Chapter 10 Chemical Reaction bie 2 oe a iothermal reaction Being cari Ot (0 Chemical Reaction Engingering conversion increases with increase in spacetime, ‘Parallel or simultaneous reactions In which type of reactor the back mixing | 228 Whats nuclear reactor? clear reactor is used to obtain nuclear energy in & led way to be used for peaceful purposes. It is also 1: What is an auto thermal reactor? 3k: Q3t: 933: Q3t prominent? fa single CSTR back mixing s more prominent a * e as atomic pile. jt are the main components of nuclear reactor? Fuel rods Moderator ‘An auto thermal reactor is one, which is complete supporting in ts thermal energy requirements. For what type of reactions the relative yield di ‘with inreasing conversion? i) Coolant For series reaclions te relative yield decree enrol os (Graphite) cing increasing conversion. How we cam improve the performance of ¢ rate of a homogeneous reaction fs a function of Es sine te eae Bilger ees introducing more CSTR in series; usually 3 10 5 ture, pressure & composition. paar aia ce ee ee ee eS eo Bete rare ar est ae SEES ae ee ee aa ps oa Sie ‘in donee ynrnre ocr eee agi peamieghvanthy if ‘order (nD) & the value of true order? . aR reacted with liquid (e.g. hycrogenat The relation between apparent order (nD) & the value of true 5 Pe eam ‘Which one is the most undesirable reactor for oo oo ee, ‘gon favors high yield? Ke flow rate & feed i ~” Se eee Seer i cra sam i domino) PR ‘What are the types of multiple reactions? pica te ee eee siete ey Mean residence time is equal to the space following conditions are satisfied: ©The feed rate'is measured at constant pressure in reabtor ‘+The temperature, pressure & the density mixture temains constant throughout the ‘© There eno change in no of moles in gaseous ‘When a semi bateh reactor is preferred? {A semi batch reactor is preferred wen0 Chapter 10 Chemical Reaction Engines iy ‘QAd: Is space fime equal to holding time in steady state mixei flow reactor when the system consists of nom-isotherm@l gas reaction’ To, space time is not equal to oldng time in steady mixed flow reactor when the system consists of isothermal gas reaction. Ts space time is equal to holding time in steady tmined flow reactor when the system consist of ‘uid density? eee seal to Ying tine in Sty nixed flow reactor when the system consists of fluid density. Give any example of the first order bin reaction? C Tnversion of cane sugar is an example of 1 bimolecular reaction. 1: What i the difference between space time and ot 04s: ‘Spacetime isthe term used for flow reactors while time i used for batch reactors. ‘What types of reactor do you mean by zero percet imix reactor and 100% back mix reactor? [At ideal conditions CSTR is known as 100% ‘reactor while PFR is known as 0% back mix reactor ‘What is a reeycle reactor? Recyele reactor is one in which some percentage ‘team from the reactor is fed back to the reactor. {ised to minimize the wastage of reactants and also 10 4: ‘Reaction mechanism 1 Conditions at which reaction is being conduced Heat and mass transfer effects {Suitable knowledge of mathematics and experie Fluid flow Why chemical reactor is known as the heart Industry? (hier 10 Chemjen! Reaction Eng incering _341 Tei becalise the efficiency of the plant is directly based on the efficiency ofthe reactor. Define space velocity? ‘Space veloity is defined as “The numberof reactor volumes of feed processed in unit time at specified conditions”. It is the reciprocal of spacetime; “Mathematically itis represented as se1/t units min. ‘What do you mean by fractional change in volume? When thre is a change in volume of reactants and products «. for variable volume reactors / reaction mixture, then we introduce an extra term which is known as fractional change in volume. Its represented as “o”. What is the formula to calculate the remaining concentration of reactants after some reaction i completed? The remaining concentration can be calculated as Cx=Cro~Cho Xie ‘Concentration of reactants afler some interval ‘Where, Ca of time Cyo™ Initial eonccntration of reactants Xq_ =Conversion at any time. Why conversion of reactants is more in case of Plug flow reactor than in CSTR? tis because there is no back mixing of products with fresh reactants and conversion increases from inlet to outlet of the reactants, Define rate of reaction? ‘The change in number of moles of a component with respect to time per unit volume of reaction mixture. Define space time? ‘This term is used for continuous reactors like plug flow reactors, CSTR, Packed bed reactors and fluidized bed reactor. « = Vive ‘Spice time = Volume ofthe reactor/Volumetic low rate. tis defined as “The time requited to process one reactor volume of feed measured at speified conditions.” “Make a reactor model that how it works in industry?Qs: Qo1: Qe 63: O64: Qs: Chap a = v¢ 10 Chemical Reaction Engine ig Raw materials ——~ Purification seps ——» Roni ” neylog Al | Product «—— Purification/Separati What are the steady state conditions for an ideal reactor? ‘The rector should full following conditions + Space time is equivalent holding ime for eensiysysen 7 4+ Composition tough aut eactor remains same + Bxitsweam has same gomposition asthe Hud reactor ‘What is necessary condition for an ideal tubular to beat steady state condion? For an ideal tabular reactor to be at steady state condi conversion ofthe reaclant varies from point to point flow path ‘What type of reaction occurs when oxygen react organic material? ‘An exothomic reaction occurs when oxygen react. organi materi What isthe order of the reaction, H, + Cl, > 2HC1 The given reaction is zero order rection. What isthe value of vessel dispersion aumber (Di plug tow? ‘The vale of vessel dispersion aumbar (D1) for pla a 1 order reaction i to be carried out in a {so mixed flow reactors, then at what condition the ‘olume of two reactors is minimum? “The total volume of two reaetors is minima when thes of equal size. ‘What is value of order of reaction ‘n’ fora reaction B, if rate is proportional © Cr & its found that reaction rate triples when the concentration of Increased 9 timex? “The onder of action i “1/2 Whupse 10 Chemica! Reaction Engineerin 33 ‘ao What isthe fractional volume change of the system for the isothermal gas phase reaction 2A R, between no conversion & complete conversion? The value of fractional volume change ofthe system forthe Isothermal gas phase resction 2A > R, is 05. If the energy of product is more than the reactants the ‘what type of reaction is occurring? Ii the energy of product is more than the reactants then the reaction i endothermic, if HETERO GENEOUS REACTOR DESIGN ‘What are the methods to check the efficiency of the packed bed reactor? The efficiency of a packed bed reactor should be in allowable kimits; ‘© The pressure drop across the bed should bein allowable Tims, ‘+ By the analysis at the inlet and outlet ofthe reactor. ‘© If the reaction is endothermic or exothermic then by ‘observing the change in temperature across the bed by using the thermocouples What is important controlling factor in very fast hheterogencous reaction? Heat & mass transfer effects are important factors in controling the fas heterogeneous reactions. ‘What is the rate determining step in reaction consisting cof ano of steps in series The slowest step is the rate determining step. What isthe effect of temperature on the rate of reaction of endothermic reaction? The rte of reaction inereases with rise in temperature What is the most Important characteristics of gas-liquid reactors? ‘The most important characteristics of gas-liquid eastors are + Specific inter-facal area © Liquid hold-up Ts chain reaction theory app! 'No, chain reaction theory isnot applicable for heterogeneous reactions able for heterogeneous34__ Chapter 10 Chemical Reaction Engin Qn 7 Quo: Qui: Qu: Qué When a bi Ts Calon ory slated emperor ap forrbltgeddate actions? cs ae Yen callson tory acted complex hy topicable or haogeneus eastons i erediaion poten Henry prewsted Detrgintoes rfc? arog ee ‘espn tics ts raga Tow you nracierae th aed bel Feacor? Fda bl rancor crete 7 ol tempers wel mine ‘how atl eestor? I ge of et ker a Pa (solid, liquid, gas), ‘ What te of ctr Iv wed for hydrogen iasing mickel as catalyat? Te ol Sit fect ee forts Teo nel nena unl vnbah pe Til pi eure fe gu Fexeon,then wht ype af column For gor qa sacton when © a) ue al tepid inate hn Scie sol ae 1: What is the rate controlling step in a solid ~ catalte reaction occurring avery high em Film difaon isthe rte cotoling sp na onal reaction occuring avery igh Which factors do control the design of «id reacior? The design of w Mud ~ solid reset is con flowing ators + Thereacton kinetics for singe particle 2) Thesize ditibusion of aid bg weted © low paiters of slide & Mid in he reactor What type of reactor do you recommend to g¢ conversion ina highly exothermic solid reaction? Fluidized bed reactor followed by 8 fixed bed reactor to get high conversion ina highly exothermic solid reaction ‘What are the recommendations, in ease of staged bed reactor carrying out exothermic reaction? Ma: 6: yer 10 Chamicol Reaction Ensincering ___ 45 To carry out exothermic reaction in a staged packed bed reactor you should use ‘© Hightooyele for pure gas {lug flow for dilute liquid requiring no large preheating of feed «Cold shot operations fora dilute solution requiring large preheating. to bring the stream up to the reaction temperature Can a reaction which is catalyzed by an acid is catalyzed bya substance which have tendency to lose a proton? Yee, a reaction which is catalyzed by an acid is also Catalyzed by a sbetance which have tendency to lose & roto. 10.5 CATALYST AND CATALYSIS, ‘What i catalyst? Catalyst is a substance, which inoreases or decreases the rate Gf a chemical reaction while itis neither a reactant nor product. Catalyst is not consumed itself during the reaction. Define positive and negative catalyst? Positive catalysts are those which increase the rate of reaction while negative catalysts are those which decrease the rate ofa reaction. Normally the term eatalyst is used only to increase the speed of reaction. Negative eatalyst ae also [known as inhibitors. Define the selectivity? Selectivity #8 defined as “the ratio of motes of @ reactant Converted into the desited product to those converted into ‘unwanted product”. ‘What is homogeneous cataly ‘These are the reactions in which the catalyst isin the same phase as that of reactants. ‘What is heterogeneous catalysis? These are the reactions in which the catalyst i in ifTerent phase as that of reactants. ‘When a catalysts said co be negative catalyst? ‘A catalyst is said to be negative eatalyst if t retards the rate of reaction, ‘What is catalyst promoter? J} catalyst promoter improves the activity of a catalyst ‘These are the substances which are added during preparation346___Chapter 10 Chemical Reaction Engines Qs: Qs: 2.0: Qa: Qn: Qua: Qus: ‘of catalyst which improves activity, selectivity end stab the catalytic agent so as to improve the catalyst life ‘What is the function of eatalst inhibitor? Its the opposite of promoter. When add in small amo luring catalyst preparation it suppresses the rate of rea by destroying active sites of catalyst. It reduces the activi and selectivity ofthe catalyst. These are also sefl to rede the undesirable reaction ‘What is the function of catalyst carriers? Catalyst cariers provide large surface area with a smount of ative material For which purpose BET fs used? is used to determine the specific surface of a catlyst, At what stage the porosity of the catalyst is Important in a solid eatalyzed reactio IF the pore diffusion is the controlling step in a catalyzed reaction, then porosity of catalyst isles imp ‘What are the methods for measuring the distributi pore volume? 1. Mereury penetration method 2._ Nitrogen de-sorption method Helium ~ Mercury method ig used to determine following * Pore volume = Solid density + Porosity of catalyst particle What factors do control the deactivation of a po catalyst pellet? Following factors control the deactivation of the catalyst pellet | Decay reaction Pore diffusion ‘© Form of surface attack by poison ‘Why does a catalyst lose its activity? ‘A catalyst loses its activity due to following reasons Loss in surface area of the ative component * Agglomeration of metal particles caused by Sintering ofthe solid surface wit 10 Chemical Reaction Engineering aay Covering of the catalytic active sites by a foreign substance (lo Whats sintering? Sintering is the term used when a catalyst is heated up above "is normal operating temperature due to exothermic reaction or due to mishandling, the surface ofthe catalyst is melted and the active sites of the catalyst are covered up or damaged. This is known a8 sintering ‘What isthe function of a promoter in reaction? It increases the no of active oonters by increasing the unevenness of a catalyst. surfice by creating discontinuities in he catalyst. ‘Can a reaction which is catalyzed by a base is catalyzed by a substance which have tendency to gain a proton? Yes, a reaction which is catalyze by a base is also catalyzed bya substance which have endeney fo gin a proton. ‘What isthe name of biocatalyst used in the syfthesis of proteins & metabolism in biological objets? Biocatalyst ase in the synthesis of proteins & metabolism in biological abject is called a fermentor enzyme. the apparent activation energy as measured fs only ha the true value, then in which region reaction is proceeding? ‘The reaction procedsin the difised controlled region when the apparent activation energy as measured is only haf the sre vue. ‘What sa dimensionless group used in catalysis? Hetia amber ‘What is the role of a catalyst in a 1 order chemical reaction? The role of catalysis to change the activation energy of the Does « catalyst increase the rate of forward reaction in a reversible 2 order reaction? No, catalyst increases the reaction in both directions with equal ates, What is the effect of Increase in surfa catalyst on the rate of reaction? By increasing the surface area ofthe catalyst, rate of reaction area of the38 ‘apie LO Chemical Reaction Engine (25: What are the methods to determine the surface area ol» catalyst? Mercury penetration method and nitrogen desorpins methods ae used to determine the surface area ofa catayi ‘What i the porosity of catalyst? Porosity i defined as Porosity = Void volume / Total volume ‘What are catalyst enrriers? Catalyst carrier are those materials which are used support the catalyst A small quantity of eatalyt i on salt cari ‘What is eatayst poison? ‘The substances either in reactants steam or in pro siteam which lowers the activity ofa catalyst emporrh permancily ae called catalyst poisons. ‘What are te types of catalyst poisons? “Types of ealalyst poisons are Deposited poisons Stability Chemisorbed poisons Selectivity poisons Subility poisons ) 5 Qa Q28: ») Q29: » Nn Xp 1) Mole Balance equation is ray frtittan " v rae pn ): tie -( ea) P| Fw) Norn getrnion) Ame Eve > ‘ > a ert kal - AX t “ko. For variable densit te] Carer ee 7 1: ene «ie te o (Chanter 10-Chemical Reaction Encineering 349 tua Bo LE (Xap—Xai) _ Cao= Sa recom + = Sabaesiad Se fae pom ete = fe ‘CSTR in series for 1" onder system 6, Cao = (14s) te (iis)! PER in series Recyele Reactor Abbreviations: ‘Mola flow (mole / ime) Fraction of conversion Spacetime (See) Space velovity (See = Volume of reactor ‘Volumetric flow rate (1) ‘Molar flow zate (mole / br) = Recycle Ratio No, of reactors Initial Concentration ‘Concentration at any time For ftst order system ee bet = ar sceond order system (When Inisial Concent 2.303 a x eb)a tala-x] 3) Half if period 2303 jog a a= 058 _ 2303 os = 8) Volume measurements tes = as Hog? K a Abbreviations: Initial Concentration mote / 2 x “Mole per liter decompose k = Rate constant t Time k,o7F/* (Arthenius equation) a k 10.7 _MULTIPLE CHOICE QUESTIONS. ‘Study of chemical Kinetis is easiest in the case of (@) Ireversible reactions (b) Reversible reactions (c) Surface reactions —__(d) Side reactions “Mean residence time is equal tothe spacetime when (@) The feed rate is measured at temperature and press the reactor. (®) The tempersture, pressure and the density of resot smixture remains constant throughout the reactor. () There is no change in number of moles in gaseous re (All @) () and ©) For reactions in parallel via A —+ P (desired product) and Q (unwanted produc) ifthe order of the desired react higher than that ofthe undesired reaction, a (@) Batch reactor is prefered over a single CSTR for yield = tn sc ts Chapter 10 Chemical Reaction Engineering 351 a ee (8) Tubular reactor is preferred over a single CSTH for high isin seen eae aa (©) "Both (a) and (6) (@__ Single CSTR is the most suitable When all the limiting reactant is consumed inthe ration, the ‘operational yield —— the relative yield (2) Is greater than (©) Issmaller than (6) Equals (@) Can be either greater or smaller than (depends o the type of reaction). Design of heterogeneous catalytic reactor involves consideration of (a) Only chemical steps (b) Only physical step (€)Both(a) and) (4) Nether (a) nor (0) Pick out the wrong satement (2) A catalyst does not alter the final postion of equirium in ‘reversible reaction, (6) A catalyst initiates a reaction. (6) A catalysis specific in reaction, (@) A catalyst remains unchanged in chemical compasition at the end the reaction ‘Slumry reactors are characterized by (2) Lack of intraparticle diffusion resistance () Presence of two mobile phases (©) Both @)and(b) (4) Nether (a) nor (6) ‘Arreaction A.—+ 3 B is conducted ina constant presse Vessel Starting with pure A, the volume of the reaction mixture increases 3 times in 6 minutes. The fractional conversion is (0.33 @os (10 (@) Data insufficient, can’t be predicted ‘The most suitble reactor for carrying out an auto-thermal reaction is, (a) Bateh reactor @cstR (6) Semirhotch reactor (4) Plug-flow reactor A first onder reaction requires two equal sized CSTR. The (1) Less when they are connected in series, (b) More when they are connected in series (©) More when they are connected in parallel (0 Same whether they are connected in series or parallel2 ren 14, 15, 16. 