the main component of low MW fuel gas?

H2
235. What lab tests will be required before a vessel entry permit is given?

Oxygen deficiency test, test for hydrocarbon and explosive mixture presence.

236. If you have to shift a heavy object - should it be pushed or pulled?

It is always safer to push, as pulling causes greater strain.

237. What should be the dew point of instrument air?

-40 oC

238. What is the purpose of Fly wheel?

Fly wheel is provided in a machine to smoothen the power impulses.

239. Which will vaporize faster, liquid LPG kept in atmosphere and liquid
LPG kept in a water bath?

Liquid LPG in water bath

240. What is full form of PLC?

Programmable logic controller

241. Space between two trays in a distillation column is known as?

Vapor disengaging space

242. What reagent is used for doctor's test?

Sodium plum bite

243. Above what volume a steam generator is considered as boiler?

22.75 liters

244. Above what operating pressure a steam system falls?

3.5 kg/cm2 g

245. For which type of services a floating tube head exchanger is used?
 For hot service where expansion of tubes may be there. The fixed tube may
buckle in hot service.

246. What is the percentage of carbon in Carbon steel?

0.30%

247. Name the three acid neutralizing agent

Ammonia, Caustic Solution, Amine.

248. Name two most commonly used cleaning methods for Heat
Exchanger?

Tube Cleaning Hydro jetting (with high pressure water jet) and
Roding

249. In case of H2S leak in the UF unit, which Personal Protective

Equipment you should use?

Self Contained Breathing Apparatus (SCBA)

250. What is full form of OPEC?

Organization of Petroleum Exporting Countries

251. In which section of the refinery the term molecular seal is

associated?

Flare.

252. What is the full form of BOD?

Bio chemical Oxygen Demand

253. How does automatic sprinkler deluge system work?

Due to high temperature (above 90oC) during fire the fluid inside the
quartz bulb will expand and will break the bulb releasing the pilot
water pressure on the fire water valve thus opening the valve.

Sometime infra red sensors are also used which Resistance of filament due to
rise in temperature.
254. In a gas detector what it actually measures?

Concentration in ppm.

255. Define 100 mesh screen or sieve:

It means a screen having 100 openings

256. How velocity measured in larger pipe?

For velocity measurement in a large diameter pipe, the device used is a Pilot Tube.

257. Name three metal impurities present in Crude oil?

Ni, V, Fe

258. During cloud point determination the temp. Is measured when the
sample turns hazy / cloudy. Why the sample turns cloudy at lower temperature?

At lower temperature the microcrystalline wax crystalline structure starts forming

inside the sample so the sample turns cloudy

259. Why furnace drying is important before it is commissioned for the

first time?

Furnace with new refractory contains moisture which may get

vaporized fast and cause the refractory to collapse if heated rapidly.

260. Does a cooling tower face fire hazard?

Yes particularly when hydrocarbon from the coolers leak into water (where H/C
pressure is higher than CW)

261. What is back flushing?

CW side stream filter may become choke over a period, to remove

the debris, the water flow is reversed which cleans up the dirt/debris.

262. What is spiking?

Term spiking used to represent mixing of a fluid with main process fluid. The flow
of the mixed fluid is generally lower than the main process fluid.
263. What is the difference in lower heating value and higher heating
value (LHV, HHV)?

In lower heating value, conversion of hydrogen into water vapor and heat absorbed
for its vaporization are considered whereas in HHV this heat absorption is not
considered

264. What is the difference between alloy and amalgam?

Mixing of mercury with a metal or plastic mixing of any two

substances is called amalgam. Alloy consists of any two metals

265. What is unit for measurement of corrosion rate?

Mil/year. 1 mil is thousandth of an inch

It is a measure of thickness for thin sheets from 0.5 mm to 7.0 mm.

266. What will happen to fouling rate of a heat exchanger if the flow is
reduced?

Fouling rate will increase.

267. What happens to energy efficiency when a plant is operated at

reduced throughput?

Energy consumed per ton of feed processed goes up if the plant is

operated at lower than designed throughput.

268. What happens to heat transfer rate if superheated steam is used

instead of saturated steam?

Heat transfer rate will go down since coefficient for condensation is much higher
than convective heat transfer coefficient

269. Crude also contains lighter fractions like LPG, however vapor
pressure of crude is much lower than LPG why?

The fraction of high vapor pressure components in crude is very less

thus following Roult's law and Dalton's law a low vapor pressure of
crude.

