Hydraulics

1. What is the equation for pressure drop in fluid flow through pipe when flow is laminar? (Huiguen Poiuselle Equation) 2. What is the corresponding equation for turbulent flow? (Darcy Wiesbach Equation) 3. You have a 2 pipe line, 2 KM long connecting two points. For a particular flow of water, we experience 2 Kg/cm2 pressure drop. If the diameter of the pipeline is changed to 4, what will happen to the pressure drop? (New Delta P = (1/32)* Original Delta P) 4. The pressure drop equations for fluid flow through pipeline consider only straight length of pipe. How do we handle pipe fittings? (By taking into account Equivalent Length which is the straight length of the same pipeline required to produce the same pressure drop as that of the original pipeline with the fittings) 5. In what service are globe valves used? Where do we use gate valves? (Globe Valves-Control, Gate Valves- On-Off Service) 6. ???How can we explain the increase in flow through a water tap in the toilet in a household ? 7. ???What is water hammer? How severe is its impact ? 8. What is the Schedule number of a pipe ? ???Where do we use higher schedule pipes and fittings ? (Schedule Number is a indication of the thickness of the pipe) 9. ???What is the function of a control valve ? What is the Control valve Cv ? (Control Valve controls the flow of a fluid through a pipeline. Control Valve coefficient is around 0.66) 10. What is a check valve ? Name a service in your house where a check valve is used ? (Checkvalve are non-return valves which permits flow only in one direction, The valve in the pipeline before the suction of a pump is a check-valve) 11. What is the difference between head and pressure ( explain at a pump discharge ) (H = P

/ density, at the discharge of a particular pump, the head remains the same for pumping all liquids, whereas the pressure and hence the power requirement increases as the density increases) 12. ???How does a centrifugal pump work?

13. What is the difference between a centrifugal pump and a Positive displacement pump? (A positive displacement pump will surely give an output for each stroke, whereas a centrifugal pump need not necessarily give a discharge at all times) 14. ???How is a centrifugal pump started? How about PD pump? (First, keep the discharge and suction valve closed, then prime the pump; fill it with the liquid to be pumped, then slowly open the suction valve and then finally open the discharge valve) 15. What is the NPSH of a pump? (Net Positive Suction Head- Pressure above the liquid in the tank + distance between the liquid level and the pumps suction vapor pressure of the liquid frictional losses along the pipe elevation of the suction nozzle above the ground-level) 16. You have been told that the pump has got an NPSH problem. How can you improve NPSH? (By increasing the diameter of the pipeline connecting the column and the suction of the pump , thus reducing the friction losses or by raising the distance between the pump suction and the liquid level etc) 17. What are the 2 NPSHs for a pump? What is the relation? (NPSHA > NPSHR) 18. Calculate the maximum lift possible in a centrifugal pump from the NPSH equation. (10.33m) 19. ???In the lab test for a centrifugal pump, why is the suction pressure always ve? (Because the pressure gauge at the suction is a vacuum gauge, hence the max reading it shows is 0) 20. ???In the above case, the suction is negative even if the discharge is blocked. Why? 21. What are the affinity laws for a centrifugal pump? (Q prop D,N, H prop D2,N2, P prop D3,N3) 22. Why centrifugal pumps sometime require priming? (Owing to leakage from the pump through the suction nozzle, when it is not running, the pump casing gets filled with air; hence the pump will not have the sufficient......???......to pump the liquid) 23. I have connected a pressure gauge and a barometer in the discharge of a centrifugal pump. Predict the readings in the two meters when the pump fluid is changed from water to glycerin/mercury? (P = H*Density; Pressure becomes 2.5 / 13.6 times the original pressure) 24. ???Why are variable frequency drives used for motors connected to centrifugal pumps? 25. ???Why are submersible pumps used in steam condenser services? What is the principle? 26. ???What is Bernoullis equation? (Pressure Head + Static Head + Velocity Head remains conserved)

27. Name a few applications of Bernoullis equation in your household (The gas burner, the hose-pipe used for watering in the garden, paint sprayer) 28. ???What is the principle of operation of steam ejector? (Bernoullis equation- The Velocity head is converted into pressure head in the diffuser section, and the velocity head is recovered in the converging section) 29. ???Why barometric legs are provided for multi-stage ejectors? 30. Why a cricket ball swings? Why it does not happen in the case of a golf ball? (OUT OF SYLLABUS)-MUST BE BOUNDARY LAYER SEPARATION

