IIChE Kochi Regional Centre organized CHEM QUIZ 2013, for chemical engineering students across 6 Engineering colleges in Kerala at Government Engineering College, Trichur. Mr. Harinath Viswanathan, BPCL-Kochi Refinery and Alumni of GEC Trichur was the Quiz Master

2. 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 !

4. HEAT
TRANSFER

5. What is the use of baffles in a heat
exchanger?

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

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

8. 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?

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

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

11. How does a thermosyphon reboiler
functions?

12. FLUID
MECHANICS

13. What do you mean by pump
affinity laws?

14. What is a centrifugal pump curve?

16. What are the two NPSH‟s for a
pump and how are they related?

17. Define in simple terms what is
Bernoulli‟s Principle?

18. Role of Inter stage coolers in
multistage compressors?

19. How can you vary the discharge
flow of a centrifugal pump without
controlling it through a control
valve in its discharge line?

20. Define in simple terms what is
Hagen – Poiseuille Equation?

22. MASS
TRANSFER

23. What is the principle behind
“OPEN STEAM” in distillation
columns?

24. Name two mass transfer
operations happening in your
kitchen.

25. What is HETP?

26. FENSKE Equation in
distillation column design?

27. VLE for uniform Vap-liq
equilibrium mixture VLE for ?

28. What is being measured if you
measure actual air temperature +
Humidity?

29. In Mc Cabe – Thiele method of
calculating the number of
theoretical plates, how can you
identify that the column is
operating under TOTAL REFLUX?

30. IDENTIFY
THE
MISTAKE

31. Distillation Column bottoms Kettle type Reboiler

32. Liquid
outlet
Distillation Column bottoms

33. Set Pressure: 8.5kg/cm2g
To Flare
Design Conditions:
Cooler
Lighter Gas Pressure (T/B) – 5.0 / 5.4 kg/cm2g
Temp (T/B) – 110 / 160oC
Top Reflux
Operating Conditions
Feed
Pressure (T/B) – 2.0 / 2.4 kg/cm2g
Temp (T/B) – 75 / 120oC
Reboiler
Bottom
product

34. DIESEL
IN
62oC
40oC
32oC
Cooling
Water
DIESEL
1” dia OUT
Carbon steel
31oC

35. Steam main header
Condensate return

36. Steam main header
Condensate return

37. Bottoms product

39. N2  3 kg/cm2g
Case-1
Disc Pr = 25 kg/cm2g
Q = 150 m3/hr
5 kg/cm2g
Tank-1
5 kg/cm2g P1
Case-2
P2 Disc Pr = 15 kg/cm2g
Q = 100 m3/hr
N2  3 kg/cm2g
P1
5 kg/cm2g H = 10 kg/cm2g
Tank-1 Q = 100 m3/hr
P2
P2
H = 10 kg/cm2g
P1
Q = 50 m3/hr

40. N2  3 kg/cm2g
Case-1
Disc Pr = 15 kg/cm2g
Q = 150 m3/hr
5 kg/cm2g
Tank-1
5 kg/cm2g P1
Case-2
P2 Disc Pr = 25 kg/cm2g
Q = 50 m3/hr
N2  3 kg/cm2g
P1
5 kg/cm2g H = 10 kg/cm2g
Tank-1 Q = 100 m3/hr
P2
P2
H = 10 kg/cm2g
P1
Q = 50 m3/hr

41. H2 Quench
@ 100 deg C P – 28.2 kg
P – 30 kg 20 TPH T – 325 C
Feed T – 350 C
100 TPH
Light Distillates
Rx-1 Product Stripper
Rx-2 Rx-3
Steam
5 TPH
P – 27.2 kg
P – 28.5 kg Heavy Distillates
T – 360 C
T – 320 C P – 24 kg
T – 340 C

42. H2 Quench
@ 100 deg C P – 28.2 kg
P – 30 kg 20 TPH T – 325 C
Feed T – 350 C
100 TPH
Light Distillates
Rx-1 Product Stripper
Rx-2 Rx-3
Steam
5 TPH
P – 27.2 kg
P – 28.5 kg Heavy Distillates
T – 360 C
T – 320 C P – 24 kg
T – 340 C

44. Trouble
Shooting

45. Trouble – 1
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  81.5oC
Boiling Pt of Toluene 
REASONS and SOLUTION.

46. Trouble – 2
A distillation column separating LPG and Naphtha.
Time Top Top Top Bottom O/H vent gas
temperature Pressure reflux temperature flow
oC Kg/cm2g TPH oC Kg/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?