270. Why HO lined up slowly to stripper while start up?

 While starting up of stripper, the HO flow is increased slowly; the overhead
pressure shoots up as lighter ends begin to lift. To avoid thermal shock of
equipment due sudden heat up.

271. Which is safer and why LPG stored under pressure or LPG stored
under cryogenic condition?

Under cryogenic condition.

Any leakage that may occur will cause slower evaporation and vapor
cloud generation

272. What hazards exist when a sour water handling equipment is opened
for maintenance?

H2S - toxic gas and iron sulfide which may catch fire when it comes in contact with
oxygen.

273. What is foaming?

Foaming is the result of which scientific phenomena

Reduction in surface tension due to process conditions or due to presence of

foreign material in process fluids.

274. While preparing to hand over a control valve to maintenance it is

isolated, depressurized and drained. Whether the control valve should be in
open or closed position after isolation?

It should remain open so that complete depressurization and draining can

take place.

275. How will you prevent a leaking hot hydrocarbon vapor from catching
fire until it has been isolated and depressurized?

Dilute with steam so that explosive mixture does not form.

276. What are the design criteria of dyke / bund wall?

Dyke wall is design to occupy 1.5 times of biggest tank volume of liquid can be
held within the dyke.
277. What risk is involved in operating fuel oil coolers at a lower
throughput?

A lower throughput means lower pressure inside the cooler, any leak in the tube may
result in water entering the fuel oil stream which may be dangerous if fuel oil is stored
above 100 oC.

278. What is the purpose of Hot well?

Barometric seal

279. Why does a pump draw maximum amperage immediately upon

starting?

In order to bring the stationary equipment into rotating state, initial

torque is very high. However once rotation has been established, it
takes lesser energy to keep it rotating due to available inertia.

280. What does viscosity index indicate about the lube oil?

It indicates the change in viscosity with temperature. For lube oils it is desirable that
viscosity index does not vary much as the oil gets heated up.

281. What is windbreaker? Where will you find it?

A helically welded metal strip on the furnace stacks to deflect wind and reduce
wind load.

282. How much is the pressure in DCP extinguisher when not in use?

Atmospheric pressure. The cylinder gets pressurized when the CO2

cartridge inside is broken by pressing by pressing the lever at the
top of extinguisher.

283. At what temperature, Reid Vapor Pressure is measured?

100 oF or 38 oC

284. What is the difference between adsorption and absorption?

Adsorption is generally on solid surface, absorption can be in liquid also.

285. How many liters of vapor will form from 1 litre of LPG in
atmosphere?

Approximately 270 times.

286. What should be the hydro test pressure in terms of design pressure?

Usually 1.5 times the design pressure.

287. What is water hammering? How is it prevented?

When flow in liquid lines is suddenly stopped due to quick closing of

valve, the kinetic energy converts into pressure energy, which
causes the water hammer. This can damage the line.

288. PONA -arrange them in descending order for crudes. (Paraffins,

Olefins, Naphthenes and Aromatics)

Paraffins, Napthenes, Aromatics, Olefins

289. Why counter weight is provided at the stack damper?

In case of failure of rope, failure of instrument air, the damper should

open.

290. Give three reasons which cause poor vacuum (for steam jet ejector
system)

Leakage, Steam quality, high pr, low pr, condenser fouling, CW temp
high, barometric seal legs plugged, ejector nozzle worn out.

291. Above what temperature the sulfur compounds in crude decompose

into H2S?

230 oC (450 oF)

292. In case level indication in DCS fails how will you find out the level?

Physical checking in level gauge glass.

293. What is the basic difference between chemistry of hydro cracking

and catalytic reforming?

In catalytic reforming, napthenes are converted to high-octane aromatics while

in hydro cracking aromatics are converted into napthenes
294. What will be the significant effect due to reduction in column
pressure for same product yield?

Reduction in heater duty

295. If the gas burner flame is blue what will happen to its color if excess
air is there and when air is deficient?

1. Yellow
2. Blue white

296. What will be effect on burner performance if fuel oil temperature is

lower than design?

Higher viscosity, poor atomization, oil spillage, flames smoky, CO

content will increase due to improper combustion, flue gas smoky,
and clinker formation on burner tip.