Heat Transfer

1. What is the equation for heat transfer by radiation? (Steffann Boltzmann Equation=> E = sigma * (delta T)4) 2. ???What is that for convection? (Dittus-Boetus equation, Nu = Re 0.8 * Pr (2/3) ) 3. What is LMTD? (Logarithmic Mean Temperature Difference Logarithmic is taken as the temperature difference between the fluids varies throughout the HX) 4. Why is correction factor provided for LMTD? (To account for the deviation from pure countercurrent flow for which the other parameters have been designed) 5. Why is the correction factor for double pipe exchangers always 1.0? (Because in doublepipe, always pure counter-current flow is achieved) 6. What are the guidelines of shell side/tubeside allocation of fluids? (Corrosive fluids, vapors with non-condensibles, viscous fluids etc are passed through the pipes while vapors are passed through the shell side) 7. Why are floating head exchangers used? (To accommodate thermal expansion of the tubes when a large temperature difference exists)

8. Where is U-tube bundled exchanger used? Name a service where U-tube is not recommended. (Used when high temperature differential exists, When the fluid contains a lot of settle able particulates, a U-Tube is not recommended as it is difficult for cleaning) 9. What is the purpose of using multiple shell exchangers? (When there is a temperature cross occurring in a HX, then 2 smaller HX can be used. Hence the area of flow through a single HX is reduced, and hence the velocity increases, and hence the rate of Heat Transfer also increases. Also, the number of tubes to be used in a single HX is also reduced.) 10. What is the use of baffles in an exchanger? (To cause a change in the flow pattern of the shell side fluid parallel or cross flow to the tube bundle, and to support the tubes)-they are basically segmented circular metal plates having holes to accommodate the tubes 11. Why are tie rods and spacers provided?(Tie-rods are used to hold the baffles in position, and spacers are tube-sections inserted over the tie-rods to maintain suitable spacing between the baffles) 12. What are the guidelines for choosing the tube layout for exchanger bundles? For fouling devices or fouling liquids passing through the shell side, usually, a square pitch is preferred as it will easy to clean, whereas for clean services, a triangular pitch or an inverted square pitch is used) 13. What is Dittus-Boetus equation? (Nu = Re 0.8 * Pr (2/3) ) 14. A heat exchanger with a design U of 200 provides only 120 when the flow through the exchanger is reduced to 70% of the original value. Is the exchanger performing well? (No it is not, because h prop Q 0.8; hence when Q1= 0.7 Q, then h1 = 0.70.8Q which is 0.75 Q) or or or (U prop Q hence U1 prop 0.7 Q, but U1 = 0.6 U, hence not working properly)

15. What is exchanger fouling? How is it caused? (When the fluid contains settlable solids, they deposit on the heat exchange surfaces and hence reduce the area available for heat-transfer, this is known as fouling) 16. ???What is the difference between heat exchanger design and rating? (In design, we have the freedom to choose the physical parameters and do the necessary calculations for making a HX, whereas Rating means to check wether an existing HX is suitable for a particular process requirement; here all the physical parameters like the diameter, thickness etc will be mentioned, we just need to necessary do the calculations)

17. What is TEMA? What is the significance of TEMA classification of exchangers? (Tubular Exchangers Manufacturers Association, TEMA classifies a HX body into 3 major parts; the front end, shell and the rear end; for eg A represents channel with a fixed tube-sheet, K represents a kettle type reboiler, U represents a U-tube bundle etc) 18. Why are air preheaters provided in furnaces? (To reduce the fuel consumption. Preheating the combustion air by flue gases makes the process more economic as well as a lesser amount \;

Latent- hidden Light key and Heavy key, specific steam, calorie, specific heat, viscosity and density of steam, water and air

1. RECYCLE: - Recycle means a part of the output stream from a process is send back to the input. It is done so as to enhance the conversion, as a single pass does not result in the complete conversion of a reactant into a product. (Ammonia Synthesis) 2. PURGE: - Purge means a part of the output stream from a reactor is taken off so as to prevent the accumulation of contaminants. 3. API = (141.5 / Sp.Gravity) 131.5 4. Adiabatic Flame Temperature:???Temperature at the flame when a fuel is burnt. No temperature loss to the surroundings takes place OR??? the temperature attained by the flame when the net heat of combustion is required to raise the temperature of the reactants and products. 5. Excess Air: Air in excess than stoichiometric quantities that is required for complete combustion is known as excess air. 6. Wet Bulb Temperature: 7. Wet Bulb Approach:

8. Live zero and Dead zero: A pressure gauge which shows a reading from 3psi to 15psi is taken as an example. When there is no flow through the pipe, the gauge indicates 3psi. This is known as live zero, whereas when the gauge is not functioning properly, then it shows the reading 0 which is known as dead zero. Hence, we can differentiate between the 2 situations when there is no flow and when the instrument is not working. The same is the case with the range from 4mA to 20 mA. 9. In an industry, usually orifices are used due to the small size and as the maximum and minimum range can be altered. A venturi will be used in rare cases like before the suction of a compressor, as the pressure drop while passing through the gauge is desired to be kept the lowest possible because, a drop in pressure will result in expansion of the volume of the fluid being handled, but a compressor usually cannot handle large volumes of fluid. 10. Tube Metal Temperature (TMT) 11. Excess Air: Disadvantage 11.1 Additional heat than required get dissipated in heating up the excess air molecules, hence the adiabatic flame temperature becomes lower. 11.2 Emissivities of binary gases are the lowest. Hence the emissivity of O2 and N2 is very low, which results in lower radiant heating. Heat carried off by the excess air will not get the same efficiency even if it does some heating in the convective section because

For Convection, Q = U A delta T For, Radiation, E = sigma * emissivity * (delta T)4 . Hence there is a difference of T3 between both the equations and that shows the difference in heat-recovery. 12. Emissivities: CO2>CO>H2O>N2>O2.; Hence when more amount of carbon is present in the fuel given to furnace, more amount of CO2 will be formed and hence a higher amount of radiant HT will take place and hence the process fluid gains a higher temperature. When the fuel composition changes, all other terms in the Steffann Boltzmann Equation remains the same. 13. Why does the flame from an LPG burner appear blue?

14. Mass-Transfer applications at home: leaching during tea making, cooling of water via humudification in mud-pots, drying of wet-clothes etc. 15. Heat Transfer applications at home: Boiling of milk, water, freezing of food, melting of ice etc. 16. Chemical Engineering Apps at homes: above, grinding, mixing etc. 17. We emphasize on a high Octane number because, if the octane number is lower, the tendency of self-ignition increases .i.e. the fuel vapors in the engine catches fire even before the compression stroke is completed and hence the engine wont be able to exhibit its full efficiency. Hence, as the octane number increases the engine will be able to compress the vapors to a greater extent and hence derive more energy from the fuel. In the case of diesel, as cetane number decreases, the tendency of self-ignition decrease, but for a diesel engine, there is no spark plug unlike a petrol engine and hence the fuel is meant to be self-ignited and hence a fairly high cetane number is also preferred. 18. In the case of a 2-stroke engine, some of the fuel escapes unburnt, whereas in the case of a 4stroke engine, this does not happen. 19. As the Euro specs increases, so has the engines to be modified as it should be able to compress more and hence utilize the greater octane number of the fuel. 20. Octane number generally ranges around 88. 21. Vapor pressure is inversely proportional to the flash point. 22. Kerosene has specifications like a sulphur max, flash point, recovery, lead max (almost zero); while MS has a sulphur max, lead max, high octane number, viscosity (2-3) etc. 23. BS focuses only on the pollutant levels in the refinery products. It did not consider the fuel modifications so as to improve the engine performance. 24. By pouring cold water over the pump, the temperature of the fluid gets reduced or the vapor pressure of the fluid falls below the suction pressure and hence cavitation can be avoided. 25. Open-steam reduces the pressure, hence boiling point temperature decreases. 26. McCabe Thiele, Ponchon Savariat constant molar overflow, assumptions 27. Diameter is a function of quantity, height is a function of quality of the column 28. Prices of fuel in petrol pumps. 29. We make sure that the irr is greater than bank interest rates.