1” Chapter 10 Chemical Reaction Engines "The concentration of A in a first order reaction A~»l) decreases (@) Linearly with time (6) Exponentially with time () Very abruptly toward the end ofthe reaction {(@) Logarithmically with time ‘The optimum performance for reactors operating in paral bined when the fod sem ert a such way (@) Space time foreach parallel lines same (b) Spare time for parallel lines is different (6) Larger reactors have more space time compared to (@ None ofthese. When a high liquid hold up is required in a reactor liquid reaction, use (@) Packed column (©) Spray column (© Tray column (@) Bubble column For nearly isothermal operation involving large reaction in a liquid-phase reaction, the most suitable reactor is (@) Stiredfank reactor (b) Tubular flow reactor (©) Batch eactor (@ Fixed bed reactor AA stired tank reactor compared to tubularflow te provides (4) More uniform operating conditions. () Permits operation at the optimum temperature for a reaction time. (©) Higher overall seletivity fora frst order consecutive tion, @ ANG), (and ©) For the same residence time, which one will give ‘maximum conversion? (@) Single stirred tank (v= liters) () Two stired tank (cach of2Slitres) in series (6) Stirred tank followed by tubular flow reactor (e 2:shites) (4) Single tubular flow reactor (¥= Stites) 'A second order reaction of the form A+ B > C is eal pseudo-fest order reaction when (0) C= Con (0) Cro> Coo (©) Ca0> Cro (Cp 2Cx0 (Chapter 10 Chemical Reaction Engineering 353 Ik. A fist order imeversile reaction, A —> B is caried out Separately ma constant volume as well as invariable volume reactor for particular period, I signifies that (@) Both conversion as well as concentration is same in the two reactors () Conversion in both will be the same but concentrations ‘willbe different in the two reactors. (© Both the conversion as well as concentrations willbe dif ferent inthe two reactors. (@) None of these ‘The use of space time is prefered over the mean residence time inthe design of () Batch reactor (b) Ideal tubular-Alow reactor (6) Slury reactor (aycsTR For all positive reaction orders fora particular duty, {) Mixed reactor isalvays higher than the plugrflow reactor (©) The ratio ofthe volume of the mixed reactor to that of the plgffow resctor decreases with onde: (©) Reactor size is independent ofthe type of low. {@ Density variation during eaction affects design. With the same resction time, intial concentration and feed rate, the reaction 2A —» B is earried out separately in CSTR fand PF of eqal volumes. The conversion will be. (@) Higher in PAE. reactor —(@) Higher in CSTR {) Same in both reactors (@) lnsuficient data, canbe predicted Foran autocaalytc reactor, the suitable reactor st up is (PF reactors series (b) CSTR in series {@) CSTR followed by P-F. reactor (@) PF. reactor followed by CSTR luidired bed reactors characterized by (4) Uniformity of temperature {(b) Comparatively smaller equipment {e) Very small pressure drop {4) Absence of continuous eatalyst regeneration facility In an ideal tubulae-flow reactor (4) There is no mixing in longitudinal direction (b) Mixing takes place in radial dreetion {e) There is uniform velocity aeros the radius (2) AIG), (0) and) Integral method for analyzing the kinetie data is usedasa __Chapter 10 Chemica! Reaction Engineerins (Chapter 10-Chemical Reaction Engineering 355 "7 (a) When the data are scattered ; (©) Increase in initial concentration ©) For testing specifie mechanisms with simple rate expe (6) Total pressure (@) Decrease in total pressure sions. AS. Archenius equation shows the variation of-----withtempera- (© Both (a) and) _——_(@)_ None of these ture 26, Differential method for analyzing the ket data is used () Reaction rate () Rate constant }(@) Fortesting complicated mechanisms, (©) Energy of activation (@) Frequency factor {(b) When the data are scattered 36. Sum of the powers of the concentration terms in the rate (@) When rate expressions are very simple ‘equation is called the-—of the reaction. (@) None of these (a) Order (©) Overall order 27, Exposure ofa, photographic plate to produce latent ima (©) Molecularity (@) None of these ‘an example of reaction. Y7. Which of the following is @ controlling factor in very fast (@) Very slow (0) Very fist hneterogeneous reaction? {) Photochemical {(@) Both (b) and ©) (9) Heat and mass transfer affect (b) Pressure 28 A trckle bed reactors one which (6) Temperature (@) Composition of reactant (@) Has altogether three streams either entering or leaving, In an exothermic reaction, the energy of the reacting substan- () Processes three reactants at different flow mates ces is as compared to that of products is () Procesies three reactants with same flow rate () More (b) Less (Same (@) Employs all the thece phases (solid quid and pas) (@) Bither (a or (o), depends on order of reaction. 29, Reactions with high activation energy are If the time required to change the concentration of reactant to (a) Very temperate sensitive _(b) Temperature insensti half its original value is independent of the initial eoncentra- (6) Always reversible (@) Always reversible tion, the order of reaction is 30. With incresse in temperature, the equilibrium conversion (2) Zero (@)One (©) Two (Tiree reversible exothermic reaction ‘The fractional volume change between no conversion and (@) Decreases (b) Increases (@) Remains unaffected complete conversion, for the isothermal gas phase reaction {(@) Decreases linearly with temperature 2AR is 31, Half-life period fora frst order reaction is. the (os 05 @Io 1s concentration ofthe reactant. ‘What is the value of ‘if the reaction rate of the chemical (@) Directly proportional to ~ (b) Inversely proportional reaction (6) independent of (€) None of these ‘A> B is proportional to Cy- and it is found that the reaction 32, Specifi rate constant fora seeond order reaction rate triples when the concentration of Ais increased 9 times? (@) Is independent of temperature ie OR} @3 (b) Varies with temperature Cold shot eooling is only practical when the feed temperature {) Depends on the nature ofthe reactants is —~ than the reaction temperature. {(@) Both (b) and (e) (a) Higher (©) Much higher 33. The resction in which rate equation corresponds, (©) Lower (@) Much lower stoichiometric equation i celled ‘A chemical reetion is of zero order when the reaction rate is (a) Elementary reaction (b) Non-lementary reaction (acy (aC (Parallel rection (d) Auto-kinetic reaction (6) Independent of temperature (4) None of these 34, Fora zero order reaction, concent tion of produc in ‘Where, Cy = concentration of reactant with (@) Increase ofreation time ‘A photochemical reaction is (@) Initiated by ight () Accompanied with emission of56 Chapter 10 Chemical Reaction Engineering 45. a. 48, 49. 50. si. 2. © Calalyzed by (4) Used to convert heat energy int. Arise in temperature (e) Normally tends to increase the eaction rate (b) Does not affect a catalyzed reaction (6) Doss not affect photo-chemieal reaction rates (2) AIL (a), ©) and (9) ‘The value of 'n' fr a chemical reaction A —»B, whose react rate is proportional to Cx, will be ~~ if the rate ofthe react increases by a factor of 8 when the concentration of A. double. @o wt (2 @3 ‘What is the order of chemical reaction A + B-+ CD, ifit ound that the reaction rate doubles on doubling the centration of B and also the reaction rate doubles when. ‘concentrations of bth A and B were doubled and quadruph ‘when the concentrations of both B and C were doubled. 53. 4 55, @l (2 (3 4 es. ‘The half life period of a first order texction is given by @ 15K (25K — ()0.9YK— (0) 6.95. ‘Where, K= rate constant In case of the irreversible uni-molecular type, first order tion, the fractional conversion at any time for constant vol system as compared to variable volume system is. (@) More (@)Less —(€)Same (a) 0r(b), depends on other factors For the non-catalytc reaction of particles with st fluid, the same needed to achieve the same fact conversion for particles of different unchanging sizes proportional tothe particle diameter when is-—the controling resistance (@) Film difusion (&) Difasion through ash layer (6) Chemical reaction (@) Either (a), (0) or (©) The catalyst ina fist order chemical reaction changes the (@) Eguilibrium constant (b) Activation energy () Heat of formation ofthe product (4) Heat of reaction ‘Te eatalystin a second order reversible reaction increases of the () Forward reaction and deereases that of backward react (©) Forward and backward reaction equally (6) Forward reaction only (rin 57. 2 * 60. Chapter 10 Chemical Reaction Engineering 351 (@) Forward reaetion to a greater extent than that of the back- ward reaction Tonic reactions occur in (@) Solid state only () Liquid state only (6) Solutions (@) Any state ‘With increase in the order of reaction (For all positive reaction orders), the ratio ofthe volume of mixed reactor tothe volume ‘of plug flow reactor (fr identical feed composition, low rate and conversion) (@) Increases () Decreases () Remains same (4) Increases linearly ‘The performance equations for constant density systems are identical for (@) PER. and back-mix reactor (b) PIF R. and batch reactor (€) PIER, batch reactor and back-mix reactor () Batch reactor and back-mix reactor In an ideal mixed reactor (at steady state), the (@) Space time is equivalent to holding time for constant den- sity ystems (b) Composition throughout the reactor remains same () Exitstream has the same composition asthe uid within the reactor @ AIG), (and ©) ‘The ratio of volume of mixed reactor to the volume of PLE-R. (for idential flow rate, feed composition and conversion) for ‘ero order reaction is @~ oo 1 @>1 When a catalyst increases the rate of chemical reaction, the rate constant (a) Decreases (Increases (¢) Remains constant (d) Becomes infinite Half life period of decomposition of liquid A by ireversible first order reaction is 12 minutes. The time required for 75% ‘conversion of A is @8 4 6 ‘The rate constant ofa reaction depends on the () Intal concentration of reactants (b) Time of reaction (©) Temperature ofthe system (@) Extent of reaction ‘The rate at which a chemical substance reacts is proportional toits (@) Active mass on (@) Molecular weight360 qui Qu Qas: Qua: us: Qus: Quy: 2 (Chapter 11 Unit Proce ‘© Unimolecular reaction © Bi-molecular reaction ©. Trismolecular reaction What is zero order reaction? ‘The reaction in which rate of reaction is independent of the eactant concentration is known as zero ord reaction, ‘explosive reactions et, What are the types of reaction based on the phase? There ae two types of reactions ‘© Homogeneous reaction ©. Heterogeneous reaction ‘What are homogeneous reactions? The reactions in which only one phase is involved th ‘ut the reaction Le. reactants and products both are i same phise ‘What are heterogencous reactions? ‘The reactions in which more than one phases are inva are known as heterogencous reactions, What are parallel reactions? Parallel reactions are those .a which more than one p is formed by separate eac‘ions and where products Tormed, do not react sgain. Usually withthe main some time side product also formed in the manufac of urea side product biureat also formed. ‘What are series reactions? Series reactions are thore in which the product of reaction goes onto react further: A >» R> 5s Where A=Reactants R= Intermediate product ‘$= Final product, ‘What are the complex series reactions? Complex series reactions ae those in which there is fi Feaction between one ofthe reactants and one ofthe p so both series and parallel reactions take pl simultaneously, ‘What is chemical-process kinetics? CChemical-process kinetics is a study of the influence of physical factors that affect chemical reaction. ‘What are the factors that affect the rate of a c reaction? Following factors affect the chemical reaction: pier LL Unis Process 361 (© Thetype & shape of reactor sed “The method of operation “Temperature control Pressure Catalyst Agitation Mixing Back mixing Stoichiometric ratio ‘What is back mixing? [Back mixing is the mixing of reactants and products of a chemical reaction by upstream diffasion and reaction while ‘the main flow isin the downstream direction. Back mixing reduced the final concentration of products ‘What are the types of reactors? These ae the followings: 2 Batch reactor Longitudinal flow reactor (Plug Flow Reactor) Stirred-tank flow reactor (CSTR) Packed bed reactor Fluidized bed resctor (©. Recycle reactor ‘What back-mixing in longitudinal flow reactor? On ideal conditions longitudinal flow reactor (PFR) is zero percent back-mixing reactor. ‘What is the back-mising in stirred-tank flow reactor’? Stired-tank reactor is known as 100% backe- mixing reactor. ‘What are the important considerations about back- mixing while designing a reactor? ‘Two items about back-mixing must be considered while designing a reactor 1. IP back-mixing is present, what addtional holding time ‘or reactor volume is needed to compensate fori? 2 If compensation is not made, what is decrease in production o yield due to back-zixin 11.2 _NITRATION ‘What you meant by nitration process? Nitraton is the process of introduction of one or more nitro sroup (-NO;) into an (reacting molecule) organic compound ‘What are different groups to which (-NO,) group can become attached during nitration process?93: Qa: Qs: Qs: Z Chapter 11 Unit Pro “The nitro group may attach tothe following groups. (Carbon to form nitro sromatic or nitro-paralin, (© Oxygen to forma nitrate ester © Nitrogen atom to form nitro amine ‘Whether nitrogen is conducted by -NO, group or nitty acid? ‘Nitrogen is conducted by - NO; ion and not by nitric ad itself ‘What isthe use of nitration products? Nitration producis are widely used as solvents, dyes pharmaceuticals, and explosives. They also serve as {nlermediate for preparation of other component. ‘What are nitrating agents? The nitraing agents are: (o Fuming nitric acid © Concentrated nitic acid © Aqueous nitric acid “The mixture of nitric acid with any ofthe following © Sulfuric acid ‘Acetic anhydride Aceti acid Phosphoric acid Chlorofoem Nitrogen penta-oxide Nitrogen tera oxide ‘What is the nature of nitrat ‘The nitrating agent is an electrophilic reactant ‘What combination of nitration agent Is more favor and why? Combination of nitric acid + Sulphuric acid is favorable as nitration agent and also more favorable di ‘excessive generation of -NO; ions which leads to the rate of nitration process. ; ‘What is the relationship b/w concentration of sul ‘cid and rate of reaction? ‘The rate of reactions increases. with the increase concentration of sulfuric acid up to 90% concentration, Further ineease in e@ncentration result in decrease in ra Why rate of reaction increases with concentratiot sulfuric acid up t 90% concentration? hupier LLUnit 3 ‘As the concentration of sulfurie acid is increased, the ‘xdaction of nitryl ion is also increased resulting in increase Bf rate of reaction. Why rate of reaction decreases with the increase in Concentration of sulfuric acid above 90% concentration? Ths Is because, above 90% concentration the sulfuric acid forms hydrogen bond with organic compound, ‘Can nitration process occur with simple nitric acld? Yes. ‘Why nitration occurs with simple nitric ac Simple nitric acid contains approximately 1.2% nity! ion That's why nitration occurs but due to very stall amount of ‘htryl ion the nitration is very slow and give Tow vied ‘Om what factor the kinetie of nitration reaction depends upon? ‘The Kinetic of nitration reaction depend on the reaction rmediam and temperature, ‘What is the order of nitration reaction? may be first or zero order reaction depending, upon whether activating or deactivating. group is artached with ‘rganie compound where -NO group is being introduced. What is the order of nitration when reacting with activating group? The order of nitration is zero for activating gr0Up. What. is order of nitration when reacting with deactivating group? “The onder ofmttation is one for deactivating group. ‘At which position the nitro group is attracted? The reactien is favored to the carbon atom of the aromatic ing where the electron density is greatest |, What is the orientation of nitro group for aromatic compound having activated group? Te nito group will goto ortho and para position, What Is the orientation of nitro group for aromatic compound having deactivated grou The nitro group will go to meta position Give some examples of meta directing groups? 1NI,NO;, COOH ete Give some examples of ortho & para directing groups? F.C), Br I, Ciete ‘What is order of reaction of nitration Aquous HNOs?368 Q23: Qa 28: Qa: 933: Qa: _ " (Chapter 11 Unit Zero order reaction, What are the effects of addition of HNO; in nitrati process? Temay have either inhibiting efector catalytic effet. i; What is the effect of addition of HNO; in react compounds? Tracts as catalyst, s: What is effect of addition of HNO: in lest rea ‘compound? Ieacts a inhibitors ‘What is oxy-nitration? The reaction bw benzene and approximately 50% nitric. containing 0.2 molar mercuric nitrate, which yields up {85% di-itrophenol and pric acid. ‘What organiciaromatic compound is used for nitration process at lab scale? Phenol ‘What aromatic compound is used for oxy-nitr process being conducted on commercial seale? Nitrobenzene. Nitric acid of what strength is recommended conducted commercial oxy-nitration process? 50% HNO, ‘What is more suitable eatalyst to conduct oxy-nits process? 1.2 molar mereurie nitrate ‘What is most likely product of oxy-niteation process Picrc aid What are the steps of oxy-nitration reaction? ‘The benzene is initially converted to phenylmercuric ‘which reacts with nitrogen dioxide to yield nt ‘The nitrosobenzene is converted to p-itropleno Fol {wo steps depending on the conditions applied. ‘What happens to nitrosobenzene, i the concentr nitric acid is less than 50%? ‘The nitrobenzene will rae! wih 2 moles of ntsc form phenyldiazonium, which forms phenol by react water, and then finaly nitrated to form p-nitrophenal ‘What happens to nitrosobenzene, if the concent niteie acid is more than 50%? ‘The nitosobenzene is directly canverid to p-nitroy ter 11 Uni (Q.35: What is the suitable phase for conducting paraffin hydrocarbon? Gaseous phase. What should be the concentration of nitric acid for conducting nitration of paraffin hydrocarbon? 70% concentration, What else can be used for nitration of paraffin hydrocarbon other them nitric acid? Nitrogen oxide ean also be used ‘What are the main products obtained from the nitration of paraffin hydrocarbon? ‘The products are nitromethane, nitrocthane, 2 nitropropane,2-nitrobutane, — I-itroisobutane, nitro} methyfbutane, 2-nitro-3-methylbutane ‘What should be the temperature during conducting nitration of paraffin? 45~ 60°C, ‘What should be the temperature during conducting. nitration of benzene to nitrobenzene? 