297. What will be the effect of very high atomizing steam on flame
pattern?

1. Flame lift off

2. Fire blow out.

298. What will happen to flame pattern if burner tip is partially plugged or
worn out?

Irregular flame pattern

299. What is the maximum allowable propane content in LPG?

50%

300. What is the smoke point of kerosene?

+25mm

301. Which hydrocarbon is responsible for low smoke point of kerosene?

Aromatics.

302. What is difference between coalscer and demister?

Demister - For gas-liquid service, Coalescer - liquid-liquid

303. What is the difference between Stripping and Rectifying?

In Stripping, liquid flow rate is higher than the vapor flow whereas in rectification
vapor flow is higher than liquid flow.

304. What is side stripper?

The liquid draw from a selected tray out of the main column into a
small subsidiary column called a “side stripper” and allows it to flow down through
several bubble trays.

305. What is the difference between pump around and pump back?

In pump around the liquid drawn is cooled and sent above the draw off tray whereas
in pump back the cooled liquid is sent below the draw off tray.

306. At what temp deg C is equal to deg F?

(-40)

307. How corrosion minimized by painting?

If unprotected the corrosion rate is 1mm per year. If the same surface is painted then
the corrosion rate will be 0.0001mm

308. If a metal object weighs 5 kg in air and 4 kg when submerged in

water - what will be its specific gravity?

309. Aniline Point of Diesel is a measure of it’s

Aromatic Content.

310. If position of a process vessel is changed from horizontal to vertical,

will it affect behavior of its level controller?

Yes, for most of the vessels vertical cross section area will be
smaller than horizontal cross sectional area. This will cause
difference in % level change for same amount of withdrawal from vessel.
311. What do we mean by noise with respect to instrumentation and
control?

An unwanted component of signal or variable. Unit of noise can be same as output

or percentage of output span.

312. What is the design ratio of fuel oil supply and return flow and why?

2:1 so that certain return flow is always there in the header - to avoid
congealing of fuel oil in the line.

313. What property of fluid is required if magnetic flow meter is to be

used for flow measurement?

Fluid should have conductivity.

314. What can be reasons of flare puffing?

Knock out Drum full.

Very high steam rate.

315. What is intrinsically safe equipment?

Equipment or wiring which is incapable of releasing sufficient

electrical or thermal energy under either abnormal or normal
conditions to cause ignition of a specific hazardous atmospheric mixture in its
most easily ignited concentration

316. What is static velocity of liquids in pipes?

Velocity above which static charge is likely to develop. For non conductive
petroleum products it is 6 um/s and for conductive petroleum products like
ATF it is 3 um/s

317. What is the correlation between Pressure and Flow rate of liquid?

P is proportional to Q2

318. In a mercury manometer, if one end is open to atmosphere and other

end absolute vacuum is created, what will be the height of mercury column (the
difference)?

760mm
319. What is the difference between TBP and ASTM distillation?

TBP is carried out in an apparatus having large no of stages with

high reflux to distillate ratio so that the temperature at any point in
temperature-volumetric yield curve represents the true boiling point.

ASTM, which also stands for American society for testing materials, is done without
any reflux or trays in the apparatus. ASTM is faster and more commonly done.

320. What is azeotropic mixture?

When two different liquids at certain composition exhibit a property in which,

evaporation results same composition vapor as the liquid, it is azeotropic mixture.
Due to this property, separation through simple distillation may not be possible.

321. What is the correlation between Kinematics viscosity and absolute

viscosity?

Vis (centistokes) = Vis (centi poise)/density gm/cc

322. How do you define specific gravity of gases?

Ratio of molecular wt of gas to air or ratio of density of gas to air.

323. In which range will be Reynolds’s no for turbulent flow

Above 4000

324. In which range will be Reynolds’s no for laminar flow

Below 2000

325. In a glass tube, water surface is concave while mercury surface will
be convex, why is it so?

Cohesive forces of water are weaker as compared to adhesive forces

with glass, this causes the concave shape, the reverse happens in
case of mercury.

326. What is the boiling point of propane at atmospheric pressure?

-42O C
327. Why an NRV is provided at the upstream of pump discharge valve,
not at the downstream of the same?

To avoid damage of NRV flapper due to back up flow during pump stopping.

328. In a fired heater, heat transfer from burning fuel to the moving fluid
inside the tube takes place by conduction/convection or radiation?

All three- from flame to the metal tube through radiation and
convection (in radiation and convection sections of heater), and from tube metal wall
through conduction.

329. Select the correct answer: Purpose of heat tracers is

A) To supplement the heat lost by process fluid to atmosphere

B) To heat up the process fluid.