47. Trouble – 3
A distillation column separating Light Naphtha and Heavy Naphtha.
Typical boiling range of Light Nap  60 – 90
and that of Heavy Nap is  90 – 140
The unit was steady and results were OK, then got an instruction at
10:00hrs to reduce the FBP of Lt Nap to 80oC.
The operator reduced the top temperature of the distillation column by
increasing the top reflux, as usual . Then….
Time Top Top Bottom Light Naphtha
temperature reflux temperature boiling range
oC TPH oC Lab 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?

48. Trouble – 4
1st January 2012 DATA OF FIRED HEATER
Fired heat duty 50 MMKCal
Absorbed heat duty 45 MMKcal
Stack temperature 230oC
Heater stack oxygen content 3.5 %
1st January 2013 DATA OF FIRED HEATER
Fired heat duty 50 MMKCal
Absorbed heat duty 40 MMKcal
Stack temperature 253oC
Heater stack oxygen content 5.5 %
Analyze the data given above and tell us what is the problem, if any?

50. Trouble – 5
A pump was used to transfer treated water from tank-01 to Effluent
Treatment plant. Pump details are
NPSHR – 5kg/cm2g
NPSHA – 6 kg/cm2g
Flow – 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
Height of the naphtha treater  15 meters
Naphtha density  700kg/cm3 @40 C
Pumping temperature  40 deg C
Please advice the operating conditions of the treater to ensure that the
pump can be effectively used in the new service.

51. Trouble – 6
The 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?

52. 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 / hr
Pumping temperature  40 deg C
Pumping 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?

53. Rapid fire

54. TRUE / FALSE
IDENTIFY THE VALVE TYPE
DATE OF SIGNIFICANCE
DIMENTIONLESS NUMBER
UNIT
EXPAND
GLOSSARY
STEAM
LOGO OF AN OIL COMPANY
ENERGY / ENVIRONMENT

55. Permanent hardness of water is due to the presence
of sulphates and chlorides of Ca&Mg , T / F
March 22
Number used to characterize
the different flow regimes
Unit of CALORIFIC VALUE

56. Expand -- IRR
Amount of extra metal thickness provided to
a pipe / vessel wall
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

57. THORIUM deposits are largely found in the
coastal region of Kerala – T/F
APRIL – 22nd
Ratio of convective to
conductive HT Coeff..
W/m2K is the unit of
_______

58. Expand -- NPV
A method to remove heat from a section of distillation column
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?

59. LINDE’s and CLAUDE’S process are used to
produce HYDROGEN, T / F
September – 16
Ratio of viscosity to Mass Diffusivity
SI unit of Kinematic Viscosity

60. Expand – PBT
Exterior temperature of a tube in a furnace or a
heater so measured are called
Economic and Energy efficient type of
insulation material used in steam lines
Who is the Union Minister for new
and renewable Energy?

61. Boiling removes temporary hardness of water T / F
National Energy Conservation Day
Ratio of convective MT coefficient
to mass diffusivity
Pascal second is the SI unit of
_________

62. Expand -- FIFO
Vapour at its dew point is
called______
Proper sizing of steam pipelines
helps to minimize _________
The only Green House Gas
produced without any interference
from human beings

63. CLAUS process is used for the
production of Sulphur, T/F
JUNE 5th
Ratio of kinematic viscosity to
thermal diffusivity
Unit of VACUUM

64. Expand – P & ID
Filling the casing of the pumps with the liquid is called _______
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.

65. Raw material for CAPROLACTUM (raw material
for NYLON-6) is Benzene, T / F
Engineers Day
Ratio of buoyancy to viscous
forces acting on a fluid
Unit of Specific Gravity

66. Expand – ROI
Vapour Pressure X mole Fraction =
Equipment where heat of Waste
process gas is used to generate steam
2013 is the UN International year of ______

67. Calcium Carbide is the raw material for the
production of Acetylene T/F
Rajiv Gandhi National
Renewable Energy Day
Grasshof no X Prandtl no =
Unit of Gas Constant ‘R’

68. Expand – ROR
Ratio of Discharge Pressure to Suction Pressure of a
compressor is called _____
Chart relating to Enthalpy, Entropy, temperature and
Pressure of steam is called _______
In the High Courts of Kerala,
Kolkatta, MP & Punjab and
Haryana, special benches
function to take care of
environmental related cases.

69. That‟s all friends…..