Nirma University Institute of Diploma Studies Chemical Engineering Department

QUESTIONS FOR INDUSTRIAL TRAINING C. P. I. & C. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.
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33. 34. 35. 36. 37. 38.

Which temperature measurement instruments are used in your organization? What is the range of temperature to be measure? What are the problems arise to these equipments? What steps they have to take to eliminate it? What are the various types of instruments used for temperature measurement? How the temperature control is being carried out at your industry? Which type of errors could be arise in temperature control and how it could be eliminate? Which level measurement instruments are used in your organization? Which techniques are used for level measurement in your organization? What are the problems arise to these equipments? What steps they have to take to eliminate it? List the modes of level control you can found at your industry. Which other equipments are used with level controller? Which flow measurement instruments are mounted in your organization? Describe working of each. What are the problems arise to these equipments? What steps they have to take to eliminate it? Which modes of flow control are used in your industries? Which equipments are used to control flow in your industries? Which modes of density measurement are used in your organization? How weight measurement is being carried out at your industry? What are the types of control valves you have found in industries? Discuss different types of valves you have operated in plant, with detail. Name the modes of pressure measurement. Name the modes of pressure control. What problems may occur with different modes of pressure control, why? and how they overcome it? Ways to find out errors in different measurement. Which kind of method they are using for emergency shutdown. Which instruments you can see in industry List manual and automatic control operation part in industry. Which auto control system they are using for plant control? What are the advantages & disadvantages of it? Describe working of that system? How they use to measure concentration or composition of stream. Are they using direct methods or indirect methods to measure Pressure, temperature, Level and compositions? List out all for four parameters. Which type of advance control system they use? Is there any specific instrument to measure physical properties like , , cp ? How they are measure flue gas flow rate, which is discharged to atmosphere? How they control composition of flue gases to atmosphere? Are they required to re-tune the controllers parameters? List out various system where they use feedback control system and feed forward control system Are they required to alter capacity of plant to make product any time? Which type of corrective actions they use to take? Ask control room officers to tell you about complete control of plant.
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Safety Management 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. What is the fire- fighting equipment you have seen during your training? What are the precautions taken for prevention of fire propagation on the plant? Which equipments are used as a supplementary to the relief valve? Have you seen any provision made to ground the static electricity produced in the plant? What are the materials, which can be considered to be flammable? What is their UFL & LFL? What are chemically toxic material you have come across? Give their TLV Which type of safety equipment you have been advised to wear during your plant visit? What care should be taken for the storage of toxic materials and flammable materials? What are the provision be taken during unloading the liquid from tankers to the storage tank, from safety point of view. What care should be taken from the point of view of safety during startup of process after shutdown period? What is the signification of a flag held at the top of chemical plant? Note down the safety slogan you have heard or seen during training at the Industry. What are the special safety devices are used in the plant? What are the safety precautions for maintenance of a reactor or any large vessel? Give statistic of accident at your industry. Which are the fist aids to prevent fire?

Energy Conservation 1. What are the non-conventional sources of energy used at your industry? How they are useful compared to other sources of energy? 2. Find out the various streams of fluids or parts of the process, which you think has a potential for giving out thermal energy. 3. Describe major modification you think to be made in your existing plant to conserve as much as energy is possible? 4. Describe any part of the process utilizing waste heat from some other part of the same process (i.e. any example of waste heat utilization) Cooling tower 1. Which type of the cooling tower is used in your industry? 2. What are the benefits of using this type of cooing tower over other types? 3. What is total cooling load? 4. Up to which temperature range cooling is provided in this cooling tower? 5. What is the r. p. m. of cooling towers fan? 6. What type of liquid distribution device is used in cooling tower? 7. Which material is used as filter in this cooling tower? 8. What is the effect of change in air humidity in cooling tower? 9. How frequently blow down is carried out in cooling tower? 10. On what concept does the cooling tower operate? 11. What is the purpose of adding make- up water to the tower? 12. What maintenance steps are taken for the smooth operation of cooling tower?
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Tray Tower 1. 2. 3. 4. 5. 6. What is the material of construction of tray? Which type of liquid distribution device is used here? How much tray spacing is provided in the tower? Which type of tray arrangement is provided for tray spacing? What is tray arrangement? What are the benefits using this arrangement over the other arrangements? Distillation