330. What is the unit of specific heat?

K cal/kg (degC) or Btu / lb (degF)

331. What is the definition of specific heat?

Heat required to raise the temperature of one unit mass of fluid by 1 degree.

332. What is the unit of Reynolds’s number?

None

333. What is the difference between a relief valve and safety valve?

The valve opens in proportion to increase in pressure over the

opening pressure and it is primarily used for liquid service

Safety valve is characterized by rapid full opening or pop up action. It is used for
gas, vapor and steam.

334. What do we mean by 1 ton capacity of an A/C?

A ton of refrigeration is defined as heat absorption at the rate of

12,660 kJ/hr. alternatively, it corresponds to the rate of heat removal required to
freeze 1 Ton of water, initially at deg C
335. We have 1/2 liter water at 100-deg c and 1/2 liter at ambient temp.
In case A we mix both and keep it for one hr. In case B we keep them separately and
mix after one hr. Which case the temp of mixture will be higher?

Case A since heat transfer rate from mixture will come down due to low delta T
between mixture and the ambient. In case B, heat loss to atmosphere will be higher
due to higher del T

336. Which is more energy efficient

1) Heating 1litre water from 0 to 50 OC on open flame

2) Heating 1/2 liter water to 100 OC on open flame and then mixing it with 1/2 liter
water at 0 OC? And why?

1) Heating 1-liter water to 50 deg C since rate of heat transfer comes down as the
delta T decreases. As the temperature of water raises delta T will come down.

337. Boiled water seems hotter than boiled tea why?

Water has higher specific heat.

338. Why we are purging the heater before igniting the burner?

To avoid explosion due to combustible gases present in the heater.

339. What is the reflux ratio of a distillation column at total reflux?

Infinity

340. Name the flow meter, which uses area to measure the flow.

Rota meter

341. What is the unit of light intensity?

Lux

342. How a pump will behave with two liquids having different specific
gravity?

Differential head will remain same but discharge pressure and load will vary.
343. What is Oxygen scavenger?

Hydrazine to remove oxygen from BFW.

344. What are the problems caused by impurities of BFW?

Scaling
Corrosion
Foaming and Priming (formation of droplets)
Carryover in the steam (of volatile minerals)

345. What are the important parameters of BFW?

pH
Hardness
Dissolved Oxygen and carbon dioxide concentration Silicates
Dissolved solids
Suspended solids
Concentration organics

346. What will happen to furnace status if ID fan trips?

Stack damper will open

347. What is lantern ring?

Ring between two stuffing box.

348. Where is dry gas seals used?

Compressors

349. What is tell tale?

Hole provided at the reinforcement of flange.

350. What is the use of test ring?

For shell test.

351. What is test bench?

Place (platform) where PRV, pressure gauge, valves, etc., are tested.
352. What is level troll?

Pipe connected to level tapping for Pipe connected to level tappings for instrument
provision - a float will be there usually inside this troll which will give signal to level
gauge.

353. What is universal coupling? Where it is used? What is its advantage?

It is type of flexible coupling. It is type of a flexible coupling.

354. What is thermo well?

Thermo well is used for installation of thermocouples and their

protection. Direct contact of fluid with the thermocouple is prevented by this.

355. What is tachometer?

RPM measuring device which used to measure the speed of the rotor.

356. What is bourdon tube?

Spiral tube inside the pressure gauge having elliptical cross section.

357. Give two advantages of vertical pumps over horizontal pumps?

Less space required, less alignment required

358. What is demister pad?

A pad made up of fine mesh or metal wool installed before vapor outlet of a
vessel - to trap the entrained liquid.

359. What are different parts of pump where cooling is provided?

Seal, Bearing, Casing, and Pump base leg.

360. Why tube test is performed in exchangers?

To test leakage in floating head.

361. What is rust?

When iron oxide is hydrated, it is known as rust (Fe2O3. XH2O)

362. What is dye penetration (DP) test?

DP test is done to find out surface cracks on a metal. The surface is

first cleaned with a cleaner, and then Dye is applied and wiped out.
Later a developer is sprayed over it, which reveals the cracks, if any.

363. Why overhead lube oil tank is provided in compressor?

Over head LO tank used to cool the screw during power failure until screw stops.

364. What is a vortex breaker?

A metallic plate - is provided above the vessel outlet (especially if it is from the
bottom). This prevents vapor ingress in the pump, which may otherwise take place.
Thus vapor locking is prevented

365. What is an impingement plate?

Impingement plate is provided specially in shell side of heat

exchanger at the inlet side of fluid to prevent fluid from hitting the
tubes directly.