0 ~ 450°C. ‘What type of processes is used in nitration ‘There are two types of nitration processes used (© Batch nitration © Continous nitration ‘What are the advantages of batch nitrator? The advantages of batch nitrator are: © Flexibility © Labor usage (for low seal production) (© More than one product can be manufactured from the same reactor ‘What are the advantages of continuous nitrator? The advantages of continuous ntrator are © Lower capital eost © Safety (© Labor usage (for high or medium scale production) (© More production ‘What is the biggest advantage af batch nitrator? Flexibility, ean be used for wide range of products. What are the two most important factors for the designing of a reactor? The important factors for designing of «reactor are366 O46: “o Resiiecatine © Contolof temperature Write dove the names of two continu sculpment? on Soh nttor © Bisa nate Weitea relationship for DVS, for mixed acid DYVS.'S/ ENR What isthe temperatare range during pe dinitrobenzene? " sat oto" What Is the temperature forthe prepara ac 100 Whether aration process endothermic ore reacto Exother What is the time for nitration in the p ‘min What i the time for nitration in the prep ‘nitrobenzene? a 0 min What ste ine for nitration nthe prepration acid? Sa Pra Wr esterfieaton?” Eserifonion ithe process in which an organic a with alcohol fon est alongwith wae I prodecton of est on commercial sae ‘What sam eter? An este is defined as compound formed by subs erga aia fr onzable argon ofan ec On what reactant the ral of esterification remut The rat of exerication depends upon the ype of involved in the esterification. i a Which alcool shows the highest ate of esteriea Methyl alcobol shows the highest te of estesfestion eL1 Unit Process —_ 361 Which class of alcohols show highest rate of ‘sterifcation? Primary alcohols show the highest rate of esterification and also the maximum yield ‘What Is the order of rate of esterification and yield for different of alcohols? The order of rate of esterification and yield is as under Primary alcohol > Secondary aleohol > Tertiary alcobol Why isthe rate of esterification is different for different lasses of alcohols? The more branched the carbon chain of the alcohol and the nearer the branches ate to the hydroxyl group, the slower Will be its esterification and lower the limit What acid shows the maximum rate of esterification? Formic acid shows the maximum rate of esterification Docs temperature affect the rate of esterification? Like other chemical reactions, esterification is also affected hy temperature ie with 10°C rise in temperature the rate esterification i approximately doubled. Why isa catalyst need to increase the rate of csterificaton, if heating can increase the rate of ‘sterfieation? In most. instances, heating alone does not speed up esterification toa practical value. For this reason, a catalyst is needed to complete the esterification ‘What type of catalysts Is used in esterification? [Esierifeation catalysts are compounds, which are acidic in| ‘What are the catalysts, which are most commonly used? Sulfurie acid and hydrochloric acid are used commonly for ‘esterification proces. ‘Which eatalyst is used for laboratory purpose? Hydrochlorie aid ‘Which acid is sed on commercial scale? Sulfrie acid Why hydrochloric acid is used for laboratory purpose? HCI is used because itis efficient as compared t0 other catalyst. ‘Why sulfuric acid is used on commercial scale? Sulfuric acid is used on commercial scale because it has lower corrosive effect on metals369 368 Chapter 11 (Chop LL Unit Process a 2.17; Whats dbadvaniage of sulfuric acid? 128: What typeof catalysts used in aeidolysis? Sulfric acid may eas the dchyration ofan alcohol Since the alkaline catalyst, whichis eficient in alysis, sat ailpee Rec ics figh Resi anno! be used, the slower acid catalyst of heat sk must Q.18: Why is esterification not completed by simple means? be used. Estrifiaton is an equim reaction, so ican proce 29: What are the catalysts used in acidolyts? to certain level, after that equilibrium is attained and Boron trifluoride, mercury salts etc. furter formation of products possible. 10.30: Can some ether compound in esterification tion Q.19: How esterification is completed when the acid, ak replace acid? and ester are non-volatile? ‘Yes, acid anfydride can replace the acid. Esteriion of Removing the water by heating, or some times by pas alcohol i more rapid by a acidic anhydride a eared to the steam can complete the esterification. respective acid. the Q20: What is the other’ method for completion 031: Can alcohol be replaced in esterification reactiot atericaton? Yes, slechol can be replaced by actylene. Aceyirescs (One method of completing esterification is by using e ‘with acti aed in presence of suitable catalyst worse of acid. The excess acid is then removed. 0.32: Can an inorganic acid prepare ester? Q.21: How esterification is completed when any of acid, alcal ‘Yes, inorganic acids like sulfuric, mitric, pkhori, or ester is volatile? s@hoylic acids are used commercially for the preion of If any of the components involved in reaction is vol ester: then distilling out water omplciesesterfcation. 10.33: What are te other methods for dhe preparationster? 022: What Is sleaboty Fstercan be prepared by any of following metho Alcoholysis is the reaction in which an alcohol reacts. © By reaction of metal salt with alky! halide ester to forma new alco and new ester © From niles Q.23: What is the utilization of alcoholysis? <_From carbon monoxide ‘An important use of aleoholysis is in prepration [114 SULFONATION & SULFATIO| monomeric cyclic polymethylene carbonate, which cant i SULFONATION & SULFATE be obiained by any other mesns. Similarly other imp ‘What group is introduced during slfonaton ps products can be obtained by alcoholysis, which cannot --HSO, (sulfonic acid group). obtained by other means 0.2: What functional group Is introduced durin Q.24; What type of catalysts is used in alcoholysis? process? The strong acids hat are used in exterifteation serve eq 10$0,0H or S0« group. 00d in aleoolyss. 3: What functional group Is Introduced di halo Q.25: What is the most commonly used catalyst in alcoholys sulfonation process? Sodium alkoxides are most commonly used as catalyst -CISO3H or -FSO3H ete, alcoholysis. Q.4: What functional group is introduced dur sulfo (0.26: How aleotoyss is completed? chlorination process? Aleohysis is a reversible reaction so we have 10 pu Soc towards completion. Removing any one of the products QS: What is meant by sulfo oxidation process? ‘he help of distilaion can complete the slcohalysis Tris the use of sulfur Uoxide and oxygen to sate an 0.27: Whats aciolysis? alkane Acidolysis isthe eaetion in which an acid reaets with to form a new acid and a new ester. ‘What is the technical name of the product if sit acid ‘group fs introduced and linked with Ns atom?Quo: Qui: qu: Qus: Qu: Qs: N-rulfonate or alfonaes (Chapter 11 Unit Be ‘What you meant by Alkytation’s process? Introduction of an alky! group into a molecule ‘What you meant by Acylation process? Ie isthe introduction of Acyl group (-RCO) into a coms ‘What is meant by sufoalkylation 1 is the introduction of sulfonated alkyl group in ‘organic compound: What is meant by sulfoaeylation? Itis introduction of sulfoaeyl group into a reacting molec ‘What is meant by sulfoarylation? Wis introduction of sulfoary group into a reacting mo ‘What are the types of sulfonates? “The sulfonates are clasifed into four main chemical © Aliphatic or Alieyetic © Aromatic © Heterocyclic (©. Nesulfonates or sulfamates ‘What are the types of sulfonates based on pr “There are thre types of sulfonates based on practical rea Sulfomates ae detved from: ‘©. Petroleum fractions. ©. Lignin ©. Fatty oils ‘What are the general procedures for preparati sulfonates? ‘There ate four general procedures for the preparatio sulfates (© Treatment of an organic compound with SO compound thereof ‘© Tresiment with compound of SO ‘© Condensation or polymerization method (© Oxidation of organic already containing sulfurin a state of sulfur ‘What are the uses of sulfonates and sulfates, when, are employed as such in acid or salt form? They are used for applications where strongly hydrophilic - $O,0H group confers needed properties ‘comparatively hydrophabic non-polar organie molecule. 311 ‘What are the uses of sulfonates and sulfates, when they fare marketed and wsed in acid form? ‘They are used as catalysts and as electroplating additives ‘What are the uses of sulfonates and sulfates, when they are marketed in salt form and used in acid form? They are used as dyes, mothproofing agents, and synthetic tanning agent. ‘What are the uses of sulfonates and sulfates, when they are both marketed and used in salt form? They are used as detergents, emulsifying. & demulsifying agents, penetrating, wetting and solubilizing agents, Iubricating additives, and rus inhibitors. ‘What isthe use of polymeric sulfonates? Polymeric sulfonates include dispersing agents, elastomers, water-soluble synthetic gums and thickening agent What are sulfonating and sulfating agents? The sulfnating and sulfating agents can be classified into following groups Sulfr trioxide and it's compounds (©. Fuming sulfuric acid © Oleum (2.0% to 30.0%) Sulfr dioxide group SulfoaTkylating agents What are the sulfur trioxide’s compounds, whi used as sulfonating agents? (© Sulfur trioxide, oleum, concentration sulfuric acid (SOs plus water) © Chloresulfonic aid ($0; plus HCD) (© Sulfur trioxide adducts with organic compounds © Sulfamic aeid ‘What are the sulfur dioxide group's compounds, which are used as sulfonating agents? (© Sulfurous acid, metallic sulfides (© Sulfur dioxide with chlorine © Sulfur dioxide with oxygen What are the salfoalkylating agent which are used as sulfonating agents? © Sulfomethylating agent © Sulfoethylating agent © Miscellaneous sulfoakylating agent; sulfeacylation sulfoarylation|Suifauiie Acid (NH,SO,OM) which is sulfamic found in what form? ‘As stable solid with high melting point (200°C) In what form sulfur trioxide is marketed? Sulfur trioxide is marketed in it's simple pol Which is trimer or known as gamma form. In which form sulfur trioxide is used?” Sulfut trioxide is used in vapor form. In which form sulfuric acid and oleum are used? Sulfuric acd and oleum are both used in liquid form, ‘What are the important factors effecting the ra course of reaction when sulfur trioxide is us sulfonating agent? Following are the factors effecting the rate and (© Concentration of SO in the sulfonating agent (© Chemical stctute of organic compound ‘© Time in relation to temperature and reagent streny © Catalysis ©. Solvents ‘What are basic component used for the comt preparation of sulfamic acid? Itmade by the rection of pyro sulfonic acid and urea, ‘What isthe strength of monohydrate sulphuric? 0,10 100% H,S0,, ‘What isthe strength of dehydrate sulphuric acid? 805.210 845% H,SO,, ‘What you meant by 45% pyrosulfonie acta? Its 280, H0 with 45% oleum, What do you meant by hydrate? ‘A compound containing combined water. How sulfonation is completed? Following methods can complete sulfonation © Use of excess acid (© Physicl removal of water (© Chemical removal of water ‘What isthe T-value? Tk is the concentration of sulfur trioxide at whi sulfonation stops, How imuch excess acid must be used to ci ut Process. ‘Acid should be used in that excess so the concentration of cid should remain above it's nvalue even when its diluted by water formed during the rection, 11; Why water is removed to complete the sulfonation? ‘The water is removed s0 thatthe acid is not diluted by the water formed during. the reaction hence keeping. the ‘concentration of acid above i-value. How water is removed by physical method? “The most common method to Temove water physically is by pyactical pressure distillation How water is removed by chemical method? ‘Water is removed chemically by introducing some chemic having capability of reacting with water such as thionyl chloride, boron riflouride ete ‘Why catalyst is used in sulfonation? Catalyst helps in sulfonation by © Changing orientation © Facilitating reaction (© Inhibiting side reaction ‘What are the catalysts normally used in saifonation? “The catalyst used is mercury, copper salt, oxide of nitrogen, acetic aid tc ‘Why the sulfonation solvents are used? “Many sulfonates are viscous liquids or solids so solvents are requited for efficient mixing, thereby ensuring uniform reaction What are tie solvents used in sulfonation? Excess acid Chlorinated solvents Liquid sulfur dioxide ‘Aqueous solvents Miscellaneous solvents ‘At what temperature H,SO, is completely dissociate into water and SO; 450°C What should be the strength of H,SO, In order to conduct effectively sulfornation / sulfation process? 98 ‘At what proportional H,SO,{s added to conduct effective sulfonation ef benzene? 2" times ofthe wt. of CaWhat should be the temperature for cond effective sulfonation of benzene? (Proportion of ‘mono-sulfurie acid. 80°C, ‘What temperature range should be maintained to s-praduels from sulfonates of Naphthalene Below 40°C(or long time) What should be the temperature range for a rom the sulfonation of Nap >for long time). Which a-naphthanol product wart utilization is more important? B-naphthl (while a-naphathol have no industrial or tec importance) Write down the names of two important nap dlisutphionie acid which are obtained by direct suo ‘of naphthanol using H,SO, followed by alum and range of 15 -80°C? 1 acid (fr dyes making). ‘What is starting material for the preparation of Gi ‘Acid (dye intermediate)? R—acid What is the raw material used for preparation of t ‘welding agents by sulfonation process? By sulfonation of alkylated naphthalene. ‘What is the strength range of sulfuric acid against wi cast-iron can resist over 2 fair range of temperature, ~ 100% What is recommended material which is suitable lining inside the kettle used for storage/reaction vessel pyrosulfonic acid? S5:16~ pes ‘They are important dye intermediate. ptr LL. Unit Praess 35 How many sulfonates are produced by sulfonation of anthraquinone and its derivatives? Four (2 mono-sulfonates & two di-sulfonate). Whether ordinary H,S0, can be used to conduct sulfonation of Anthraquinone? No. What should be preferred reagent used in order to conduct the effective sulfonation of anthraquinone and their derivatives? 20% oleum in the presence of meroury sulphate (as eatlys) ‘Whether sulfonation of heterveyctic (Furan, Thiophene, Indole ete.) compounds ean be conducted with acid or not? They cannot sulfanate with SO; and its hydrates because they decompose in the presence of aids ‘Write down the name of heterocyelie compounds, which ‘ean pve stable sulfonation process? 3-pyridene sulfuric aid, an intermediate used for producing ficotinie acid. ‘What is the status of SOs and its hydrate in order to conduct suifonation of aliphatic hydrocarbon compounds? SO; and its derivatives are generally unsuitable for sulfonating saturated aliphatic “compounds. Either no reaction occurs or oxidative decomposition takes place, ‘What sulfonating agent is more preferred (o conduct the sulfonation of ether? 80, ‘Why chloro sulfuric acid sulfonating agent is preferred ‘over H,SO, 0 conduct sulfonation of certain reagent? Because, we have to adopt a long routes and laborious method if we use H\SO, for the sulfonation of certain compounds like aromatic sulphonyl chloride or sulfonates, ‘The chemical removal of water (water produced as by product sulfonation reaction) can be effected by the ‘addition of ? $0, or SOCI, and BF What term is used for the stage at which water produced during sulfonation, dilute 180, and when no further sulfonation i possible?pyglinc st aly 7 ae Sette ape Unit Process —___— 3. St Peesonivat to aranes are Geviveives of armen Q.68: SOs an important sulfor eee em erent ora le eT TEN ee en Tie wiphapiae deco otra 15_AMINATION] 1: What you meant byte proce oan? isa process of prparaton of snes by ined cee ty inroducing 2 What are different methods of ania sof amination? # Aminatin by redution + Amit By ea 934] Wan anvexleaiin “Amines may be defined as derivatives of ammonia, other groups replace one or mo other ous re then one hyde QA: What are group from which a replacing hydrogen’? Ttpogen some have been replaced by organie aid 11; What is amination by reduction? Wat aig reduction involves syaheis of amines PY eduetive methods. 12; What is amination by ammonolysis? What Flan by amimonolysis isthe prosess. of forming amines by the ation of ammonia ae aa Tring difference between reduction and hydrogenatio to eeepenavon, Hydrogen is dretly used in the Doses, In by roettaide souree. While in reduction NyUTDEED Bs S tee produced during the course of reaction and Pen 4; WMEh method Is wsed for the prepration of amides” We early prepared by ammonlysis reaction a es can be produced oka eed ‘not by reduction method. ot eee, 15: What are the methods for ‘amination by reduction? Sen peyee at Following are the important ‘methods for amination by cece Tolan Hane ots woup erm Suerte we. co Catalytic, Q.5: What are different classes of amines? 