2013

1.NO NEGATIVE MARKS

2.ANSWER LEGIBLY & CLEARLY

3.No Mobile Phones, No books…..

4. Its not just your knowledge which is being tested,

but common sense, speed, different thinking, and

discipline.

5.ENJOY THE QUIZ !

1. HEAT TRANSFER2. FLUID MECHANICS3. MASS TRANSFER4. IDENTIFY THE MISTAKE5. TROUBLE SHOOTING6. RAPID FIRE

HEAT TRANSFER

What is the use of baffles in a heat exchanger?

1

In a Furnace, tubes in the convection section are usually provided with studs / fins. Why?

2

What is the main purpose of floating head type tubes in Shell and Tube heat exchanger and where are they typically used?

3

4

What is the name given to a heater if there is an Induced Draft fan as well as a forced draft fan to function the heater?

5

What is the main purpose and principle behind Steam jet ejectors?

6

What do you mean by fouling factor in Shell and Tube Heat Exchanger?

7

How does a thermosyphon reboiler functions?

FLUID MECHANICS

What do you mean by pump affinity laws?

1

What is a centrifugal pump curve?

2

What are the two NPSH’s for a pump and how are they related?

3

4

Define in simple terms what is Bernoulli’s Principle?

5

Role of Inter stage coolers in multistage compressors?

6

How can you vary the discharge flow of a centrifugal pump without

controlling it through a control valve in its discharge line?

7

Define in simple terms what is Hagen – Poiseuille Equation?

MASS TRANSFER

What is the principle behind “OPEN STEAM” in distillation

columns?

1

Name two mass transfer operations happening in your

kitchen.

2

What is HETP?

3

4

FENSKE Equation in distillation column design?

5

VLE for uniform Vap-liq equilibrium mixture VLE for ?

6

What is being measured if you measure actual air temperature +

Humidity?

7

In Mc Cabe – Thiele method of calculating the number of

theoretical plates, how can you identify that the column is

operating under TOTAL REFLUX?

IDENTIFY THE

MISTAKE

Kettle type ReboilerDistillation Column bottoms

Liquid outlet

Distillation Column bottoms

To Flare

Design Conditions:

Pressure (T/B) – 5.0 / 5.4 kg/cm2gTemp (T/B) – 110 / 160oC

Operating Conditions

Pressure (T/B) – 2.0 / 2.4 kg/cm2gTemp (T/B) – 75 / 120oC

Set Pressure: 8.5kg/cm2g

Feed

Cooler

Lighter Gas

Bottom product

Top Reflux

Reboiler

1” diaCarbon steel

DIESEL IN

62oC

DIESEL OUT31oC

Cooling Water

32oC

40oC

Steam main header

Condensate return

Steam main header

Condensate return

Bottoms product

P1

Tank-1

P2

5 kg/cm2g

5 kg/cm2g

Case-1Disc Pr = 25 kg/cm2gQ = 150 m3/hr

N2 3 kg/cm2g

Tank-1

P1

P2

P1 H = 10 kg/cm2gQ = 100 m3/hr

P2 H = 10 kg/cm2gQ = 50 m3/hr

5 kg/cm2g

Case-2Disc Pr = 15 kg/cm2gQ = 100 m3/hr

N2 3 kg/cm2g

P1

Tank-1

P2

5 kg/cm2g

5 kg/cm2g

Case-1Disc Pr = 15 kg/cm2gQ = 150 m3/hr

N2 3 kg/cm2g

Tank-1

P1

P2

P1 H = 10 kg/cm2gQ = 100 m3/hr

P2 H = 10 kg/cm2gQ = 50 m3/hr

5 kg/cm2g

Case-2Disc Pr = 25 kg/cm2gQ = 50 m3/hr

N2 3 kg/cm2g

Rx-1Rx-2 Rx-3

Product Stripper

Feed100 TPH

Steam5 TPH

P – 30 kgT – 350 C

P – 27.2 kgT – 360 C

P – 28.5 kgT – 320 C P – 24 kg

T – 340 C

P – 28.2 kgT – 325 C

H2 Quench@ 100 deg C

20 TPH

Light Distillates

Heavy Distillates

Rx-1Rx-2 Rx-3

Product Stripper

Feed100 TPH

Steam5 TPH

P – 30 kgT – 350 C

P – 27.2 kgT – 360 C

P – 28.5 kgT – 320 C P – 24 kg

T – 340 C

P – 28.2 kgT – 325 C

H2 Quench@ 100 deg C

20 TPH

Light Distillates

Heavy Distillates

Trouble Shooting

A distillation column separating BENZENE & TOLUENE

06:00hrs sample result Toluene content in Benzene was 10ppm

08:00 hrs Toluene content became 100ppm and then at

10:00hrs reported 1.0%

And the maximum allowable toluene in Benzene is 50ppm

Boiling Pt of Benzene 81.5oCBoiling Pt of Toluene

REASONS and SOLUTION.

Trouble – 1

A distillation column separating LPG and Naphtha.

Trouble – 2

Time Top temperatureoC

Top PressureKg/cm2g

Top refluxTPH

Bottom temperatureoC

O/H vent gas flowKg/hr

06:00 75 9 45 150 100

06:03 78 9.8 47 152 110

06:06 80 10.7 52 155 200

06:08 85 12.2 60 162 450

06:10 100 14.5 NIL 175 1000

06:00hrs…all was fine…but in 10 mins….

What probably might have went wrong between 06:00 and 06:03?What is the reason for ‘NIL’ top reflux at 06:10hrs?

A distillation column separating Light Naphtha and Heavy Naphtha.Typical boiling range of Light Nap 60 – 90 and that of Heavy Nap is 90 – 140The unit was steady and results were OK, then got an instruction at 10:00hrs to reduce the FBP of Lt Nap to 80oC.

Trouble – 3

Time Top temperatureoC

Top refluxTPH

Bottom temperatureoC

Light Naphtha boiling rangeLab result

06:00 92 40 150 62 – 91

10:00 92 40 150 62 – 92

14:00 85 48 147 62 – 105

What probably might have went wrong? Operator did the right thing, he reduced the top temperature to reduce FBP of Light Naphtha or was he wrong?

The operator reduced the top temperature of the distillation column by increasing the top reflux, as usual . Then….

Trouble – 4

1st January 2012 DATA OF FIRED HEATERFired heat duty 50 MMKCal

Absorbed heat duty 45 MMKcal

Stack temperature 230oC

Heater stack oxygen content 3.5 %

Fired heat duty 50 MMKCal

Absorbed heat duty 40 MMKcal

Stack temperature 253oC

Heater stack oxygen content 5.5 %

1st January 2013 DATA OF FIRED HEATER

Analyze the data given above and tell us what is the problem, if any?

Trouble – 5

A pump was used to transfer treated water from tank-01 to Effluent Treatment plant. Pump details are

NPSHR – 5kg/cm2gNPSHA – 6 kg/cm2gFlow – 100 m3 / hr

Tank-01 was decommissioned by July 2012 and the pump was redundant. Later during Dec 2012, the company set up a small unit for treating impure Naphtha and the company decided to use this pump as part of cost reduction measures. New conditions are

Please advice the operating conditions of the treater to ensure that the pump can be effectively used in the new service.

Height of the naphtha treater 15 metersNaphtha density 700kg/cm3 @40 C Pumping temperature 40 deg C

Trouble – 6The unit was shut down due to power failure at 09:15 am today.

• Operators and other officials are working hard to start the unit and bring it back on line.

• The heater had cooled down and reached a furnace outlet temperature of 200oC.

• As part of their start up activities, operators ignited the fired heater at 09:38 am and started to increase the furnace outlet temperature to the required temperature of 400oC @ 40oC / hour.