366. For what process conditions do we specify gate valve and globe
valve?

Gate valve is provided in places where valve is required to be kept fully open or
fully closed. Globe valve is provided when a flow
regulation may be required by partial opening of the valve - like centrifugal pump
discharge.

367. In which equipment Extended surface tubes are used?

Fin fan coolers and furnace convection tubes.

368. Where is rupture disk used?

To prevent contact of fluid with PRV and in cases where even minor leakage is not
allowed.

369. Which are the major constituents of stainless steel?

Fe, Cr, Ni
370. What is the difference between welding and brazing?

In welding complete fusion of weld material takes place. In brazing the filler metal
is fused the parent metal does not melt at all.

371. What do we mean by chemical cleaning and where is it required?

Cleaning with chemicals like sulfuric acid to completely remove the loose scales
and dirt from inner surface of pipelines. Chemical
cleaning is done for compressor suction lines usually.

372. What is a torque wrench?

It is a type of wrench, which applies the specified torque on the nut, thus providing
uniform tightening for critical equipment

373. What is the purpose of dampener in positive displacement pump?

To minimize the pressure swing this occurs at each stroke of the

piston. A dampener is provided in discharge/ suction line.

374. Above what vapor pr of a liquid, its storage vessel will be called
pressure vessel?

1.25 kg/cm2 a

375. When are belts or gear boxes used in air coolers?

Belts are usually used in drives up to 50 HP motors. Gearboxes are recommended

for motors in excess of 50 HP.

376. Name the equipment / instrument to measure furnace tube Temp?

Optical Pyrometer

377. What is stiffener ring?

The metallic rings welded on the body of a large column or vessel to prevent it to
take the elliptical shape.

378. What is vessel davit?

It is a rotating arm at the top of a tall column or vessel to lift any heavy gadget.
379. What is the difference in partial draw off and total draw off?

In partial draw off, the draw off from column is taken with help of
level controller, which controls stripper level. As the outgoing flow is varied from
stripper, the LC changes quantity of liquid drawn from
the column

380. While furnace starts up, Only FD fan is started initially? Why ID fan is
not run during initial phase of heating up?

For two reasons:

1. Cold gases are likely to overload ID fan due to

higher density and

2. Cold flue gases are likely to condense in the APH

and associated ducting which will be corrosive.
Flue gases are introduced into APH and ID only
when we are confident.

381. What is the rate of COT?

Increase during start up15 to 20 deg C per hour.

382. What is the purpose of tube skin temperature indication?

Tube skin temperature rise indicates coking or fouling inside the

tube. The TST is not allowed to exceed a specified value - above,
which the metal fatigue will result.

383. While soot blowing operation the furnace damper (stack damper)
should remain open/close? Why?

During soot blowing operation the stack damper is opened so that

soot does not enter the APH and ID fan and foul it.

384. In vacuum distillation unit, heat load is introduced for two important
reasons, which are they?

1. For reducing residence time and minimize

cracking (and coking)

2. For reducing partial pressure of hydrocarbon

vapors for better vaporization
385. Kerosene should have low smoke point or high smoke point?

High smoke point.

386. What is the purpose of flash drum?

To reduce pressure rating of the down stream Equipments.

387. How can I clean the inside of a sour water tank and still maintain a
high degree of safety?

Water washes it well. Purge it with air. Force air flow through the
tank. Blind, lock out and tag the lines in and out of the vessel. Use
protective clothing and external air source for entry and work.
Specific procedures should already be developed by your plant's
HS&E personnel. If not, contact a contractor that specializes in this
sort of work.

388. What action will you take if kerosene is off on smoke point?

Try to reduce heavier ends by reducing the end point and thereby
reducing the aromatics.

389. Viscosity of visbroken residue will be higher or lower than feed

viscosity?

Higher

390. What is the flow regime in Riser & Stripper?

Riser - fast fluidization or pneumatic. Stripper

- bubbling.

391. What is the difference between a dome roof and a low pressure tank?

No difference

392. On what basis the type of the storage tank is selected

Based on the vapor pressure of product at storage temperature.

0 - 0.05 kg/cm2 abs - Cone roof

0.05 - 0.85 Floating roof
0.85 - 1.25 Dome roof
1.25 and above Pressure vessel
393. What do we mean by positive isolation?