1. What are the flow rates of various steam inlet and outlet from the column? 2. Which type of support is used for column? 3. Which type of condenser is used for column? 4. What is the material of construction of shell of the distillation column? 5. What material is used for insulation? 6. What are the temperature conditions for various parts of the cooling tower? 7. Give the type of distillation according to pressure conditions? 8. How many reflux ratios they are maintaining? 9. What is the position of feed inlet? 10. Explain the significance of relative volatility: 11. Under which conditions the vacuum distillation and steam distillation used? 12. What is the effect of temperature and pressure on distillation operation? RE & T 1. 2. 3. 4. 5. 6. 7. 8. Write down chemical reactions involved in your industry? What type of reaction involved in your industry? Write various type of catalyst used in your industry? Type of reaction single/multiple? If it is multiple reactions then write the reaction. How many no. of nozzles are used in reactor? What is the various type of feeding arrangement to the reactor? Weather the reaction involved in mfg. Process is constant volume or variable volume reaction? 9. How cooling & heating carried out in the reactor? 10. What are the various types of reactors are used in industry? 11. Type of the reactor: 12. What are the various types of heating & cooling arrangements available in you industry? 13. What is the material of construction of the reactor? 14. What is the conservation of main reactor? 15. How liquefaction of gases carried out in the industry? 16. List out the various units of the pressure used in the industry? 17. What are the various types of valves used in the industry? 18. How the valves are operated? 19. What are the various type of oil used in your industry? 20. Is there any check valve used in your industry? Give the name of the valve. 21. List out various types of pumps used in your industry? 22. How the valves are operated? 23. List out various parts of the various pumps. 24. List out suction pressure & discharge pressure of the different pumps 25. What is the material of the construction of the pump based on the operating condition of the pump? 26. What is the material of the construction of the valve?
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27. In which condition pump does not give discharge? 28. In which condition pump give noisy operation? 29. Is there any stand by pump used in your industry? How many? 30. What is the capacity of pump? 31. How many mechanical operation are used in industry, list out them. 32. How the raw materials are charged to the reactor? 33. How the products are transported to the storage? 34. Indicate type of storage vessel. 35. How will they avoid cavitation in the industry? 36. What are the various types of agitation equipments used in the industry? 37. What is the material of construction of agitation equipments? 38. List out various unit operations & various unit processes used in the industry? 39. Which type of valve now a day generally used in the industry for better control? 40. How corrosion problem is avoided in the industry? 41. What are the various flow measuring device used in the industry? 42. What are the various type of the heat exchanger used in the industry? 43. What is the material of construction of shell? 44. What is the material of construction of tube? 45. How many no. of tubes are in the heat exchanger? 46. How the tubes are arranged in your industry? 47. Which is the service stream used for heating/cooling in the heat exchanger? 48. What is steam trap? Where is it used? What are types you have seen? 49. What is the capacity & economy of the evaporator? 50. What are the various types of evaporators are used in the industry? 51. How the scaling is found out in the heat exchanger? 52. How the scale is removed? 53. What are the various type of heating media used in the evaporator? 54. What are the range of cooling & heating of heat exchanger? 55. How many no. of equipments are in which heat transfer takes place due to radiation? 56. Which type of boiler is used in you industry? 57. Which fuel is used in the boiler? 58. What is the steam pressure? 59. What is the capacity of boiler? 60. What are the various types of insulating material used in the industry? 61. List out various types of fitting are used in the industry? 62. What will happen if friction increase in pipe system? 63. What shut down is necessary? 64. List out various types of filters are used in the industry? 65. List out material of construction of filtration equipment based on the operating condition? 66. Name the by product formed during reaction:

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PCWD 1. By which manner the effluent is transferred to E. T. P. 2. Which is the pretreatment is employed? 3. Which is the primary treatment process used after pretreatment & Why? 4. List the secondary treatment processes used? 5. Steps for operating secondary treatment processes. 6. Step for maintenance to the secondary treatment process. 7. Which are the major organic and inorganic wastes present in effluent? 8. What is the B. O. D. & C. O. D. of the effluent leaving the ETP? 9. What is the value of B. O. D. & C. O. D. of the effluent coming the ETP? 10. List the various characteristics of effulent leaving the ETP and compare it with GPCB norms? 11. List the various tests performed on ETP 12. List the instruments, which are in the laboratory for analysis of effluent? 13. What are the sources of water to the plant? 14. What is the capacity of ETP? 15. What is the per day consumption of water by the plant? 16. Which are the routine maintenance problems? 17. How frequently the people from GPCB are visiting the ETP for vigilance? 18. Where is the treated water disposed off? 19. Which are the other methods by which solid sludge can be removed? 20. By which method the solid sludge are disposed off? 21. What is the height of the chimney that is disposing the gaseous emission? 22. How many samples are taken per day? How many at single point? 23. How many NRV are used in the plant? What is the exact location? 24. Which are the major components of all valves? 25. What is the material of construction of pipe & why such a MOC is used compared to other cheaper MOC? 26. Which are the various types of joints done in between the pipefitting? 27. Under what conditions, the weld joints are used? 28. Where is the flange joint is used & what do you understand by blind flange? 29. Which are various flow measurements devices used? 30. List the different types of temperature measuring devices used? 31. List the different types of pressure measuring devices used? 32. What is the application of pump? 33. Write the formula for calculating BOD? 34. Give full form of BOD and COD 35. What do you mean by D. O.? 36. Name the controller device used in ETP. 37. What do you mean by biological aeration process? 38. Name some Nutrients, which are added in aeration tank. Adsorption- Stripping 1. 2. 3. 4. 5. 6. 7. Which type of contact pattern is used there in tower for gas liquid contact? What are the flow rates of inlet and outlet of stripper Tower? What is the consumption of total steam? What are the temperatures & Pressure condition in various part of tower? If packed bed is used then which type of packing is used there? If tray tower is used then what is tray arrangement? Which type of tray is used in tray tower?
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Packed Bed Towers 1. 3. What is material of construction for packing? 2. What are the arrangements provided for liquid distribution & liquid redistribution? Which type of support is used for packing? Dryer 1. 2. 3. 4. 5. 6. 7. Which type of dryer is used there? What are the moisture content of dried product & feed? How much moisture content is calculated? What is the maximum temperature of heating media? Which type of temperature is used to measure the temperature? What is the benefit of using this type of Dryer over others? Is there any provision to avoid carry over of solid particle with gas? CHEMICAL MFG. INDUSTRY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. List the equipments in the industry Which type of Reactor is there? Inside details of Reactor (lining, stirrer, Capt, Jacket, Cover, bottom, etc. What is the type of reactions carried out in the reactor? What is start-up & shut down procedure for reactor? What care to be taken during operation? What are the mountings on the Reactor (pr. Gauge, temp. gauge etc.) Types of heat exchangers used in plant. Methods of cleaning & de-scaling of each. Types of pumps used in plant, with capacities. Type of cooling tower and its capacity. Type of boiler with its capacity. Is there specific action to be required to take at the time of failure of air, steam, cooling water, hot water or power? What? Methods of filteration. Way of working and trouble shooting of filteration system. Storage tank types in plant. Loading & unloading process for different chemicals and necessary care to be taken.
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18. 19. 20.

Parameters tested in Lab for quality measurement of produce. Discuss any specific problem occur during your stay and the action taken by plant people as corrective measure. Material packing & despatch methodology with various equipments.

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