PC, MO, FFO, MTO1, CRE1, HTO, PED1, PED2, CRE2, MTO2

1. What is NPSHa, NPSHr & cavitation?

2. Methods to estimate fitting losses?
Equivalent length and velocity head
3. What is L/D ratio for a horizontal separator?
2.5-5
4. What is cryogenic conditions? Its main use?
Extreme low T conditions, even <-100 degC. Gases are liquified when T<T c.
5. Explain pump sizing steps
Determine the phase of liquid under given conditions
Using flow rates and velocity, calculate pipe dia
Calculate Re and friction factor (16/Re for laminar, use f vs Re chart for others using e/D
roughness parameter, e=f(MOC))
Calculate pressure drop per unit length
Estimate total linear length of pipe by sketch
Calculate losses due to expansion & contraction & convert to head loss
Estimate pressure drop via orifice, CV, other fittings
Estimate total pressure drop
NPSH calculation
Calculate Power of pump
6. Functioning of Cooling Tower?
7. What are the different types of agitators?
8. Difference between agitator & impeller?
9. How is reactor size decided?
10. Velocity guidelines for liquid, gas & steam in line sizing?
1-3, 15-30, 30-60 m/s
11. What is Schedule number & its significance?
(Safe working pressure)/(Safe working stress)*1000, gives an idea about thickness of pipe. Sh40
has a thinner wall as compared to Sh80.
12. What is BEP of a pump?
13. General guide for NPSH?
Above 3m for capacities upto 100m3/h, 6m above this capacity
14. How to calculate power of a pump?
Power(kW) = (H)*(Q)/(3.6*106) (Pa*m3/h)
15. Which formula is used to calculate pressure drop?
Darcy’s equation and Hagen Poiselle
16. What is pump shut off P, its formula?
17. Downstream of a pump is designed at which P?
18. Explain refrigeration cycle
19. Explain Froude number?
20. Mach number range for different types of flows?
21. Is Control valve an on-off valve?
No, Gate valve is.
22. What is a check valve?
23. P is high at upstream or downstream of orifice plate?
Upstream
24. How to prevent cavitation?
Elevate supply tank
Increase liquid level in tank
Use purging of inert gas
Increase dia of suction pipe to reduce losses
Remove strainer & other unnecessary fittings
Use VFD to change speed of impeller and ultimately KE (very costly)
25. Converging & Diverging angle in venturi meter?
15-20, 5-7 degrees
26. Different outputs of crude distillation?
27. Differences between PFD & P&ID?
28. What is FEED?
29. Role of a process engineer?
30. Meaning of erosion velocity? Conditions at STP & NTP?
31. Different types of pumps used in industry? Significance of performance curves in sizing?
32. Difference between pump & compressor?
33. Explain the effect of specific gravity to calculate head
34. Meaning of relative volatility?
35. How to increase turbulence on shell side & tube side?
36. Meaning of LMTD? Role of baffles in HE & its types?
37. What is Fouling & its units?
38. Define diffusivity, unit of molar flux?
39. What is superficial velocity?
40. For a pure liquid, what is the Bubble point T?
Bubble point = boiling point
41. Meaning of minimum boiling & maximum boiling azeotrope?
42. Which equation helps to find number of trays theoretically?
Fenskey’s equation
43. Different types of distillation?
Fractional (used industrially) (highest feed flow rate, higher degree of purification, side products
withdrawal), Steam, Batch, Flash, Vacuum, Azeotropic, Extractive
44. Difference between partial & total condenser?
If Desired product is liquid – total, If DP is mixture – partial. Separation occurs within partial
condenser & so composition changes and it is considered as a tray. Reboiler – partial, Condenser
– total (in general)
45. From where will you introduce liquid & vapor feed in a column?
Liquid – top, Vapor - bottom
46. Other names of batch distillation?
Simple distillation & Differential distillation
47. Define vapor pressure & Reid vapor pressure
48. Assumptions of McCabe Thiele?
 Constant molal overflow, heat losses are negligible, only latent heat exchange occurs on plates
(liquid & vapor on plate are saturated)
49. Rayleigh’s equation is applicable to which distillation?
Batch distillation with equimolar mixture
50. What are the Flare system components?
51. Types of insulation?
One for heat conservation, another for personnel protection
52. Difference between flow orifice & restriction orifice?
53. Types of strainer? When to use which?
Y type & basket type. When line size > 4 in, use basket type
54. Format of line number?
Line size – Service code – Pipe spec – Line number – Insulation type (50-NA-A1A-10021-IP)
Service code shows the fluid being carried
Pipe spec shows MOC, Pressure rating & C.A
55. Which principle governs working of orifice?
56. Effect of flow rate on head?
57. How to reduce pressure drop around CV?
58. Meaning of liquid & vapor leaving a tray are in equilibrium with that entering the tray?
Liquid & vapor are at same temperature
59. Difference between evaporation & distillation?
Evaporation – one volatile + one non-volatile (salt solution), Distillation - both components
volatile
60. Different ways of obtaining VLE Data? How is it expressed?
Raoult’s law, Experiment, Perry’s Handbook. T-x-y, P-x-y and H-x-y, x-conc. of MVC in liquid phase.
Complete representation of Equilibrium data requires 3-D figure, so we either keep P or T
constant and plot it in 2D.
61. What is the degrees of freedom? What is its formula called?
F=C-P+2. Gibb’s Phase Rule. D.O.F = Number of variables that need to be specified to define a
system in equilibrium. For binary distillation, F=2-2+2=2. So, two variables need to be specified
to define the system completely. Total variables – T,P,x,y. Fix T & P, x & y automatically will be
automatically set (we generally fix intensive variables)
62. D.O.F of water at Triple point?
F=1-3+2=0. Means variables are fixed, we cannot alter them.
63. What is the significance of Relative volatility=1?
No separation possible. Relative Volatility = PAsat/PBsat. A=MVC, B=LVC. So, relative volatility is
only a function of T
64. What is Antoine’s equation? Its use?
lnPsat = A – B/(T+C). Used to calculate boiling points of unknown species in pure form
65. Raoult’s Law for binary system? Its use?
Pt = PA + PB = xAPAsat + xBPBsat. To calculate partial pressure.
66. Effect of pressure on ease of separation?
As P rises, B.P rises, thickness of curve narrows, D.F is not obtained for entire system. Undesired.
As P rises, Alpha reduces, No. of trays increases
67. Significance of minimum & total reflux?
 Minimum reflux – product quality being obtained is already good, R=0, infinite trays required,
total reflux – product quality too bad, no product withdrawn, minimum trays required, used only
as a test run during commissioning of plant, R = infinity
68. If R = minimum Reflux ratio, what is the optimum Reflux ratio?
1.2-1.5R