Double block valve with facility to insert a blind.

394. What is the purpose of a pig?

Purpose of a pig is to clean the line and mainly for separation of different
products.

395. What is auto sampler and why it is provided?

Purpose of auto sampler is to collect a representative sample from the pipeline. This
is done by intermittent collection of sample at specified interval based on the flow
of fluid. It helps in reducing the time for storing, settling and then sampling from.

396. Name the losses from the Storage tanks?

Breathing, Filling, Leaks, PVRV passing, ERV passing & Boiling.

397. Should we keep roof drain of floating roof tank always open?

Yes

398. How do we fix the safe filling height of petro chemical storage tank?

Based on time taken to reach maximum allowable limit. Normally SFC fixed
below approximately 10% to 15% of the reference height from reference height.

399. Why is the difference between siphon drain and bottom drain?

In bottom drain the drainpipe comes out from below the pad and in
siphon drain the drain line comes from within the tank and exits from shell. Siphon
effect is used to drain off the sludge/water.

400. How the flash loading is prevented while filling the tanker?

By controlling the velocity until the fill pipe is submerged.

401. Tanks storing petroleum products above what flash point may be
provided without flame arrestor according to API 2000

37.78 oC
402. What is cycle of Concentration?

Ratio of dissolved solids in the re circulating water to dissolved solids in the

make up water.

403. What is the purpose of tempered water system?

To supply cooling water at 60 oC for mild cooling of services to avoid condensation of

vapor.

To avoid potential viscosity problems at ambient temperature.

404. What is the boiling point of Oxygen?

Boiling point for Oxygen is (-183) deg C

405. What is the boiling point of Oxygen?

Boiling point for Nitrogen is (-196) deg C

406. Why the Discharge valves of all pump around pumps are kept open?

As these pumps are having auto start facility, Discharge valve

remains open.

407. True or False :

MP steam is used to vaporize LPG in LPG vaporizer?

FALSE: LP Steam.

408. True or False : Fuel gas drum is blanketed with Nitrogen? FALSE

409. What are the four utility lines normally there in a hose station?

LP steam, Plant air, Service Water, Nitrogen

410. The equipment which helps in removal of tracers of solids from a

liquid is known as Clarifier

411. What is the range of TDS value in the potable water?

500-1500 mg/lt. ~ 0.05% to 0.15%

412. How much time a 10 kg DCP extinguisher will take to empty out
completely?

10-11 seconds

413. Air to fuel ratio in a petrol engine is around?

14:01

414. What is carburetor icing?

In cold and humid countries, ice formation takes place at the fuel injection venture
when gasoline takes up heat of evaporation from the surrounding air. These blocks
up the fuel supply.

415. What will the flame pattern if atomizing steam is wet?

Sparking flame (or fire flies)

416. What will happen if lube oil level in gear box is very high?

Too much oil in gearbox will cause lot of churning of oil, this kinetic
energy will convert into heat and thus gearbox will overheat.

417. An LPG cylinder has a ring on top (around its valve), what is it called
and what is the purpose?

Valve protection ring (VP ring)

418. What are some common causes for pressure build up in the vapor
space of a LPG storage vessel?

1. The tank undergoes a heat up or temperature

change.
2. Non-condensable are introduced (Example: N2 for
inerting).
3. Liquid product is pumped into the tank faster the
vapor can achieve equilibrium with its liquid
content.
4. A significantly different composition of LPG is
introduced into the tank (a lighter component).

419. Entrainment will be higher in Bubble cap tray or sieve tray - for same
operating conditions?

Bubble cap
420. What is the purpose of weep hole?

To drain out column internals completely when shut down.

421. What is weep point?

Minimum vapor velocity that will provide a stable tray operation preventing
liquid from passing through holes and bypassing overflow weirs and down
comers.

422. What will be the effect on column delta p when the ceramic packings
are broken in a packed column

Will increase.

423. A tray is fallen in a column. What will be the effect on Delta P?

Will decrease.

True or False:

424. Absolute pressure at the furnace arch is higher than absolute

pressure near stack outlet

True.

425. Draft is absolute pressure inside furnace?

False.

426. MP steam is used in atomizing fuel oil fired furnace?

True.

427. Suction to APH is from below the stack damper?

True.

428. If ID fans trips it will lead to tripping of FD fan.

False (it will cause stack damper to open)

429. For liquids with different specific gravity the differential head of a
pump will remain the same.

True.