0 Sulfide, nly ioe 9 Electrolytic, %, -Bespedany sear co Metal and alkali, So TR SRR, co Sulfite, Q.6; What are primary amines? ‘o Sodium hydrosuilfite, ey o Metal hydrides, ru nine ais, wich ann em aydrogen atoms attached to ammonia nitrogen. a Q.7: What are secondary amines? a ‘Secondary amines. ar the ge the amines, which contain temining byogen tom tached amon Q8: What are tertiary amines? eh ae “erry amines se the amines, which ines, which contain no rea pydogen slo aiached to ammonia ntogen od all hydrogen alors are replaced 9: What yo meant by aides? © Sodium and sodium aleohotate, & Stongeste ostfatON 8 Hydrogenated quinolines and naphthalene. Smee ste more favorable method In amination PY reduction? Fremtt acid method. (Bechamp’s method). se ea ae alferent mcial which are used im metal & rmetal method? Sn, Zn, Fe‘What are different acid recommended for acid & method? HCI, H,S0,, HCOOH. Which combination of acid & metal is most Fe/ HCl What are the physical and chemical factors that. the Bechamp’s reduction? ‘The faciors are Amount of iron used, Physical condition ofion, Amount of water used, ‘Amount of acid used, Effect of agitation, Renetion temperature, Addition of solvent, Testing for completion, \Work-up of reaction mixture, Continous processing, Recovery of By-product, ‘Yields of amines. ‘Who much irom is used in Bechamp’s method’ In plant practice, normally itis used slightly over 2-mol pret mole of nitro compound Docs the quality of iron has an effect in Bech method? Yes What type of iron is best to use? It is important to use good grade of cast ion, genera form of turnings or borings, free of other material impurities ‘What is effect of physical condition of ron? Clean, finely divided, sof, gray cast iron yields the result ‘Does the physical condition of irom have an effect rate of reduction? The rate of reduction depends upon the fineness and p of the iron What physical condition of iron is used? Iron baring. turnings,or shavings are generally used. ‘What is effect of goarse particle? er 11 Unit Process 3 “The oxidation of ron is relarded and an excess of iron as to be used. low much amount of water Is used? 4~5 moles of water per mole of nitro compound is used. Why itis suggested to use warer in excess? The water is used in excess for following reasons (© Theagitation of reaction mass (© The promotion of smooth active reaction ©The conservation of heat of reduction 1: Why unnecessary dilution avoided? Unnecessary dilution not only places undesirable restriction on the productivity of each redueer but also reduces the concentration ofthe catalyst so that itis les effective. What isthe amount of acid used?” Small amount of ferrous fon is requited to act as catalyst Generally about 0.05 ~0.2 ofan equivalent of acid is used. What isthe problem with the use of HCI? HT sometimes causes the formation of small amounts of chlorinated amines ‘What is the problem with the use of H,S0,? H.SO, rearrange the intermediate arylhydroxylamines to hhydroxyarylamines and cause the formation of darker amines in low yield, particularly inthe ease of solid amines. In such tases acetic aed or formic acid shouldbe used, How the disadvantage in use of H,SO,can be avoided? The disadvantage in the use of sulfuric acid can be ‘minimized when sulfuric acid is introduced as sodium acid sulfate (niter cake), ‘What isthe effect of aptation? ‘citation increases the rate of reaction How agitation creases the rate of reaction? ‘Agitation Morovides bayer contact Between the ni compounamiron and catalyst. What are shé reactions involved in the amination by ammonolysi The ammonolytie reaction involves: © Double decomposition. © Dehydration, (© Simple addition, © Mulliplescnvity ‘What is double decomposition reaction for amination?380 . hapler-LLUnit Pr (Chapter 1] Uni = Th this method, NH, splits into -NH, and -H, The f Ae Linilecile Paco, ; becomes part of new amine and the ler utes with {52 What iy the. order ef amination by ammonolyls radical -Cl NO; ec reaia Q40; What is Dehydration reaction for amination? Tie tid tea 3 . Jn this reaction water and. amines are resulted 10553: What is the order of reaction when ammonis is used in rrmonolysis of either alcohols ar phenols excess? QA1: What is Simple addition reaction for amination? Fre eae Wis mia Gate In this reaction both fragments of NH ener in the fost: WHA isthe effect of molecular weight om the rate of sompourd reaction? (0.42: What is muliple aetivityreaetion for amination? The pester the moleclar weight, the Tower 16 the rte In this, nascent or reeycled amines compete with am ammonol a ao reactant, resulling in the formation of tertiary amines by aminolysis. QA3: What are the aminating agents? 1: Whatlsiheoxt Liquid ammonia Oe Meant i adtion of oxygen, removal of Hyérogen ot Solution of ammonia in water or organic solvent sition of elecirons Bee o Asagas 10.2: What are the principle (ypes of oxidative restions? Ammonia evolved from solid compounds such a5 The principle types of oxidative reactions af€: Q44: What isthe hydro ammono}ysis ornate Hydro emmonolyss is the type of ammonolyss reac Introduction of an atom of oxyeen, ‘which emination i erred out inthe presence of hy S Gambiation of dehydrogenation and inttaduction of land a hydrogenation catalyst. ped 4s: What are the catalysts used Inthe aminati 4! Dieaipeelent” aseormioisi by 5 woleoubr ammonolysis? condensation. ‘There are two types of catalyst © Dehydrogenation, oxygen introduction snd destruction © Metal catalysis of carbon linkage, © Dehydration catalyst aroun Q46; What are the metal catalysts? (© Olefins may be oxidized, Copper, Arseni and Silver. (©. Peroxidation. 047; What metal catalyst is used commonly’? fp: Whats dehydrogenation? Copper, Copper oxide, and Copper salts are used Itisthe removal of hydrogen. commonly 4: Whats oxidizing agent? Q48: Where metal eatalysts are used? Thay. chemical which cause oxidation reaction is called “They are used forthe ammonolysis of halogen cor oaleee tgalt (049; Where dehydration catalysts are used? (Qs: What are oxidizing agents? ‘They are used in production of amines ftom alcohols, Poa ngs sree as CR 50; What are the dehydration catalysts? oe reaigeneee Dehydration alumina and silica gel are commoa Senos catalysts ofthis ype © Hydrochloous acid and als, Q51: What ir the molecuarity of amination by am So Gldtmn cuore AIRES Aide, Chlorates,382 Qs: 8: Qa: Q3: 4: Qs: aot (Chapter 11 Unit Pe c Peroxides Nitric aid and nitrogen tetra oxide Copper salts Alkali fasion Fuming sulfrie acid (oleum) Ozone ‘What types of permanganates are used as oxida agents? ‘The permanganates used as oxidizing agents are of d ‘ypes © Alkaline solution, © Neutral solution, © Acid solution, ‘What are peroxides used as oxidizing agents? The commonly used peroxides as oxidizing agent are Lead peroxide, Manganese dioxide, Hydrogen peroxide, Sodium peroxide, Silver oxides ‘What is the cheapest oxidizing agent available? What is polymerization? TThe combination of small identical molecules to f bigger molecule, which is the chain of small molecul called polymerization ‘What is monomer? The small molecule i called monomer. Its the single What s polymer? The bigger molecule formed by polymerization is polymer. It isthe chain of monomers. ‘What are types of polymerization reaction? ‘There are two types of polymerization reactions LL Addition polymerization, 2, Condensation polymerization ‘What is addition polymerization reaction? ‘The polymerization reaction that occurs due to addition of monomers and & single product (pos formed ver 1) Unit Process 58 ‘What is condensation polymerization reaction? The condensition polymerization reaction is the one in Which the polymer is formed along with elimination of some kind of byproduct such as water or methyl aloobo. What is degree of polymerization? Degree of polymerization means how mich monomers combine to form polymer. ‘What are the types of plastic? There are two types of plastics © Thermoplastic, © Thermoseting plastic What type of polymerization results in thermoplastics? Addition polymerization What type of polymerization results in. thermosetting pasties? Condensation polymerization ‘Why thermosetting plastic cannot be recycled? Thermosetting plastic result fom condensation polymerization, in which one by-product is formed along ‘with polymer, the by-product formed is removed during the course of reastion so the reaction can't be reversed so thermosetting plastics deform upon heating ‘Why thermoplastic can be recycled? Thermoplastic results from adaition polymerization. In this process simple addition occurs and no by-product is formed slong with polymer so it canbe recycled. 11.8 __ FERMENTATION. Whats Termentation? Fermentation is any microbial process control that produce useful products, What are the types of fermentation? Ichas two types + Aerobie fermentation: Fermentation wok place in the presence of oxygen. + An-aerobie fermentati the absence of oxygen, What are applications of fermentation? Fermentation of ftuits 0 aleohol and making of various heverages out of fruits and grains: Molasses is mostly used for fermentation whichis sugar industry by product Fermentation took place in26: an Qs: Qs: Quo: Qu qu Qu3: Quad: Qus: ‘Which seientst discovers the fermentation? Louis Pasteur How the fermentation process is done? Ie is done in the presence of microorganism, cont conan empresa at it cnet ‘What are the types of microorganism? Itconsists of bacteria, yeast and molds. 16: Both process took place inthe presence of micro In fermentation controlled conditions are used wl protfication uncontrolled conditions are used like de ‘atural matters in uncontrolled conditions ‘Which of the microorganism is unicellular? Yeast and bacterial are unicellular and of very dimensions. What isthe shape and size of yeast? Yeats ineully oral shape nd around 0904 tl What isthe size of bacteria? Bacteria are small mostly less than 0.007 mint dimensions and more divers in shape. How yeast grow? ‘Yeast mulipies by budding. How bacteria grow? These grow by binary fission. ‘What is the time of reproduction of bacterial and y Negative reproduction cycle of these bacterial and short and measured in minutes (Bacterial as 1-2 minut ‘What are the important products of fermentation? ‘These are the following Citric acid, Alechol, Gluconie seid, Lact acid and ealcium lactate, Acetic acid, Buty] aleohol, ‘Major antibiotics are produced through fermentat ‘What are the applications of enzymes? Enzymes are used for the production of alcohol produce high fructose syrup from cor, 025: ier IL Unit Process 385 How the cheese is produced? Protease produced from mold enzyme are used to coagulate protein in mill: to produce cheese ‘What are the chemieal processes done by fermentation? 1. Oxidation, 2, Reduction, 3. Hydrolysis, 4. Esterfieation. What are the examples of fermentation done by ‘oxidation? 1. Alcohol to acetic acid, 2. Sucrose to circ acid, 3,_ Dextrose to gluconic acid. What are the examples of fermentation done by reduction? “Aldehyde to alcohols (Acetaldehyde to etbano!), 2._ Sulfur to hydrogen sulfide. What are the examples of fermentation done by hydrolysis? 1. Stach to glucose 2. Sucrose to glucose fo frase & to alcohol What are the examples of fermentation done by cterification? Tr Hlexose phosphate from bexose and phosphoric acid ‘What are the five steps required for fermentation? required which complete the 1. Microorganisms fermentation process and give the useful product 2, Beonomical rw materials for the substrate eg, starch oF one of the several sugus 3, Acceptable yield 44. Rapid fermentation '5)_ A product is readily recovered and purified ‘What isthe use of incolein? Incolcin is ¢ biochemical whichis used asa catalyst ‘Which reaction occurs in cells? ‘Combustion reaction oveurs ‘What is absolute alcoho? [Absolute aleobo is pure alcohol which is 99.5 %.356 Qa: Qa: Qs: ar: a8: Chapter 12 Jnsioumen INSTRUMENTATION AND PROCESS CONTROL 12.1__INSTRUMENTATION ‘Whats instramentation? A set of instruments used for a particular purpose, ‘example, operating a machine or controlling an aireraf ‘What are the measuring devices? ‘Measuring devices are those, which measure some pro fof the fluid, which is used as information & used it control of process e.g. thermometer is used for temp ‘measurement, pressure gauge for pressure measurement. ‘What process variables, we measure & control in pro industry? These ae five in number (Level, Pressure, temperature, ‘& composition) ‘What is range? Every instrument is designed to operate between a To upper limit These limits express the range of an in 4. thermometer measure temperature from -5 10 110 range is 115°C. Define span? The absolute difference between the highest and I range limits isthe span of an instrument. For ex pressure sensor with & range of 100 to 400 pst has 5p 300 psi Define measurement? ‘The value of a process variable as indicated by a sul instrument is called the measurement. What is sensor? A sensor is a piece of equipment that is used to me system variables. Sensors are normally transducer ‘change energy of one form into something different. S ferve a8 the signal source in automatic control 5 ‘These are normally used to detect some fuid property Define fidelity (precision of reproduction)? Degree to which an insirument indicates the chi measured variable without dynamic error is called fide What type of fidelity is desirable characteristic instrament? igh fidelity isthe desirable characteristic of an instr Dhapter 12 Instrumentation and Process Control____387 ‘What should be the duration of dead zone? shouldbe less than 0.2% of the scale. ‘What is calibration? Comparison of proces valu withstand vale is know as calibration Why we do calibration? Calibration is dane to check the accuracy of measuring What is the controling range of pneumatic and electrical signals? The controlling range for electrical signals is 4 t0 20 mA, while the range for pneumatic signals is 3015 psi What are transducers and its types? Transducers are used to convert one form of signal to other eg. They convert electrical signal to pneumatic and ‘pneumatic signal to electrical, There are the fllowing types of transducers: © VP Converter © PConverter ‘What are the benefits of instrumentation and control? Instrumentation and control is very important from industry point of view. Following are the benefits; > Manpower requirements are reduced. > Accuracy of measurements is increased. > More reliable in emergency conditions. > High quality products can be produced. > Greater safety of operation > Greater economy of operation How accuracy of an instrument is judged ? ‘Accuracy ofan instrument is judged by the static eror. When pneumatic transmission equipment is considered? Pheumati transmission equipment is considered when: > The extreme accuracy isnot necessary. > The exiremesspeed is not necessary. > The transmission distance is short. What is accuracy? Comparison of indicated value agninst accepted scandard val ‘What is level?388 (Chapter 12 Instrumentation and Proces Qa: 03: a6 a7: Qs: Qs: This the interface between two phases, normally Ii phase. ‘What are the methods for liquid level measurement ‘There are two methods a. Dirctmeasurements _b. Indirect ms ‘What are the types of Level measuring instrum Following are the types of level measuring devices Visual devices (Sight glasses, Level gasses) | Float actuated devices (Internal & exter ‘mechanism = Differential pressure measuring devices ( transducers et.) ‘+ Displacer devices = Conductivity measurements (For electrolytic 6g, caustic soda solution ete:) How the level of a liquid under pressure determined Differential manometer, differential pressure diaphragms can determine the level of a liqu pressure ‘Where dipsticks are use in daily life? It is used in automobiles like motorcycles & vel ‘check te lube ol level iow inferential level in pressure vessel is measut Manometer of float type can be used to measure i level in pressure vessel ‘Why weuse color liquid? ‘To measure accurate reading, of liquid level and How liquid levels in autoclaves are measured? Liquid levels in autoclaves are measured by di type manometer. ‘What is the pressure at the bottom of a colnn meter height? is 10 kyjeny 12.3 _ FLOW MEASURIN¢ "What is flow rate? ‘The flow rate is a quantty/amount of fluid passing fi ‘point per unit time, It canbe represented as 1 Volumetric flow rate: It has unis mh, tik pier 12 Instrumentation and Process Control 389 2, Mass flow rate: Volumetric flow rate x density Ithas units (Tb/sce, Ke/hr, Tow, eram/sec) ‘What are the types of flow? And how the type of flow can bbe determined? Flow has the following three types, with their ranges by ‘which we can determine the flow type. Range depends on Reynolds's no. Laminar flow Re,No. <2100. Transition flow Re. No. 2100~4200 Turbulent ow Re. No. >4200 So maximum eddies formation occur in turbulent flow. This ‘actually ogcurs inthe industry ‘What are open channel & closed channel flow and w! struments are used for measurement in these ‘Open channels:- These are rivers, lakes, ponds ete and flow ‘measured in these by weir & notches, ‘Closed. channels:- These are pipes, tubes, ducts ete. and these we used rotameter, orifice meter, venturimeter, pitot tubes, nozzles, magnetic flow meters ‘Which flow-measuring device can measure the flow rate directly without measuring the pressure drop? ‘The flow measuring device like rotameter, magnetic inductive flow meters are used. But it is necessary to measure the pressure difference for devices like orifice meter, venturimeter, pitt tubes ec ‘What is other name of rotameter? Variable area meter How continuous measurement of flow rates of dry ‘granular fertilizer is done? ‘Weighing meters docs continuous measurement of flow rates of dry granular fertilizer. Where orifice meters are mostly used? “These are used for closed channels, where thee is no necd to remove the parts, How the flow rate of sludge is measured? Kennison nozzle is used for the flow rate measurement of sludge. ‘To which the pressure difference signal is proportional to in ease of flow measurement by an orifice?Qua: Que: Qar: Quo: qu: Qus: Th case of flow measurement by an orifice, the difference signal is proportional 9 Where Q= Volumetric flow rate, ‘What is use of V-notch? V-notch is used to measure flaw rate of liquid in an channel ‘Which is not a head flow meter? Rotameter is nota head flow meter. How the flow rate ofa liquid containing Keavy soli sand can be best measured? ‘The flow rate of liquid containing heavy solids eg. bbe best measured by electronic orifice. What is accuracy for orifice measurement? Orifice plates for low measurement has poor acc high orifice ratios (above 0.75. ‘At, which condition the Pitot tube is used? Pitot tbe is used when the line is large and the vel high, ‘What are characteristis of flow ina rotameter? mn an area meter (¢ rotameter, the flow rate isin from the position of float (changes in area of an ori the flow line across which the pressure diferent constant What is pressure drop ina rotameter? ‘A rotameter incurs constant, but small permanent drop. ‘What i the most suitable low-measuring device for a stream flowing at $0 liter/minute in 3 em LD. sti steel tube? Rotameter is the most suitable flow-measuring device fs stream flowing at $0 liter/minute in a3 em LD. steel tube, How the Flow rate of clear water steam flowing liter/minute in a 1.5 em LD. horizontal copper tube: be best measured? Orifice meter ean best measure the flow rate of clear steam lowing at I lterminute in a 1.5 em 1D, ho copper tube 0.19: plates for as: ‘Do specify a suitable flow-measuring device for slarry flowing at 3 minate/minute ina 2 em LD. horizontal glass tube? ‘We use Magnetic flow meter. What should be the Best flow-measuring device for molten polythene flowing in a 2" schedule 40 steel pipes? Venturimeter should be the Best flow-measuring device for molten polythene flowing in a2" schedule 40 steel pipes. How flow rate of river is measured? ‘Vane meter measures flow rate of river How liquid flow rate in a small cha measured? Pitot tube best measures liguid flow rte ina small channel. What is the diaphragm elements used for pressure They are composed of rubbery material, They are used for low pressure applications up o 100 psi ‘What is principle of electromagnetic flow meter on which itworks Wased on faraday's flow of electromagnetic voltage will be induced in a conductor moving through a magnetic fel ‘What is the Principle of Orifice meter? Orifice meter:- an orifice plate is a restriction with an ‘opening smaller than pipe diameter, which is inserted in pipe. It has smaller area, sharp edged opening due to this fluid velocity increases, causing corresponding decrease in pressure drop across the orice plate. tis simple, reliable, Cheap