• Initially the operators encountered no trouble with the furnace. • But by around 12:30 pm when they were trying to increase the

temperature by increasing the fuel flow, a sudden back fire occurred from the furnace, injuring two operators who were below the furnace.

What all may be the reason for the incident and how it can be avoided?

Trouble – 7

A pump was used to feed an old Crude Oil to the distillation Unit. Details of the pump are

Minimum / Normal / Maximum Flow 600/700/750 m3 / hrPumping temperature 40 deg CPumping Density 800 kg/m3

The company decided to cut down the charge rate of the CDU from 560 TPH to 300 TPH as the unit efficiency was very low. Company wanted to use the same charge pump for the reconditioned unit also.

Can the company use the same charge pump?Do they require any modification in the pump?If so, what cost effective modifications are possible so that the same pump can be used for a revised charge rate?

Rapid fire

TRUE / FALSE

IDENTIFY THE VALVE TYPE

DATE OF SIGNIFICANCE

DIMENTIONLESS NUMBER

EXPAND

GLOSSARY

ENERGY / ENVIRONMENT

STEAM

LOGO OF AN OIL COMPANY

UNIT

March 22

Number used to characterize the different flow regimes

Unit of CALORIFIC VALUE

Permanent hardness of water is due to the presence of sulphates and chlorides of Ca&Mg , T / F

1

Amount of extra metal thickness provided to a pipe / vessel wall

Expand -- IRR

Indirect steam heating makes use of ____ heat

_____ is the only form of energy which derives directly from the relative motion of the Earth – Moon system

APRIL – 22nd

Ratio of convective to conductive HT Coeff..

W/m2K is the unit of _______

THORIUM deposits are largely found in the coastal region of Kerala – T/F

2

A method to remove heat from a section of distillation column

Expand -- NPV

Steam trap that operates based on the difference in temperature between steam and condensate is _____________ trap

Which is the Nodal agency for

coordinating the energy conservation

activities under the EC act of India?

September – 16

Ratio of viscosity to Mass Diffusivity

SI unit of Kinematic Viscosity

LINDE’s and CLAUDE’S process are used to produce HYDROGEN, T / F

3

Exterior temperature of a tube in a furnace or a heater so measured are called

Expand – PBT

Economic and Energy efficient type of insulation material used in steam lines

Who is the Union Minister for new

and renewable Energy?

National Energy Conservation Day

Ratio of convective MT coefficient to mass diffusivity

Pascal second is the SI unit of _________

Boiling removes temporary hardness of water T / F

4

Vapour at its dew point is called______

Expand -- FIFO

Proper sizing of steam pipelines helps to minimize _________

The only Green House Gas produced without any interference from human beings

JUNE 5th

Ratio of kinematic viscosity to thermal diffusivity

CLAUS process is used for the production of Sulphur, T/F

5

Unit of VACUUM

Filling the casing of the pumps with the liquid is called _______

Expand – P & ID

Water that has been softened / deaerated for use in boilers

Started in Mexico in 1943 by famous environmentalist Norman Borlaug which changed the face of the world.

Engineers Day

Ratio of buoyancy to viscous forces acting on a fluid

Raw material for CAPROLACTUM (raw material for NYLON-6) is Benzene, T / F

6

Unit of Specific Gravity

Equipment where heat of Waste process gas is used to generate steam

Vapour Pressure X mole Fraction =

2013 is the UN International year of ______

Expand – ROI

Rajiv Gandhi National Renewable Energy Day

Grasshof no X Prandtl no =

Calcium Carbide is the raw material for the production of Acetylene T/F

7

Unit of Gas Constant ‘R’

Chart relating to Enthalpy, Entropy, temperature and Pressure of steam is called _______

Ratio of Discharge Pressure to Suction Pressure of a compressor is called _____

Expand – ROR

In the High Courts of Kerala, Kolkatta, MP & Punjab and Haryana, special benches function to take care of environmental related cases.

That’s all friends…..