30. Irr is the discount rate when discounted to the zero year, the cash inflow and cash outflow matches i.e. NPV = 0. 31. NPV is used to compare 2 projects. IRR is used to check the prof 32. NPV can use different rates everyday 33. Rate at which we get 34. We use Open steam in 2 cases:34.1 In crude distillation. The lighter component will have to apply a large partial pressure (its vapor pressure) to accomplish the separation and cracking of some of the hydrocarbons may occur and hence, open steam is used. 34.2 In alcohol/glycol-water separation, where water is the heavier product. This water which can be passed through a heat exchanger gets converted into steam and the same can be used instead of a reboiler. 35. Propane first gets vaporized in LPG and then Butane; sometimes some liquid gets retained in the cylinder, this is due to the reason that the pressure adjustment by the regulator is not sufficient for vaporizing the butane too 36. Flame from LPG Burner appears blue because:37. Steam Distillation 38. Surging 39. Equivalent Length 40. Darcy Wiesbach equation 41. Valves 42. Pump surging - if a pump doesn't have a minimum flow it will build up discharge
pressure. When this discharge pressure gets high enough the pump cannot overcome it anymore and the water starts to flow backwards. When the water starts to flow backwards, the pump slows down. The impeller will start to spin backwards building up pressure again. The water inside the pump will shift back and forth wreaking havoc with your pump impeller. This cycle of spinning forwards and backwards will repeat itself and will destroy your thrust bearing and destroy your pump.

This can happen with any type of centrifugal pump, if you block the discharge the pump will build up pressure and surging can take place. 43. Pumps & Systems , August 2008

44. In part one of this two-part column, we will define water hammer and explore the events that cause it. We will also try to gain perspective on the additional pressure it generates. 45. Water hammer (also waterhammer) is a pressure surge that can arise in any pumping system that undergoes an abrupt change in its rate of flow and usually results from pump starts and stops, the opening and closing of valves, or water column separation and closure. These abrupt changes can cause all or part of the flowing water column to undergo a momentum change. This change can produce a shock wave that travels back and forth between the barrier that created it and a secondary barrier. If the intensity of the shock wave is high, physical damage to the system can occur. Oddly enough, it can be more of a concern in low pressure applications. 46. Water hammer is yet another example of conservation of energy and results from the conversion of velocity energy into pressure energy. Since liquids have a low compressibility, the resulting pressure energy tends to be high. 47. Perhaps the best way to visualize this action is to start with a hypothetical example. Figure 1 below shows a pump pumping water into a pipe that was empty when the pump started. The two valves, located at the pump discharge and the far end of the pipe, are fully open and have the ability to close instantaneously. The pipe, valves and other fittings are entirely inelastic and no volume change can occur, regardless of the pressure. The column of water flowing through the pipe also has a perfectly flat leading edge that matches that of the cross sectional ID of the pipe. When the leading edge of the water column reaches the downstream valve, it closes at nearly the speed of light and entraps no air ahead of the water column.

48. Even though the leading edge has struck the closed valve, flow into the pipe continues for the next few milliseconds. Just as flow ceases, the upstream valve closes (this time at the true speed of light), and the water column is completely isolated between the two valves. What events occur as the column strikes the closed, downstream valve and why does water continue to enter the pipe even though the valve is closed? 49. If this moving column was a column of metal instead of water (hypothetically, of course), a couple of things could occur. Depending on its coefficient of restitution (its ability to avoid permanent damage), the kinetic energy due to flow (motion) could be transformed into mechanical energy as the leading edge of the metal column is crushed against the closed valve. If this occurred, the column would come to rest and remain motionless at the valve. If its restitution is high enough to prevent crushing, that same kinetic energy could be used to reverse its direction in the form of a bounce. Regardless of the outcome, the "entire" metal column would either come to rest or bounce in the opposite direction. Neither of these events occurs when water is involved.

50. Water is a nearly non-compressible liquid, which seems to suggest it is slightly compressible. At ambient temperature, 1-psi will decrease its volume by about 0.0000034 percent. That seems pretty small, but the larger the volume, the easier it is to see the effect. For example, if water did not

compress, sea level would be roughly 100-ft higher than its current level! At very high pressures, say 40,000-psi, its compressibility is increased to about 10 percent. But, most water is not just water-it also contains air, which is primarily nitrogen (78 percent) and oxygen (21 percent). Otherwise, fish could not survive! Dissolved air composes about 2 percent of a given volume of unprocessed water, and adds substantially to its compressibility.

Slip
Slip and Efficiency A major effect on positive displacement pump performance is the loss in flow due to slip. The expanding cavity on the inlet side of a positive displacement pump creates a low pressure area that asks to be filled with fluid. This cavity can be filled with fluid from the inlet line in normal performance. However, if slip occurs, the cavity will also be partly filled with fluid flowing back through the pump clearances from the outlet side.

Pump performance is dependent on the slip which occurs in a pump.

Slip Increases Directly with Pressure

Directly with Clearance

Inversely with Viscosity

When actual flow (Qact) in pump is greater than theoretical flow (Qth) then negative slip occurs.....