and commonly used in the industry. It eauses much pressure drop. ‘What is the prineiple of venturi meter? ‘Venturi tube: It 8 designed to nearly eliminate boundary layer separation, and this form drag. Change in cross sectional ares venturi tube causes a pressure change biw convergent and throat section, and flow rate can be ‘determined fiom this pressure drop. It causes less pressure drop than orifice meser but itis bulky snd requite much space and costly ‘What is the principle of flow nozzle? Flow nozzle It consists of a restriction with an elliptical ‘contour approach section that terminates in a cylindrical thyoat section nel Is esta 3K = Chapter 12 Instrumentation and Process ‘What is the principle of elbow meter? Elbow meter: A differential pressure exists when a {uid changes direction due a pipe or cloow. The difference results form the centrifugal fore, ‘What i the principle of pitt tube? Pitot tube and annular:- it measures the stat dynamic pressures of the fluid atone point in pipe re ean be determined from the difference Ww st ‘dynamic pressures, which is velocity head of fuid fl Annular consists of several pitot tubes placed across a provide an approximation to velocity profile, and toa can be determined based on multiple measurements, ‘What is the principle of turbine meter? Turbine meter: As uid flows through turbines, i the turbine to rotate with an angular velocity proportional to fluid flow rate. Frequency of rotation ‘measured snd used to determine flow. ‘What is the principle of positive displacement meter Positive displacement:- This fluid is separated individual volumetric elements and no of elements time are measured. eg. wettest meter ‘What i the principle of rotameter? Rotameter:- When the fluid is passed through it position of flat indicates the flow rate, Buoyancy & force (in direction of flow) is balanced by gravity f then float stabilizes at some position. Flow is noted agains! calibrated seale with reference to float postion, also called variable area flow meter. ‘What is vena contracta? “The minimum area available for flow of fluid is coniracia, In Venturimeter, i is formed at the posi throat, while in orifice meter itis after the orifice. : What flow meter is used for high pressure & pressure measurements in Industry? Orifice meter is the most commonly used flowy meter. reliable & cheap; less maintenance is required and moving parts ‘Which is most costly, DPC or orifice meter? DPC is more costly Q29: 930: Qat: Qa 3%: 035: 038: CHIE tiation Process Control 328 ‘Which instrument docs not need to be replaced du Tee ating ands very cheap, K replacement i necessary? Orifice meters and thermocouples. ‘What are the limitations of rotameter? Rotameter isnot widely sed in process industry because ‘© Tis fragile & easily breakable + thas limited capacity of flow + teannot used for high temperature & pressure ‘Write down the advantages and disadvantages of orifice rmeter and venturi meter? Advantages of orifice meter: 1. Simple in construction 2. Flow capacity can be easily changed by replacing corte plate 3. Reliable 4. Now moving part Disadvantages: 1, High pressure drop Advantages of venturi meter: 1. Low pressure drop 2. Nomoving part 3, Have Tong life (liable) Disadvantages: 1. Costly 2. Bulky in size (Requite more space for installation) 3. Repair and maintenance is not easy 4. Noteasily movable ‘What is emperat tis measure of homess or cokiness of abody. ‘What are the types of temperature measuring devices? Following i the type of temperature messuring devices. + Filled system (Thermometer) ‘Thermocouple Bi-metallic thermometer Resistance thermometer Pyrometer Thermister Oscillating Quartz Crystal394 Chapter 12 Insérumen Q3: Qa Qs: Os: Q7. 28: Que: Qui: ‘Wha types of fluid are used in thermometers? Mereury, Alcohol ‘What isthe working principle of thermometer? 1t works on the principle that on temperature increase available in capillary tube expand and show the ona graduated scat. ‘What is the difference between a laboratory and thermometer? Laboratory thermometer is designed for continuous ‘of temperature while medical thermometer is designed ‘mercury rise i the bulb then it stay there tl thermome shake again, It has small bend inthe capillary tube, ‘What isthe working principle of bimetal thermome It consiss of composite material made of strips of. ‘more metals fastened together. When heat is supplied ‘metal expands and contrat for temperature ideation, other have low expansion coefficient & does not position, These are mostly used in reffigerator & Write the following metals. in decreasing th ‘conductivity iron, copper, silver and aluminum)? Silver, Copper, Aluminum and Iron ‘What is te most suitable instrument for measu temperature inthe range of 40 to 425°C? Bimetallic thermometer is the most suitable instrument measuring of temperature in the range of -40 19 425 °C. Bimetallic thermometer uses same metals or diff metals? Bimetallic thermometer use two strips of different ‘welded together having different co-efficient of expansion, ‘What is thermocouple? It is a device which is commonly used in industry for ‘measurement of temperature. It works on Sesback effe When two dissimilar metals are joined togcther, junctions are formed , one is cold junction and other one hot junction, an emf is induced” This emf ean ‘measured by using multimeter. It has following types ket Hype ete ‘What is PT-1002 Itis the other name of J-type thermocouple, 023: Qu: Qs: 12s ud Process Control. 2 (0.12: What is thermopile? ‘Asetof thermocouples, cither joined in series for increased ‘voltage or in parallel for increased current, used to measire radiant energy oF to convert radiant energy into electric ccurent EMLE developed by a thermocouple while meas ‘temperature of 800°C is about 31 mY. What i the type: ‘thermocouple? (Chromel-Alumel type is used. BAM. developed by a thermocouple while measuring a temperature of 400°C is 22 mV. What is the type of ‘thermocouple will be used? Tron constantan thermocouple i wsed. Inconstantan thermocouple is used to measure temperature in which range? From 0 to 600°C. : Which device is ot suitable for the measurement of ‘temperature inthe range of 800-1600°C?, ‘Thermocouple is not suitable for the measurement of temperature inthe range of 800-1600°C. : Which property of thermocouple for industrial use is an undesirable? ‘Non-linear relation of em, to temperature is undesirable. For platinum thermocouple, lead wires are made of which materia? Copper and eopper-nickel alloy. ‘What is constantan? Constantan is an alloy of Cu (55%) and Ni (44%). 3 thermocouple is suitable? For both high and low temperature thermocouple is suitable (up 10 600°C) or even up to 1000 °C. ‘What are probes & its types? Probes are used for detection of some property of fui, it has three types a. Bareprobe b. Insulated probe ©. Probe with concentric shield ‘Where thermo-wells are used?‘hapter 12 Instrumentatior "Thermo-wells ae used in temperature measurement to against and oxidizing aetion on thermocouple materi protect it ffom high pressure & temperature. Thermo actually a protecting device. For measuring the temperature of red-hot ‘Which is the most suitable instrument? Optical pyrometer Which device shows maximum dip effect (t reverse direction of temperature change)? Meroury thermometer. Jn case of resistance thermometer, by incre temperature the resistance increases or decreases? Increases In ease of platinum thermocouples, lead wires are ‘of what material? ‘Copper and copper nickel alloy ‘What is the composition of monel alloy? Ni= 69.0% , Cu=28.0% ‘What is the composition of constantan alloy? Ni=44% — CU=55% ‘Which relates the absorption and evolution of heat junction of a thermocouple to the carrent flow in creuit? Seaback effet relates the absorption and evolution of the junction of a thermocouple to the current flow circuit. How minute dispersion of freezing point of a solvent on addition ofa solid solute can be measured; Minute dispersion of freezing point of a liquid sob Addition of a solid solute ean be measured by thermometer. What is order of exn.f generated by the thermocou EMF generated by the thermocouple iin mill-volts, How sub-zero Celsius temperature is measured, industry? Resistance thermometers doit ‘What Is starting temperature of optieal radi pyrometer? Starting temperature of optical radiation pyrometer is Which thermocouple can be used to measure temperature around 1400°C? (Chapter 12 Instrumentation and Process Contr 391 latin platinum and hod hermocouple can Be used 0 ‘measure the temperature around 1400°C. ‘What is effect of heating on a stip made of ion and Shen satrip made o iron and coppers heated it bends with iron on eneave sie How mach area the pressure thermometer bulb showld have? Te should have large sea What, is thermistor, ako write 16 advantages & rivantages? ‘Thamar i somicondctor whose resistance decreas Teil temperature rise It has negative coeficent of Tnsancee The detector dimensions are sell and tcmporaure sesiviy igh They have low messing tCoperatre ange and incl nolnear characteristics ‘Which deviee i sufable for measuring the temperatare Mra re hot moving object (eq. stel ingots on rller tabley adaion pyrometr issuable for meaning the tempera of red bok moving object (sel ings role tbl) ‘Where cald junction compensation i required? Thermocouples need cod junction ompensition. On which parameter the ssleston of material for fhermoconpte depends? Solecton ef material for themnocouple depends on the minimum and maximum temperature For a given thermocouple the eam. depends on which thing? Tt dopends upon diference bw coli and hot en. What is temperature range of Tron-contantan Thermocouple? ‘Temperature ange of Irn-constanian thermocouple is-30 0 100°C. ow very high temperature (1200-1700%) can be ensured? Vee high temperate (1200-1700°C) can be measired by optical promt ‘Wnt is baste principle involved im the measurement of temperature by thermocouple?398_ Chapter 12 Instrumentation and Process Ce 46: aan: a9: O50: ost: 52: 5% ast: ass: ‘The basic principle involved in the “measurement ‘temperature by thermocouple is plter and Seebeck. How temperature rise in a bomb measured? ‘Temperature rise ina bomb calorimeter is| measured Beckman thermometer. On which law the working of a constant volume ‘thermometer is based on? ‘The working ofa constant volume gas thermometer is ‘on Charles law. Do specify the element whose resistance decreases the increase of temperature? ‘The element whose esistance decreases with the increas ‘temperature is carbon. How the tube side temperature in shell and tube exchanger is measured? The tube side temperature ina shell and tube heat exc is measured by a thermocouple, What is the important parameter the vapor py thermometer should have? The important parameter the vapor pressure should have is large area. Jn which temperature ranges the pyrometers are useful? Photocleetic pyrometers are usefil in the tem ranges of $00-16000C. What is RTD? sdeercases with increase of temperature. They give temperature reading up to 600 °C. RTD are cheap, measurement of temperature of Mercury in lass thermometers, ier 12st and Process Control O56: sr: O58: Qs: 2.00: O61: Qa: Vapor pressure thermometer. > Resistance thermometer ‘What is Thomson effect? ‘Thomson effect relates emf genertted in a single homogeneous wire and the temperature difference. ‘What i peti effect? Peltier effet relates absorption and devolution of heat atthe junctions ofa thermocouple tothe current flow in the circuit. On increasing the temperature, the resistance will decrease for which material (Pt, C, Cu, and Constantan)? Carbon, ‘What is effect of temperature on thermistor resistance? Itdecreases with increase of temperature. From which material the thermistors are made? Salts foxides of metal aro used for construction ‘What is the working principle of thermistor? The themistor works onthe principle that electrical resistance of thermistor decreases with temperature. What is the working principle of resistance thermometer? ‘The resistance thermometer works on principle that electrical resistance of metals increases with temperature, like copper, nickel & paltinium. It has measuring range from ~ 85 to 850 bel What is the working princi ‘thermometer? 1k based on the principle that platinum’s eletrcal resistance changes when itundergoes a change in temperature. Which device is used to measure the temperature of famnace? Pyrometer ‘What are the types of pyrometers used? Here are two types; Optical pyrometer:- ‘Those instruments in which the brightness of the hot objects is compared with that of a source of standard brightness, like disappearing filament pyrometers Radiation pyrometer:- It based on the rate of energy ‘emission per unit area over a relatively broad range of wavelengths or which compere the radiation at two wavelengths. It works on the principle of Stefan-Boltzman aw. lo of platinum resistance400 (Chapter 12 Insteumentation and Process 0.66: Qo: 968: 9.69: a0: Qn: Qn: 73: Qa: Qr6: ‘Which (ype of element is the bulb of a vapor pre ‘thermometer? ‘The bulb of a vapor pressure thermometer is a pi element. ‘Which type of clement is the tube of a vapor pi thermomete ‘The bourdon tube of vapor pressure thermometer secondary element Ordinary mercury in lass thermometers is ‘measure temperature in which range’ From -30 to 350°C Vapor pressure thermometers are used to mea temperature in Which range? gas thermometers emplo s: hydrogen gas is used to measure temperature in range? yo: Biv and log'c. ‘Which device is suitable for measuring temperature 250°C? Constant volume helium thermometer is suitable ‘measuring temperature of 250°C, For. which liquid the volume expansion caused temperature change is minimum? ‘The liquid for which the volume expansion caused temperature change is minimum is mercury. How continuous shell temperature measurement liquid ~liquid heat exchanger is done? Continuous shell temperature measurement is a ligu liquid heat exchanger is done by thermocouple ‘What are the common resistance materials for RTD which is the best? Platinum, nickel, copper, tungsten. Out of this platinum Why composition analyzers are not preferred? They have the following disadvantages 5 Large delay time (Dead time) Low operation relibility > High cost ‘What is the most utilized Instrumes measurement, used in process industry? Q7: Qs: 09: 10: oat: ear: aut for temperati Danse 12 mstiitation and Process Control _401 “Thermocouple is mostly uilized 12.5 _ PRESSURE MEASURING DEVICES Wath pressure? Wis the force acting per unit area ‘What are diferent units of pressure? Different units of pressure are: Ib / in’, kg / em’, Pascal, Bar, Atmospheric, mm of water, mm of Ha. et. What are the eypes of pressure measuring devices? Pressure measiting devices are ofthe following types Elastic elements: Bourdon gauge, Bellows, Diaphrgam Strain gauges, Pizzo sensitivity elements For which purpose pitot tube is used? Itis used forthe measurement of static pressure For which purpose barometer is used? tis used forthe measurement of absolule pressure. ‘What is the working principle of Bourdon gange? Bourdon gauge is also known as C-tube. K-consists of bourdon tbe element. When pressure i applied inthe tbe, de to clasiity it moves towards the outward side and deflects the needle, which then actually represents the pressure What is pressure gauge? ‘An insitiment used 10 measure he pressure, above than atmospheric pressure For what purpose vacuum gainges are used? Vacoum gauges are used. iy measure pressure below atmospheric pressure, Usually in mm of Tg ot inches of water For low pressure measurements which type of pressure ‘gauges are used? Helical or Spherical ‘What i tue range of bourdon tube elements? thas range fom Oto 10,000 ps What are compound gauges? ‘These gauges are used to measure both pressure & vacuum. ‘What is use of Pirani gauge? tis used for the measurement of high vacuum, ‘What is relation bw flow rate and pressure differential? Flow rate though an orifice is proportional to the square oot of pressure differentia P=F/A402 Chapter 12 Instrumentation and Flow tate a VAP Ds: Q.14: How pressure is measured in an ammonia reactor? Pressure im an ammonia reactor is measured by mi number of Bourdon gauges. QS: How the pressure of 0.01 psi or lower (absolute) measured? The pressure of O.01-psi (absolute) ean by measuy 5: Meloid gauge (<0.0001psi Q.16: What is maximum differential pressure in i ‘Maximum differential pressure in liquid manometer i i Q.17: How bellows are made? ‘They are made of thin copper shes, tightened by finely welded Q.18: From, which materials the bellows can be made? Bellows are made of thin sheets of meal plastic and le Q.19: How much range of pressure the alphatron measures ‘Alphatron measures the pressure >3 microns For, which pressure measurement the liquid col manometers, are used? LLiguid column manometers are used for the measure a: <2kglem For what amount of pressure measurement the Bot gauges are used? Bourdon gauges are weed for presure measuremenl 24: 22Kgle ‘What is the working principle of strain gauges? 29: ‘When a wire is stretched elastically its length is incre and diameter is decreased, Both of the dimensional cl result in an inereate in electrical resistance of conductor pL A a. Bounded strain gauges , Unbounded strain gauges ‘What is working principle of bourdon-tube element? Bourdon-tube gauge indicates pressure by amount defletion under internal pressure ofan oval tube bent in ate of circle and closed at one end, these gauges are avail fo all pressures and below atmospheric pressure. has two types. Q23: pier [2 Instrimentalion and Process Control 493 ‘What is working principle of bellows? ‘The bellows is an elastic clement which is used for low ‘pressure measurements. It has high accuracy. The pressure to bbe measured may be applied either tothe inside or outside the bellows, with other side exposed to atmospheric pressure Which type of instrument is used for differential pressure measurement? Normally a differential manometer is used for differential pressure measurements. The height to which a fluid rises in tan open vertical tube attached to an apparatus containing liquid is a direct measurement of pressure at point of attachment. Manometer fluid is used in liquid immiscible with uid under pressure. For high vacuums or for high pressures, the gauge liquid is of high density liquid generally ‘mercury for low pressures «ow density ligud e.g. alcohol, ‘water i used. ‘What is gauge pressure? ‘The difference between given fluid pressure and that of atmospheric pressure is called gauge pressure. The readings cof pressure gauges are postive gauge pressure Which instrument is used to show negative gauge pressure? ‘A vacuum gauge is used to show negative gauge pressure i Fluid pressure lese than atmospheric. In which units vacuum pressure is measured? ‘Vacuum pressure is measured in mm of Hg or inches of Hg ‘What is absolute pressure? 