430. If pump speed increases, available NPSH increases.

False.

431. If pump speed increases, NPSH required increases.

True.

432. Synchronous type of motor is used where constant speed is required

True.

433. Excess level of lube oil in gear box will cause overheating of gearbox

True.

434. IF the vapor pressures of liquid higher than design what will happen
to pump performance?

Tendency to Cavitate.

435. There are two type of efficiencies related to compressor. Name those
two?

Polytrophic and Adiabatic

436. Why inter stage cooling is provided in multistage compressors

To increase its efficiency

437. Non lubricant type gas compressors have generally more loss
compared to lubricated type compressors.

True.

438. Loading/unloading facility can be provided in a centrifugal

compressor?

False.
439. Caustic solution is to be cooled in a Shell and Tube Exchanger by
fresh water; which of the above service you will keep on shell side?

Fresh water

440. In a heat exchanger, triangular pitch gives higher shell side pressure
drop compare to square pitch.

True.

441. In a heat exchanger, heat transfer rate varies square of area and
LMTD

False.

442. In a vertical Thermo siphon re boiler process fluid is in which side of

exchanger?

Tube side

443. Why BFW requires treatment?

The treatment and conditioning of boiler feed water must satisfy three main
objectives:

Continuous heat exchange

Corrosion protection
Production of high quality steam

444. Why LP steam is used in de-aerator operation?

LP steam to remove dissolved Oxygen in the DMW. LP steam has less saturation
temperatures.

445. Why closed drain system is used?

Recover valuable products and re processing.

Safe drain of hazard material to protect Environmental. Avoid loss
of low volatile material.

446. What is the purpose of floating head?

Purpose of floating head is to avoid buckling of tubes.

447. Distance between two tube walls is called as…clearance.

448. What is the maximum height permissible for tanks?

One and half times of the diameter or 20 m whichever is less

449. LPG spheres can not have separate inlet and outlet nozzle.

True.

450. Approximately what fraction of the nominal capacity of a tank is it's

working capacity?

0.85

451. In case of floating roof tanks the initial velocity of inlet stream is kept
lower at about 1 m/s until the roof becomes buoyant. Why?

To prevent static electricity generation

452. Name any two types of floating roof?

Internal and external

453. How it is float?

By means of Archimedes principle by Pontoon pocket.

454. Is our central control building blast proof?

Yes.

455. What is the voltage of electrical connection for plant distribution in

GFPC Ltd?

33 KV (incomer from SEC)

4.16 KV (used for HT motors)
460 KV (used for LT motors)
240 V (used for lighting, UPS and instrumentation)
456. What is a battery?

The combination of two or more cells is called a battery.

457. What are miniature circuit breakers (MCB)?

Miniature circuit breakers are switches which automatically turn off when current in
a circuit exceeds the safe limit.

458. What are the reasons for excessive currents in electrical circuits?

One reason for excessive currents in the circuit is the direct touching of wires.
Another reason for excessive current is the connection of many devices in a
single socket.

459. Explain the working of fuse in a circuit.

A fuse is a device that checks the currents in a circuit. In buildings, fuses are inserted
in circuits. There is a maximum limit of current which can safely pass through the
circuits. If current exceeds this limit, the wire in the fuse melts and breaks, thus
breaking the circuit. Thus fuse helps to prevent damages to electrical circuits.

460. Why do we get electrical shock more easily when we are wet?

Since ordinary water is ionized due to presence of various salts which increase
its conductivity.

461. What is the capacity of our EMDG?

1.5 KW, 460V

462. What are the emergency supply equipments in GFPC plant?

Instrument air compressor

Closed Cooling water pump
Fire water jockey pump
Raw water pump
DMW pump
Boiler feed water pump
Boiler burner ignition and FD fan Flare
KOD pump
Flush pump
Hydraulic oil pump
Recycle benzene pump
463. What are the three main parts of an EMDG?

Cylinder and piston

Crank shaft
Fuel injectors

464. What is the function of a crankshaft in an EMDG?

Crankshaft changes the reciprocating movement of the piston into rotary Motion.

465. How does the crank shaft get force to turn in an EMDG?

The power stroke provides the force that turns the crankshaft in an
diesel generator.

466. What are four major functions of lubrication system in a diesel

generator?