51. BPCL at present is expanding to the capacity of 15.5 MMPTA from the present 9.5 MMPTA. It is at present producing 80% EURO-3 and 20% EURO-4 fuel. The expansion and revamp aims at producing 80% EURO-4 and 20% EURO-5 fuel. It is also introducing petrochemical units for propylene derivatives and phenol derivatives. In the Integrated Refinery Expansion Project, the CDU and VDU is being completely replaced having higher crude handling capacities, a hydro-treater is introduced, a Coker which gives more flexibility to the operations is also being introduced. In the petrochemical complex, there will be ethylene unit, propylene unit etc. 52. MRPL is expanding from 11.82 MMPTA to 15 MMPTA. It has already commissioned its CDU and VDU units. Itll be also introducing an FCC unit and a subsequent propylene recovery unit too . 53. Slip is the phenomenon which occurs in the motor due to which it is not able to rotate at the maximum speed.

54. Surging occurs in compressors and only for compressible fluids. Unlike pumps, for compressors, the H vs Q curve is the shape of an inverted U, hence if the compressor is operated at a flow-rate to the left or right of the point of maximum head, then back flow of liquid from the discharge to the suction occurs and the flow again reverses causing havoc to the impeller as well as the pump. 55. Shut off point of a pump signifies the head at zero flow rate or when the discharge is completely closed. 56. The flange to flange distance in the body of a Gate valve is smaller in comparison to that of a Globe valve, hence it can be identified. A Gate valve cannot be used for control purpose as the pressure drop during the flow through valve causes heating of the valve parts and gradual wearing off of the parts, and thereby, the valve later on will not stop the flow even when tight shut; leakage will be there. 57. The control valve coefficient is defined as the flow in gallons per minute of water through a valve 2 when the pressure drop is 1 kg/cm . Cv is used to rate the control valves. It is a rule of thumb that in a pipeline containing a control valve, connecting 2 columns, 50% - 60% of the pressure drop in the line is given by the valve for only then will a slight cange in the valve position bring in a significant change in the flow of fluid. 58. Relative humidity is the ratio of actual humidity to the saturation humidity. When these 2 terms becomes equal, then Relative Humidity = 100 and therefore precipitation of the moisture in air takes place resulting in rainfall. Saturation humidity is the maximum humidity in air beyond which water vapour cannot enter the air at a particular temperature. 59. The principle of an AC is dehumidification. According to Joules Thompson effect, when a substance undergoes compression a decrease in the temperature occurs which will lead to the cooling of Freon. In Kerala when the body is covered with sweat, there takes place NIL mass transfer as the driving force is zero because the surrounding air is also saturated with high humidity level. When the cold Freon comes into contact with the warm ambient air, it expands and the air gets cooled, when this cool air comes in contact with the body, there exists a driving force and the sweat vaporizes into the air taking latent heat from the body and hence we feel cool. This evaporated sweat precipitates and forms water droplets which flow out of the AC. 60. Whereas in the case of an Air cooler which is used in North-India where the humidity is around 20%, humidification of air takes place. There is sufficient driving force between the ambient air and the water and hence the water vaporizes into the air taking latent heat from the air and hence the air gets cooled. 61. Equivalent Length is the net straight length of a pipe after incorporating the effects of various fittings and bends along the pipeline. 62. BWG, LNG 63. The suction pressure of a centrifugal pump taking lift always shows negative and still the pump is able to lift the liquid. This is because the vapour pressure of water at room temperature is 0.05 atm absolute and hence 0.95 atm gauge, which is less than 1 atm and hence vacuums. In the equation of

NPSH, we can neglect the friction losses in the pipe, the pump suction elevation above the ground level. The suction pressure will be around -0.2 atm gauge. Hence on substituting in the equation, we get NPSH = - 0.2 (- 0.95) + 0 = 0.75 atm and hence the net NPSHa is positive and hence the pump is able to lift the liquid. When the water is boiling, its vapour pressure will be 1 atm and hence 0 atm gauge and hence the net NPSHa will become negative, thereby the pump will be unable to lift. 64. Bernoullis equation steam jet ejector-barometric leg 65. NPV, IRR 66. LPG, LNG 67. We always keep the discharge of a centrifugal pump closed during starting to develop the sufficient head. 68. A PD pump has a by-pass valve 69. CEMP, IEMP 70. Directors , abouthttp://www.matche.com/EquipCost/Index.htm