1 is total pressure and is equal to gauge pressure and atmospheric pressure. Absolute pressure = gauge pressure + atmosphere pressure ‘Witch manometer is used for extreme precision? Micro manometer based on liquid column principle are used for extreme precision and accuracy. It ean measure minute pressure differences. ‘Which instrament measurement? A pressure gauge consisting of bourdon gauge with an appropriate flexible diaphragm to seal off process fluid may be used or bubbler is used for systems operating at atmospheric presture or open to atmosphere. Is used for corrosive fluid(Chapter [2 Instrumentation and Proces Whatie fanetion of regulator? is used to control the pressure or it regulates the according to requirements ‘What do you mean by a dead weight tester? Dead weight tester is used forthe calibration of measuring devices, It is a standard device, which, fing the hydraulic pressure of oil and’ appli weights, ‘On which scale manometer is mostly used? (On lab Scale because itis fagile and easily breaks. For low-pressure measurement which mano rased? Inlined manometer What are disadvantages of using mercury 28 ma liquid? has following disadvantages > Corrodes many metals. > Expensive > Poisonous Which of the following manometer jiquids mercury, ethyl alcohol, carbon tetrachlo ‘maximum capillary rise relative to mereury? (Carbon tetrachloride. Liquid column manometers are used to measure in which range? [Ciguid column manometers are used to measure diff pressure of less than 30 pi How local atmospheric pressure is measured’? By « mercury barometer. How absolute pressure is measured? By an aneroid (not containing or using liquid) barr ‘What is pressure sensor? Pressure sensors are those, oyhich are used 10,8 pressure, They may be classified as; > Bourdon gauge > Manometer > Pressure sensor ‘Which instrument is known a5 the universal instr Differential pressure cell is usually known a i ‘Why DPC is known as universal instrument? 12 TraientaoM ANE Process. Como 405 Dpe is called universal instrument because Ht ean measure pressure difference that is helpful in determining level, flow and pressure drop across equipments. For what purpose manometer is used either pressure [pressure measurements? 12.6 COMPOSITION MEASUREMENT / ANALYZERS, ‘Wat are the different types of composition analyzers? ‘Oxygen analyzer, gas analyzer, moisture analyzer, pH meter, conductivity meter. ‘What is use of psychrometer? Payehrometer determines humidity of gas. How continuous measurement is done in paper industry? Measuring elestrieal resistance through the paper does continuous measurement of moisture content of paper in paper industry. How optical activity of «solution is measured? Optical activity of a solution is measured by polarimeter. How continuous measurement of sp. gravity of aliquid is done? Hydrometer and displacement meter does continuous measurement of sp. gravity ofa liquid. ‘What i the use of stalagmometer? [eis used for the measurement of surface tension. ‘What i the use of stroboseope? Iti used for measurement of RPM of a iywheel How continuous moisture in paper is measured? High resistance Wheastone's bridge circuit does it How many cells pH meter has? Ichas two eels ‘How composition of natural gas cam be measured? Composition of natural gas can be measured by gas chromatograph ‘What is principle of the analysis of a component by chromatography? ‘The analysis ofa component by chromatography is based on the principle of relative absorption of various components in a liquid ‘How humidity is measured?406. as: aa Qas: Que: oar: Qs: Que: Q20: oat: 22: Chapter 12 Instrumentation and Process Humidity is most commonly measured by dry and temperature measurement. ‘What is Orsat apparatus? It is used to determine the Y%éage of CO, CO; ete gases How the %age of O: in the fue gas is determined? The Yhage Of Os inthe fe gsi determined by 2 probe. ‘What is tachometer Tachometer is used for the measurements of RPM, How the continnous acidity measurement in the neutralizer is done? PH meter does the continuous acid fertilizer neutralizer, ‘What is polo graph? Polo graph is used forthe analysis of solids How composition of alloys can be determined? ‘Composition of alloys and solids ean be determined by} graph For- which purpose the zeronia probe (also kn zirconia probe) is used? ‘The zeronia probe is used for the continuous measur the oxygea influ gases going out ofthe chimney. For whieh purpose the mass spectrograph is used? The mass spectogaph is used for ompeston ana alloys. ‘What is Thermal conductivity principle? Thermal conductivity measurement comprises the principle of CO, analyzer ‘What is working principle of refractrometer? ‘Change of angle of refraction with composition co ‘the working principe of refractrometer. ‘What is working principle of pH meter? Generation of an emf when a thin glass wall separates solutions of diferent hydrogen ion concentration forms ‘working principle of pH meter. What is specific conductance (micro-mbos/em) distilled water? Specific conductance (micro-mhos/em) of distilled round 1 Aptoe 12"nstrumentation and Process Comrol 407 125: What is specific conductance (mlero-mboslem) of good quality raw water? Speeifte conductance (micro-mbos/em) of good quality raw water is about 100, 26; How composition of CO: Is determined in a fue gas? We measure itby teal conductivity eel, 127; How many experiments, we ean perform on flow controller apparatus of GUNT type RT-S22.? ‘We can perform following experiments; > To check te calibration of rotameter & flow meter, Study behavior of open loop & closed loop system. % Study the different pes of controller a its ting parameters P,P, PD, PID etc) > Study cascade conirol system, by combining both Level trainer & flow rine. > Study the recorder working 0.28: What i effect of temperature on conductivity? Ttdecreases withthe crease of temperature. 0.29: How many level measuring instruments are installed on the apparatus of level measurements RT-S122 > Pressure wansducer > Transparent glass cylinder > Sight pass of storage tank 2.30: What Is effect of temperature on refractive Index of lass? The refactive index of glass is inversely proportional to temperate 0.31: How amount of moisture is determined? Itis determined by hygrometer, 0.32: On which principle the rapid moisture meter works? Rapid moisture meter works on the principle of loss oistre by beat (0:33: What i the use of dilatometer? Dilatometer is used to measure contraction/expansion duc to chan ‘Whats process control? Process contol is the control of various sections ofa plant by electron, hydraulic or pneumatic means with a view toQs: 26: Qn 28: Qs: Chapker 12 Insirumertation and Process er TBE and Process Control__400 ep flows, pressures, lempertures, compositions sing a closed-loop contol system. They mus be minimized erin st values fr reasons of safety and qual for good contol ‘What are the types of process variables? What considerations should be kept while determining ‘There are five types of proces variables the controls that need tobe Integrated atone pace whore Following considerations should be kept in mind: “Temperate ‘+ What isthe technical implication of the specific control Presare in whole process? Flow What factors will determine the insallation within the Composition analyzer contol room? Composition analyzer includes density, vis ‘What sssocsted controls are required for specie somposition, color, conductivity, pH, harness et. All contol? ropes exc heer, presen Mo The cram epee Under the heading of ecmposition analyre. Define open lop contro system? What are the rulator systems? A yates Hh WHEAT ra BSH Btn Most proces contol systems maintain constant proc variable are not fed back to controller or Fial contol conditions and hence are regulator systems clement known a open fop control syste Write the name of some advanced controllers? What is close loop control system? Feed forward contol A system in which information sbout the controlled variable Ratio conta is fed back to controle & Final control lesen is kaown Splitrnge contol closed lop / Feed Backward contol system Override contol 3: What are the components of controlled loop diagram? Cascade contol ‘The following are the mia components of controlled loop ‘What ae the types of process variables? diagram ‘There are the following types of press variable? Process 1. Controlled variable Sensor 2. Manipulated variable Comparator 3. Disturbance variable Controller ‘What is manipulated variable? Final contol clement Ie is the variable used to maintain / adjust the conto variable atts st point cai Whats conta pant? t=} — Te The actual value being maintained is the contrl point. What is setpoint? ‘The desired Value ofa controlled variable, whichis sti the conrller,iselled the se point co ‘What are disturbance variables? raat The disturbance variables (D) are process input varia iagram that affect the controled variable Dut are not contol Feed Backward Control Loop Di the control system. Disturbance variable is. capable as See hanging the ladon the proces and are the main eason{ Acca sa it eeeam errmat lat ealays pmeumatc,cleeoni, and/or mechanical energy to perform‘Chapter 12 Instrument apter 2 tasiroi@hfation and Process Contral__al Spam conte operation. These units ae de 123: What i function of recorder and what iypes of recorder as: 20: Qa: oar raintain a process variable at = predetermined are available in industry? Comparing is exising value to that of desired Function of recorder is to displays data in analog or digital vale form. Anelog recorder display by varying response © ‘What is control variable? Pointer or sale, While digital dati recorded in coded form The variable, which we want to contrl, is known af or on mngnetic paper. Analog recorder includes variable or any process variable that is. manta Acletypewriter, Srp printer and data logging Selecting through contol system is called a 6 i: What is feed backward syst? ‘arable, For example, one controled variable ina In closed loop control system information's about controlled process might be the level of liquid in a tank variable are fed back to the controller and final contol Examples ae pressure, flow rate and composition. element. It uses dircet meesurements. of the controlled What the basi funetion of a controller? ‘arables to adjust values of manipulated variables. It does The basic. fumetion of the automatic controler not directly measure the disturbances. continuously compare the measured variable with point If difference between the measured value and} point is detected, the controller changes its outpt the contol valve in auch a way thatthe eror is el In other words, there is a continuous feedback of inf fiom the process vi the controller to the contol yal ‘known as final control element. ‘What are the types of contol system? ere ate wo basic types of contol system are ‘© Manual system Automatic system What i on-off controler? In this type only on and off phenomenon takes pl thermostat in refrigerator. “When desired 2 sees achieves it tums off the compressor. On off contol Esed Backward Contra! special control of proportional contol ‘What is fed forward system? ‘What is proportional control? In this process disturbance are measured in advance and In this type of contol controler generate a signal, ‘compensa without waiting fora change in contol variable. directly proportional tothe exer. 1 is used for dizeet measurements of the disturbances to ‘What is integral control? adjust values of manipulated variables. It measires the In this type eontoller generate a signal, which i int Aisturbanes before they ae the system. ‘What is dorivative control In this controler generate a signal that is derivative of What is error? Itis difference between set point and measured variable Error = Set point ~ Measured variable,(Chapter 12 Instrumentation and Process Control__4)3 Q.33: What type of control is used for traffic signals & washing ‘machine? tis time based control and work in a sequential manner. So me itis open loop contal system. Q34: In an exothermic reactor what is the manipulated ora variable of flow rate? Jn an exothermic reactor, the manipulated variable of flow rate is coolant OAS: What is the advantage of use of integral-control afong ‘with proportional-control? ‘Advantage of use of integral-control alongwith proportionalcontro is the elimination of offset. 0.36; Which controller has least maximum deviation? controler, Q.37: What isthe importance of process control? Process control in one form or another isan essential part of any modem process industry. In all processes. such as ‘conversion of crude ol into many by products, production of chemical and pharmaceuticals, generation of stezn from a fossil or fissile fue, there arises the necessity to keep cersin variables within specified Limits. Inthe processing industry, controllers play a erucal role in keeping our plants running = virtually everything fro simply Gilling up of a storage tank to complex separation processes and chemical reactions. 0.38: Differentiate b/w continuous and batch process in terms of process control. ‘A continuous process produces an uninterrupted flow of product for extended periods of time. A batch process, in fontrast, has an interupted and periodic flow of product. 4 Feed Forward Control 26: What is cascade control? The mangement of a controler supplying, set point nother controller is known as cascade control ‘OR tn cascade control the system can be connected to any pparatus to computer through which we can operate it 0.27; Which type of controler isthe flapper nozzle Teispneumatic controller. f What are the types of automatic system used in in ‘Phere ae two main fypes of conrol system exists Feed Backward control system {Feed Forward control system ther [Examples of processes include a dary, a petroleum refinery, ‘A process could also be deseribed as an operation BS 4 fertilizer plant, a food-processing plant, a candy factory, an fchieve an industrial manufacturing, function, Sa ene te Gee eran i level, mechanical ily hydraulic controller? sen emp ol one wend se so: Mum ea whch ws = Oil is used in hydraulic controller. costs Wh conte a he mina fe? eee ee con What ine prcendgren freedom nae? Wha ho om oes he as weSeottr eeu (0.39: What is the reason of taking interest in process control (One reason forthe intrest in process contol is because plant ‘engineers have soen improved control as one route to greater productivity, Tighter environmental regulations, more expensive raw materials and intemational marketing competition caused process control to receive greater 0.40; What are factors, which cam influence the temp. of uid in a container when controls variable is temperature?aus a4: as: oar: Qs: Chapter 12 Instrumentation and Pr Factors flueneing the temperature of the Mud include Ambient temperature change, causing different heat through the wall ofthe vessel. Fluctuation in steam pressure, directly affecting the ‘ofthe process fluid Changes in the flow rate of fui. ‘Change in set point, which would require ether more What is load change? Those factors affecting the process are known 38 ‘What is the disadvantage of manual system? It is necessary forthe operator to be constantly on the see changes as they opeur, and to make the neces ‘adjustment, but if several variables are being contol specially if the points of measurement and indication ‘well spreaded, it is doubtful that an operator could tveurate in his adjustments for longer period of time. fand other reasons, such as economy, efficiency and Satisfaction, make the use of process contol essential ‘Complex processes where many process loops are involved Define offset? ‘When there isa constant difference between the set point the control point, the difference is called the offset, What is relation of offset with time? Offset doesn’t vary with time. It sa steady state value, ‘What is primary clement? “The device, which detcots changes in the value of ‘yriable, is called primary clement, It is also known. fetector o sensor. ‘What is transducer? ‘This device receives the output of a primary element converts it nto a st adard signal, ie. eletrcal or pewmati Define error signal? When the controller detects a difference between measured value and the set point, it produces a signal call the error signal ‘What is response time? It is the lag or delay that occurs between the time durin ‘which disturbance occurs and the final control element ma adjustment ic Tasttumentation Process Conrol ‘What is steady-state condition! A process is said 10 be at steady state when none of the variables are changing with time. Many open systems in engineering operate for long periods of time with relatively small changes in the operating conditions. Under these conditions, the systems are often modeled as operating &t steady state con ‘What are setpoint regulator systems? Any process system that maintains its developed output at 3 consistent level in spite of load changes is classified asa se point regulator system. In practice, the set point of the controled variable ofthis type of sysiem is seldom changed Heating. systems, pressure regulator’ units, and voltage regulator circuits are examples of this type of contol. ‘What are se point follow-up systems? A setpoint follow-up system isa feedback control process in ‘which the setpoint sina constant state of ehange. The basic function of this type of system is to keep the contolled variable as clase as possible to any value change in the set point. In system ofthis type, the setpoint value is called the reference variable, Industrial applications employing this type of control ae found in graphic recording equipment and valve positioning equipment. ‘What is negative feedback? ‘The measured value is subtracted from setpoint & then errr signal is generated. It reduces the difference between the actual and desired values, s0 it is beneficial. Positive ‘feedback increases the difference, so itis undesired. Define real time system? ‘A real-time system is used when rigid time requirements fave been placed on te operation of processor or he Now of dats; thus, it is often used as a control device in 2 flere to. govermenal ren Covirounenal andar Maximize or contol on specications of Proacton ras > Minimie operating ox. Whats conventional contrat? Conventional contol devices, being ofan anslogu Sinhasserwommlor, ae usual capble of hand See input and one op. Hence they ae con Single top ystems andthe contol stem is bull puber of sah ops Whats deviation? Diftrene at ny inant bith valu of controled tnd the st pint eae eration, ‘Whats derivative dime? The