Lubrication system helps to:

i. Reduces friction
ii. Reduces wear
iii. Cools bearings
iv. Cleans the system

467. Some correlation of operation and electrical:

Operation Electrical

Pressure Voltage
Flow Amperage
Friction Resistance
Line isolation means closed. Line isolation means open

468. What is the device that converts electrical signal to pneumatic signal
for a control valve operation?

I/P (I to P) Converter.
469. What is the name of the thermometer based on the principle that
different metals have different coefficient of thermal expansion?

Bimetallic thermometer.

470. What is the characteristic of an RTD element metal?

RTD element metal has a resistance 100 Ohms at Zero degree C.

471. How does an Annubar measure flow?

An annubar is similar to a pitot tube used to measure the flow of gas
or liquid in a pipe. The biggest difference between an annubar and a
pitot tube is that an annubar takes multiple samples across a section
of a pipe or duct. In this way, the annubar averages the differential
pressures encountered accounting for variations in flow across the
section.

A pitot tube will give a similar reading if the flow of the gas or liquid
in the pipe is reasonably laminar such that the variations in velocity
across any particular section are insignificant when compared to any other section.
472. What is an excess flow valve?

Excess flow valve is a type of valve, which blocks the flow when the flow exceeds
certain limit. It is used where tanker loading for
hydrocarbon is done with flexible hoses. In case a hose snaps, the excess flow valve
prevents a hazardous situation.

473. If position of a process vessel is changed from horizontal to vertical,

will it affect behavior of its level controller?

Yes, for most of the vessels vertical cross section area will be
smaller than horizontal cross sectional area. This will cause
difference in % level change for same amount of withdrawal from vessel.

474. What is the range of electric current to operate control valve from 0%
to 100%

4 to 20 m Amp.
475. Who is the supplier of our DCS? What is the type & version used?

Yokogawa.
Centium CS 3000 version R3.

476. What is the scan rate of DCS?

1 sec

477. What is the nature of current coming from UPS?

AC (Alternating Current)

478. What are the four process variables?

Temperature
Pressure
Flow and
Level

479. What are the major valve actuators?

Solenoid

Hydraulic

Pneumatic

Motor operated

480. What is split range controller?

In split range control, one process parameter causes two (or more) control valves to
operate at predefined range of the output.

481. What is level?

Level is a measure of how much liquid is contained in a tank or Vessel.

482. What is flow rate?

It is a measure of the amount of fluid that moves past a point in a certain time.
483. Why instrument air is used to operate control valve?

Instrument air is dry, dust free and oil free.

484. Why do we monitor the dew point of instrument air system?

Instrument air supply is continuously monitored by meter to check the required dew
point reading to avoid condensation and ensure high quality dry air supply. (-40oC)

Select the answer:

485. DCS stands for:

Direct Control System

Digital Control System
Distributed Control System
None of the above

486. In a plant, it is important to maintain __________ at their desired

values.

Pressures
Temperatures
Compositions
All the above

487. A thermocouple used to measure the temperature is known as the:

Sensor
Controller
Transformer
Indicator

488. The instrument used to transfer the sensed signal to the controller is
known as the:

Indicator
Analyzer
Transmitter
Sensor
489. What is meant by PRD?

Primary Reverse Device.

Primary Reverse Direct.
Primary Direct Mode.

490. The error is defined as:

SP - OP
PV - MV
SP - PV
MV - OP

491. A control system is said to be open loop when the controller is in:

Automatic mode
Manual mode
Cascade mode
PRD mode

492. A control system is said to be closed loop when the controller is in:

Automatic mode
Manual mode
Either a or b

493. In an open loop control system, the error does not affect the
controller output.

True
False

494. In an open loop control system, a set point change does not affect
the controller output.

True
False

495. What is a cascade control?

Two controllers act on the same manipulated variable

simultaneously.

One controller's output is fed to the other controller as a set point.

There are two controllers, but only one controller is used at a time.
 Either controller can be used by switching depending on the process condition.

None of the above.

496. In a cascade control, the controller which provides the set point is:

The father controller

The master controller
The supreme controller
None of the above

497. In a cascade control, the controller which receives the set point from
the other controller is:

The parent controller

The slave controller
The child controller
None of the above

498. In a cascade control, the out put of primary controller used by

secondary controller as Set point, only when the secondary controller is in:

Automatic mode
Manual mode
Cascade mode
PRD

499. In a cascade control, the output of the master controller can be

manipulated manually.

True
False

500. In a cascade control, the secondary controller can be operated only

in cascade mode and not in automatic or manual modes.

True
False

**