tie ference by which the ouput of P-D cas the inp when th ipl shanges inary with caled derivative tine ‘What is integral a Deontoter action in hich, tere is a conn ‘eon Between vale of he contol varable and ‘hange of eonolled opt signal called cera a What is proportional ation? A convo action in which there i 2 continuous Beinn valu ofthe contlled variable andthe ai eutpa signal ofthe conte called proportional a ‘What is proportional sensitiv? Steady sate aio of the change of proportional co futut variable andthe change in achating steal proportional esti. ‘What fon contr? OME On consol ia two-poston (lly open oF fil oniol adequate 10 consol» process wil slow read Shemini dead time or taser a ‘Whats oating contra action? Floating contol action moves the fra consol ch consant speed in iter diction i response fo sisal %, (Chqoter 12 Tasirumentation and Process Control 417 0.03: ‘What is cascade control? Cascade contol is > The continuous adjustment of the set point index of an automatic control loop by a primary (smaster) controller. > Used when changes in process conditions cause serious upsets in controlled variable. > Very useful to contol flaw from temperature, ‘Which type of special eases the on-off control is? (On-off control is a special case of proportional control with very high proportional guin or sensitivity. ‘What is control variable ina heat exchanger? Outlet temperature of cooling fluid is control variable in & beat exchanger For whieh controler the offset is zero and it has highest ‘maximum deviation? The controller for which the offset is zero and it has highest ‘maximum deviation is PL-contralles Which controller requires minimum stabilizing time? The controller, which requires minimum stabilizing time, is P-D controller. How solenoid valves operate? Solenoid valves operate like on-off controler. ‘What is outlet temperature of heating/cooling uid in a hheat exchanger? In a heat exchanger, outlet temperature of heating/cooling fluid isa controlled variable. Which of the following has the smallest. maximum deviation among P, P-l,P-D and P-I-D controllers? P.D has the smallest maximum deviation among P, P-1, PD and P--D controllers ‘What is not present ina se operated controller? Final control element is not present ina self-control element ‘Which type of variable the reactor temperature in case of exothermic CSTR represents? ‘The reactor temperature in case of exothermic CSTR represent controlled variable. ‘Which type of variable the feed temperature in case of exothermic CSTR represents? ‘The feed temperature in case of exothermie CSTR represent load vanable.and Process Cont Chale 72 laneRion and Process C 41 418 _—___ Chapter 12 Insrumenat Q74: Which ype of variable the flow rate of evoting Hukd Postagulisatile: (, BL Bacto cmmolion Gaye case of exothermic CSTR represents? terrane, The flow rate of cooling fui incase of exothermic CS Bre eae ae pid teeta ‘epresents manipulated variable Cascade contol employees two feed back contro Q.75: Which of the following has the maximum offset amo Q.88: Which control is used along with proportional control? the P, P-1, P-D and P-I-D controllers? Derivative contro! is used along with the proportional P contoler has the maximum offset among the P, P,P al and P-LD controllers 0.89: Which exemplifies a distributed parameter system? 0.76: Which type of variable the flow rate of heating oF cool ‘Tubular eactor exemplifies dstbuted parameter system. fui in ease of heat exchanger represents 10.90: What is smplitederatinot tag? The flow rate of heating oF cooling uid in ease of Amplitde tio of lags 1 exchanger represent manipalated variable. Q91: Which system for CSTR can be taken for the sake of Q77: Which type of variable the entering hot or cold simplicity? {emperatures in a heat exchanger represent? Lamiped parameter system, can be taken for the sake of The entering hot ov cold uid temperatares. in a simpliiy Fn 092: Mow we compare P-1 controller with P controller. Q.7%: Which controler has zr0 offsets? P- contzolle as compared to P contol: has P-Land P-1-D has the zero offsets. ‘Which controller has the highest maximum deviation? P-L controller has the highest maximum deviation. Which type of variable in water heater, the inlet wa Q9%: QBI: Wii type of variable in water heater, the outlet os: Cemperature represents? In the water heater, outlet water temperature repre controled variable. i Q482 Which type of variable the heat input in case of W eater repress The eat npr cas of water heater represent manip variable Which controller has the maximum stabilizing time? P-lnolerhos the maxim stabilizing ime Which type of controller is mostly used for level cor In industries? P type of controller is mostly used for level control indus 85: Which type ofconteoller Is suitable for fow loads? Oncol controler is suitable for low loads 86: Which type of controller i suitable for high toads? > ater simu doviaton > Longer response tine > Longs period ot eslision > Newfie Whats phase tg of P-contrller? Phase lag of otters What is eros over requeny tps lag? Alphas lo erst oer equncy equal to 180 What type of diferent equation the. estrbuted parameter spproach gives? Distributed parameter approach gives pari diferent ow controling clement i exemplified? Preuati console exemplifies contelling element How a seioperatd contaler is exemple? Themselves exempi a seoprated eon A whieh postoning the controler has the smal iaximum deviation? "ATED potoning te cool asthe sale maxi What i the effect of addtion of derivative control to Proportional contrelec? ‘Aadion of denvatve contol to proportional contler reduces subiing tie and ints sensaa ‘Chaote-12 rsiramenation and Pr Q.100: What i the effect of addition of Integral cn proportional controler? Addition ‘of integral contol to. proportional liminatesoffiet and increases response time, For a given duty, which I coslest controller? Hyarauie a Where fed forward controle is used? Feed forward controllers sed to account fr load Shell and tube heat exchanger is evample of ot parameter system? Shel and tbe heat exchanger is example of dat parameter ayer Miner i example of which type of parameter syst Miner is example of imped parameter system, Up to how many variables the describing fant be used?” Up to any number of variable the deseribing fanci te used What i most commonly wsed controller for ci {he ow rates i industries? PLis most commonly used sontrole for controling ti rates in ndusties. What is most commonly temperature in indus FID is most commonly wed controller for 66 tenets What is the function of reorder? An gives us the previous record trough which we ean the wend of system if thee is any disturbance or the is at steady state : How many variables are there in a chemal proces ‘The variables (Now rates, temperate, pressure, com sociated with chemical process te divided a Sa fp yey are edie ees skfrounding onthe chemical process 2) Output variables are tat which denote the ef {he proces on he suroundig ‘The input variables are fre classified into the fall categories, Wheclee 12 itriémaion and Provess Control —_421 4) Manipulate (adjustable) variables, iFhaman operas 2 contol meshanism can adjust thei ace Rec b) Disturbances, if their values are not the seca or adjustment by an operator ora conc. ‘The output variables ae alo classified inthe following categories, 8) Measured output variables, i heir values are known by diretly measuring them 5) Unmeasued ouput variables, if they are nt or cannot be measured directly. (0.111: Define control configuration? A control configuration isthe ifmation structure tha i ‘used to connect the avilable measurement fo the avatabis manipulated variable. 1.112; Define control objective? The ental element in any control configuation is the ocess tht we want to contol and this isa cena objec M113: What are the operational objectives that x control sotean {scalled upon to achieve? > Ensuring the stability ofthe process 2% Suppressng the inlience ofthe extemal disturbances, > Optimizing the economic performance ofa lens At the “begining. the control objectives ve devned qusliatively.Subscquemly they are quantified, usualy terms of oulput variables, 114: What is control system? A sonttl system is device o set of devices to manage ommand, diet or regulate the behavior of other deren systems L115: Define linear system? A linear system isa model ofa system based on some kind of linear operation, Linear systems typically exhib eta, and properties tht are much simpler than ihe gene) onlinear case. This is a matheaticl absractag nee Useful in automatic contol theory, signal procecang oy {clecommunications, For example, the propagation edn for wireless communication systems can often be meant by linear systems 116: Whats sliding mode control? 4m contol theory slding.mode control isa ype of variable Structure contol where we fry to allt the Upnensee at$22 Chr 12 stanton and Pra Switching control. This is a state feedback contol ‘where the feedback isnot continuous function oft What is open loop controller? An open-loop controller, also called a non controler, isa type of controller, which computes Io a system using only the eurent state the system, What is under actuation? Under actuation is a technical term used in robo control theory (0 deseribe mechanical devices that ‘ower number of actuators than the degrees of feedr ‘What is virtual Instrumentation Virtual Instrumentation is the use of customizable s and modular measurement hardware to ereate use measurement systems, called vetal instruments, so preferably known as inferential systems, ‘What is feed back? Feedback isthe signal that is looped back to contol a ‘within ise. Ths loop is called the feedback loop. A é system usually has input and output to the system: wh ‘output of the system is fed back into the system as par input, its ealled the feedback.” What is auto feedback? Auto feedback is @ common example of positive feed | the familiar squeal that results when sound loudspeakers enters a poorly placed microphone and amplified, and asa result the sound gets louder and loud Define pneumatic actuator? A pneumatic actuator converts energy (in the f ‘compressed ait, typically) into motion. The motion "lary or linear, depending on the type of actuator. ‘What is PID? ‘The so-called PID controller is probably the most com used feedback conirol design, being the simplest on.“ ‘means Proportional-Integral-Derivatve, referring to the i terms operating on the error signal to produce a signal ‘The Controller compares @ measured value from @ (ypically an industrial process) with a reference set value. The difference (or "error" signal is then used Viankte T2TiIREntation and Process Control a3 calculate a new value for a manipulatable input to the Process that brings the process’ measured value back to its ‘desired set point. Unlike simpler control algorithms, the PID controller ean adjust process outpats based on the history and rate of change of the error signal, which gives mot ‘accurate and stable control (It ean be shown mathematically that a PID loop will produce accurate, stable control in eases Where a simple proportional control would either have a steady-state error or would cause the process to oscillate). PID controfiers do not require advanced mathematics to design and can be easily adjusted (or “tuned” to the desired application, unlike more complicated control. algorithms based on optimal control theory. ‘What is adaptive control? Adaptive control uses on-line identification of the process Parameters, or modification of controllers gain, thereby ‘obiaining strong robustness properties, What is automation? Industrial automation oF numerical contol is the use of control systems such as computers to contol industri! ‘machinery and processes and replacing human operators, In the scope of industralization, “it is a step beyond ‘mechanization. Whereas mechanization provided human ‘operators with machinery to assist them with the physical requirements of work, automation greatly reduces the need for human sensory and menial requirements as well. ‘What is degree of freedom? Any one of the numbers of independent ways in which the space configuration of « mechanical system may change. ‘What is botted gas? Bottled gas isa term used for substances which are gascous, at Standard temperature and pressure (STP) and have been compressed and stored in carbon stel, stainless steel luminum or composite bottles known as gas eylinders What is reference? ‘The desired output ofa system is called the reference ‘When one or more output variables of a system need to follow a certain reference overtime, «controller manipulates the inputs to a system fo obiain the desired effect on the ‘output ofthe system, ‘What are logic controllers?424 Chapter 12 Instrumentation Pure Togie contcols were historically implement cleotricians with networks of relays, and designed ‘notation called ladder logle. Nowadays, most such 8 are canstucted with programmable logical controllers, Logie controllers may respond to switches, light sa pressure switches ete and cause the machinery to Some operation. Logic systems are used to seqt mechanieal operations in many applications. include elevators, washing machines and other systems interrelated stop-go operations, Q.130: What is linear control? Linear control uses negative feedback 10 keep some de process within an accepiable range. For exam thermostat is a simple negative feedback control: wheq. temperature goes below a threshold, a heater is switched) Another example is a reftgerator, where the mechanis ‘switched on when the internal temperature rises. {Q131: What do you mean by fuzzy logic? Fuzzy logic is an attempt to get the easy design of 10 controllers and yet control continuously varying. sy Basically, a measurement in a fizzy logie system can partly true, that is if yes 1 is and no is 0, 2 fi ‘measurement can be between 0 and I Q.132: How logie controllers are made? Logie controllers are constructed from relays, hydraulic pneumatic devices, and electronics using both transistors ‘vacuum tubes (feedback controllers can also be construc in this manner), (0.133: How many types of feed back control are there? On-Off Control: This is the simplest form of contol, used by almost domestic thermostats, Proportional Control: A proportional controler attempts to perform better than (On-Off type by applying power. Proportional control is ‘often used for liquid level where variations inthe controll variable carry no economic penalty, and where other cont modes ean easily destabilize the loop. It is sctually recommended for controlling the level ina surge tank whe ‘manipulating the flow of feed to a critical downstream process. By setting the proportional band just under 100) md Process Control _425 percent, the Feel is allowed to vary aver te fll ange ofthe tank capacity as inflow fluctuates, thereby minimizing the resulting rate of change of manipulated variable Proportional Derivative Control ‘The stability and overshoot problems that arise when a Ls > Dead zone 4 1.147; Svar is comidered about over damping (Situati eater enonrundeirabl hing)? Histo bod trast be mine. (148; How many categories of presure: measure there Meet enepris of presre measurement Thostae: ese whieh i the erence, fresured espe and apres voce 2 Gruge preoure, whieh is the fernce tneduael presse, an local amospheic press 4 Dire pressure which i te diference Peued procures, nether of Which tmsphere pes ‘ (149 Were shoul beth contol om situated? The Zot rom sald be situated near the proce tact dane, ‘1st: Wh should be the control room stated neat WNP eonsterains shout be hep in mind? Control rom sated ee ease 2" Toredice sel raneision css, 5 Ta provide open spiciou place. 1 To RCep workers cafe in cate of plant Jestuction This is defined as the minimum difference inthe values of a ‘quantity that can be discriminated by a device; In essence this is the largest change in input that can ‘Occur without the output changing. Sd: What are ite Filfers are devices which transmit a specific range of the frequency spectrum of a signal and which reject the remainder. They can take many physical forms-but the most Inghly developed and convenient types are electrical filters, 155: How many types of electrical filters exist? Name them, There are two types Analog filters = Digital filters 156: What is controller tuning? is the adjustment of controlle’s parameters in onder to achieve a satisfactory contol. 157: What are the criteria of a good control? Two criteria used Minimum overshoot # Yedecay ratio The other entra is © Minimum rise time Minimum seting time 188: What are different tuning methods? These are asunder Lo Hit teal method 2. Ziegler Nichlos method 3. Cohen & Coon rule ‘What is the function of transmitter? The job of transmitter isto convert sensor signal (differential pressure) into contol signal 4-20 ma inorder to anit it1160: Quoi: Que: Qu63: O64: Qa: Qs: 428 Chapter 12 Instrum OR Transmitter: ~ It is the interface between process a control system. It converts sensor signal (mV, op) control signal (420m). Up to which distance the pneumatic controllers are ‘The pneumatic controllers are used up t0 a dis to0on. Up to which distance the hydraulic controllers are us ‘The hydraulic controllers are used up toa distance ofl Up to which distance the electronic controllers are us ‘The electronic controllers are used upto a distance of or preater. in which industries the pneumatic controllers are us In petroleum refineries, What is the term analogous to the electric curre thermal control system? The term analogous to the eletrc current in thermal Iaat fh ‘What is computer control? (Computer contol is applied to systems in three ways! 1+. Supervisory. 2 Direct digital 3. Hierarchy contro. ‘What i supervisory or optimizing control? Supervisory or optimizing. contol is used to trim pl ‘operation for example to improve plant performance lower costs ‘What is direct digital control? Direct digital control employs a microprocessor evice to replace a number of single loop anal controllers. Its greater computational ability: makes substitution possible, and permits the application of ‘advanced control techniques. ‘What is hierarchy control Hierarchy contol systems apply computer techniques plant situations simultaneously. Ths simplifies the activi ofthe facilities manager or maintenance personnel ‘What is distributed control system? — (icscer 12 tisietinehalon and Process Control__439 Distributed control systems (DCS) are used in industrial and civil engineering applications ‘9 monitor and control ‘isitibuted equipment with remote human intervention. DCS isa very broad term that describe solutions across a large variety ofindustries, including: Electrical power grids and electrical generation plants Fnvironmental control systems Trafic signals Water management systems Retining and chemical plants Pharmaceutical manufieturing, ‘What is intelligent control? All control techniques that use various AT. computing approaches like neural networks, Bayesian probability, fuzzy logic, muchine leaming, evolutionary computation and genet algorithms can be put into the class of intelligent contro What is HVAC system? A TIVAC control system is 4 computerized system for climate control in buildings. HVAC stands for heating, ventilation , and air-conditioning. Often, these integrate fre, security, and lighting controls into one system. These systems typieally use one or more central controllers 10 command and monitor the remote terminal unit controllers, and they communicate with one oF mare personal computers that are used asthe operator interface. These contro systems are typieally used on large commercial and industrial buildings 10 allow central control of many HVAC units around the buildings), ‘What is SCADA system? Ic mean supervisory control and data acquisition system, This type of control system is mostly used for a system Which is expanded in large areas, where cabling is not possible ez. Natural gas transmission lines, Eletrie power contro, ligation contol system. In this system microwaves are used and mostly controlled through satelite ‘What is the difference between DDC & DCS? DDC mean direct digital control while DCS stands for distributed control system. In DCS multitoops are controlled easly. PLC is also part of DCS, For contol point of view various controls ate distributed into. different vyvvyyQuo: Qui: Qua: Qus: Qu 2: iru nd ‘cetion, Hone section have problem all the system fal Write names of some of the companies, wi providing services for DCS, control system? Honeywell USA, Fisher, Foxboro and Bailey ‘What is data acquisition system? Wis a system that conditions a number of analog si converts them inlo digital form for procesi ‘compute. What are analog filters? Analog filers are electrical networks of resistors, snd amplifiers used to condition continuous signal, ‘What are digital filters? Digital ters consist of (software within a mien ‘which processes sampled data signals. I'the power fof 2 measurement signal occupies a different range frdm that of any noise or interference, then afl substantially improve the signal to noise ratio ‘measurement signal. A large variety of such fill available. The one having the required characteristics be selected in terms of the ranges of frequencies requ rejected. What is interlocking? 1k is connection of linkage of various equipment instruments and switches in order to control the system mostly used forthe safety ofthe equipments and proc Before some mishap occur it shut down the ysiem, Mi is operated by PLC system. Solenoid valves are cont used in this system. Write down some industry? ter locking of pumps: In process industries {wo pumps are used one is operating and other one j futomatic mode. When the operating pump trip d fny reason (Other than low level of suction tank) pump automaticaly stats. Inter locking of pump with level: Mostly pumps interlocked with level at water tanks, waste Water ‘When level become low pump start and when terlocking examples of pt er 12Ynsermetation and Process Control __431 ‘become high pump stops. Level swithes ae used to detect high and low level. 3. Compressor on / off: | Mostly air compressor has ressure switch when pressure rises upto maximum set Dressure it shut down the compressors and when Dressure become low iton the compressor. 4. In reftigerator/ Air conditioners: Thermostat are used to ‘on/off the reftigerator and air conditioners according 1 their temperature Write down the securities of boer and Furnace? Boiler: tis crtal vessel its securities are the following 1. Low level of boiler: When boiler level become low due {0 tiping of bole feed pumps or due to any reason ‘The boiler tues may damage die to overheating so level switch in boiler automaticaly shut down the fuel supply to fumace in oder to save the boiler tubes 2. High pressure of furnace: When furnace pressure inereases up to certain limit it shut down the fuel supply valve, in order save it rom some accident. 3, Combustion air failure: If combustion ai fall than it shut down the fuel supply valve 4. Tripping of fuel valve on abnormal pressure of line high orlow: ‘Write down some securities of centrifugal compressor? ‘High level of inter stage coolers I inter stage cooker level become high it may cause damage of compressor. ‘There must be no liquid i the compressor Vibration level high: If axial” oF radial vibration ‘nereases from certain limit than compressor trip Low (LL) lube oil pressure: If lubricating oil presure ‘become low from certain limit due to tipping of lube oil ump or chocking of fier of die To any reason. Compressor tripped in ordet to save bearings. Low (LL)eontrol oil pressure: Tripping of compressor ‘occur if contol el pressure become low 5, High (HH) sal oil flow 6. Low level of run dow tank What is PLC? PLC stands for Programmable Logie Controller is a small computer used for automation of real-world processes, such a8 conto! of machinery on factory assembly lines. The422 6: Qn: ‘control complex sequencing and is oflen Wi engineers. The program is stored in batery-bac andlor EPROMs. Unlike general-purpose ‘comps PLC is packaged and designed for extended ranges, dirty or dusty conditions, immunity 10 noise, and is mechanically more rugged and vibration and impact ‘What are the main features of PLC? ‘The main difference from other computers is the input/output arrangements, These connect the sensors and actuators, PLCs read limit switches, te indicators and the positions of complex positioning Some even use machine vision. On the actuator sk rive any kind of electric motor, pneumatic or cylinders or diaphragms, magnetic relays or solent ‘nputvoutput arrangements may be built into sin fof the PLC may have extemal JO modules attack proprietary computer network that plugs into the PL PLCs were invented as less expensive replacements viomated systems that would use hundreds or thous relays and cam timers, Often, a single PLC programmed to replace thousands of relays. Progr controllers were initially adopted by the aut ‘manufacturing industry, where software revision the re-wiring of hard-wired contro panels. Give some examples of PLC controlled syst process industry? ‘Water treatment section Inert gas generation system Instrument air generation system Side steam filters of cooling to Gas drying system, 12.10 __ CONTROL VALVE What is control valve? A control valve is deve to control the process ‘A valve with variable opening for flow is used to in variable resistance ‘What are failure to open and failure to close valves? Q3: Quo: Qu: Qn: Qua: Process Control. 433 “The valve in which when air supply close, it fully opens is called failure to open. The valve in which when air supply ‘open it filly close is ealled failure to close valve. ‘What are selection criteria for fallure to open and failure to lose valve? Tt depends upon the process requirements and the safe bbehavior of proces in case of emergency. ‘What is a block valve? {A block valve is that one which close the line. Normally solenoid valve, gate valve are known as. block valve According to their application these are used for fully open and fully close positions. ‘What is the principle of pneumatic control valve? It shows response with inease or decrease of instrument ait pressure and provides flow area. ‘What is symbol for locally mounted instrament in Instrumentation diagram? ‘What i the symbol for pneumatic control valve? Se What is the symbol for the capillary line in Instrumentation? ‘Where diaphragm valve is used Diaphragm valve is used for corrosive chemical Nuids, ‘Which valve is used to supply ofl tothe burner? Rotary plug valve is used to supply ol tothe burner. For, which pressure the pneumatic control valves, are ‘generally designed? Pheumatic control valves aze generally designed for pressure ‘up to 5000 pi. ‘What is the function of good hydraulic uid? “The function of good hydraulic Dud iso > Transmit fluid power. > Actasa sealant, > Lubricate the components ofthe uid power system, ‘What is the range of pneumatic controller in ease of standard alr pressure?484 Chapter 12 Instrumentation and Process “The wultable range is $-25 ps Qld: What is instrument air? Instrument air is used to operate different instruments like pneumatic valves, transmitters, transducers ete, This isthe air having some properties Minimum amount of moisture or moisture fee Athigh pressure. ‘Should not be corosive Should be cheap and commonly available, Free from suspended particles ‘What is plant air? Simple air at high pressure is known as plant ar. This ig at plant for cleaning, purging and cooling purposes ‘What isthe function of bypass valve? tis used to isolate the control valve from circuit maintenance or repair is required in main line than diverted to bypass valve and after work has been ct itis diverted back to main line. ‘What is pressure range for control val Pressure range for control valve is 3-15 Psi, Why diaphragm Is proferred over the other valves? Because ofthe following; > Less maintenance cost > High accuracy > Tran be usd for suspended solids ‘What isthe difference between instrument air and pl air? Pant air contains action of moisture, while that instrument air is completly free from moisture and contaminations. What are types of air regulator? > Self operated rogulator > Pilot operated regulator Over pressure regulator ‘What are the malntenances required In diaphri wales? ‘These aze the fallowing maintenance required in diap valve; > Replacement of diaphragm > Maintenance for seals > Opening the choked line. ‘What is failure to open philosophy for control valve? Failure to open:- In such phenomena if the instrument air fail the control valve open and allowed the Muid to pass ‘These type of valves are installed where no critical position is present or not so much loss with fllure of instrument at ‘What is failure to close philosophy for control valve? Failure to close:- In such phenomena with the failure of instrument ar the valve comes in close position. These types of valves are installed in critical position where huge Toss ‘ean occur with the failure ‘What is relief valve? “The relief valve i a type of valve used to control or limit the ‘pressure in a system by allowing the pressure source Muid to flow from an auxiliary passage, away from the main flow path. The relief valve is designed or set to open at a predetermined pressure to protect pressure vessels and other ‘equipment from being subjected to high pressure thal exceed theit design limits. ‘Why sometimes a bypass valve is known as relief valve? In some cases, a so-called bypass valve acts as a relief valve by being used to return all or part ofthe Mud discharged by 1 pump or gas compressor back to either a storage reservoir ‘orto the inlet of the pump or gas compressor ‘What is a tip valve? . ‘The trip valve is part of a system that is used where @ specific valve action (i. fail up, fail down, or lock in last, position) is required when pneumatic supply pressure to the control valve falls below a preset level. ‘Where isthe trip valves used? Trip systems ate used primarily on spring less piston sctuators requiring fai-open or fail-losed action. An air storage or “volume” tank and a check valve is used with the trip valve to provide power to stroke the valve when supply pressure is lost. ‘What is 0 special about trip valve designing? Trip valves are designed with hysteresis around the trip point, to avoid instability when the trip pressure and the reset pressure settings are to9 close to the same value ‘What isan actuator?“An actuator is the mechanism by whieh an agent acts fan environment. An actuator isa device that applies the (orgie) necessary 10 case a valve’ cli men move, Actuators must overcome pressure and fiction from packing, bearings or guide surfaces, and) ‘and provide the seating foree. ‘What is safety valve? {A safety valve isa valve mechanism for the release of a gas from a boiler, pressure vessel, or System when the pressure o temperature exceeds Timits. They are often called by more specific names s pressure relief valves, T&P valves, or temperature presture elif valves. i |: Where were the first safety valves used Safety valves were first used on steam boilers duri industrial revolution. Early boilers without them were {to accidental explosion when the operator allowed! pressure to become too high, either deliberately oF incompetence ‘What are uses of compressed alr? Compressed aris used to refer to: }"Preumatis, the use of pressurized gases to do wor ‘sed in the Air car. > Breathing gus, often used in scuba diving, also ti buoyancy devices. > Compressed air can also be used for cooling us vortex tube. > Can also be used to propel grappling hooks. ‘To which temperature range of the fluid the contol are normally provided with radiating fins? Gon valves ae normaly provided with rang the uid temperature exceeds 450°F. AE hat place deresingsemitvty & Ines ‘sensitivity valves are used? Decreasing sensitivity valves are used where fluctua ‘maximum, while increasing sensitivity valves are ‘where fluctuation i minimum & work only when disturbance happen. Where weir valve is used? This used for slurry type materi. ‘Chapidt 12 Wihthtavion and Process Control a7 ‘Also known as final correcting element, control clement or final element. It is usually 2 control valve but it can be a heater, variable speed pump, conveyor, electric motor relay switch ora similar device that directly affects how a process runs. The final control clement receives an output signal from the controller and regulates a provess by reducing the How final control element is exemplified? ‘The final control element is exemplified by solenoid valve. ‘What are the selection criteria of control valve ‘A valve is selected because itis simple, reliable, relative low ‘ost and available for wide range of applications. "The criteria ‘What type of contol is required from the control valve? ‘What is up-stream pressure and down stream pressure? ‘What is the throughput required through the valve? Material of construction is selected on the basis of uid ‘What is pressure drop through the valve ‘What is type of valve body? Control valve bodies may be serewed, Aanged or welded in flow lines. Define turn dow The tundown is a direct function of the range of an instrument and is the ratio of the upper range value of the instrament (0 the lower range value. For example, if an instrument is required to measure pressures which range from 100 KN to 1000kN/m? then it is said to have a turndown of 10:1 + Define sensitivity? This may be defined as the rato ofthe change in magnitude of the output signal corresponding to the change in the ‘magnitude of the input after a steady state has been reached. In the limit this becomes the rate of change of the output with respect to the input What are the industrial applications of linear valves, Equal percentage and High sensitivity valves? Linear valves: These are used for normal control of flow, where we require slow changes with the opening of valve like fuel flow, raw material flow et. Equal percentage valve: These are used where we have less sensitivity like level control from the outlet of vessel, a theWhat is stability? Most of the processes used in manufacturing. operationser 12 Instrumentation and perform well when variables are held within certain ‘When a process variable is subjected to some type of it takes a certain amount of time for the process 10 itself Process time lag refers to the time it takes @ correc itself and seek a condition of balance after a thas changed. Inertia, capacitance resistance, and are typical causes of process time lag, + Define capacitance resistance? Capacitance resistance has two components. Capat time-Ieg condition that refers to the ability to store 8 certain quantity of material. The walls of a storage tank, for example, tend to retain some of energy initially applied to the water. Any type of storing capacity retards the ability of the system t0 change. Resistance refers to those things thet tend to 8 transfer of energy or material when a process occurs: The water inside a tank has different resistance that must be overcome before the tank: reaches a prescribed value. When resistance and capaci ‘combined, the resulting condition is called atime lay Define dead time? Dead time isa property, which refers to the time required. 4 process to change ffom one value to another. If temperature of the incoming water ofa heat exchanger rops to 2 Tower value, a certain amount of time will e before the tank can sense that a change is needed. Dead is not retarding effect, but refers specifically to the a time in which no change occurs. Dead time is dependent the speed with which a change is transported through system, Capacity, resistance, and process inertia ll inh dead-time delay, Define stability with respect to transient response? The stability of any control system is determined: argely its response toa suddenly applied signal, or ancient. Tr ‘signal causes the system to overcorrec, hunting is likely take place in which the system overcorrects in one di and then overeorrets in the other direction. To prevent damping is added to the system. Damping slows system response and prevents excessive over corrections overshoot, Q8: Define frequeney response? pter 12 Instrumentation and Process Control 4a ‘Frequency response i its response to a varying input signal at various frequencies. 19: For which parameter the symbol stands? L It stands for summing function, 20: For, which parameter the symbol stands? ——* td um Ste TS In an instrument diagram represents which quantity? receerae p22: The symbol = eras In an instrument diagram represents which quantity? Itrepresents pneumatic line ij 23: Whleh mode Is used for transmitting signal for one- kilometer distance? Electronic mode is used for transmitting signal for one- kilometer distance oe 24: What is use of pilot in transmi ‘The use of pilot in transmission (pneumatic) is to change the flow of ar. 25: What do you mean by load changes? Load mean input streams, like feed streams. Load changes ‘mean change of input streams conditions of temperature, pressure, concentration and flow rate et. 26 For over damped second order system, what isthe value ‘of damping coefficient? Les than one ‘12.12 _IMPORTANT FORMULAE ATorAE 39 Range Proportional band442 __Chapter 12 ft ler 12 Instrumentation and Provéss C 10. ‘What is final control element? 4. Atype of radiouctive element, 16) . Step that controls the measured variables, x6) P4s) Gin = Ke =

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