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1. What are the three principle types of diagrams used by process engineers to
describe the flow of chemicals in a process? On which of these diagrams
would you expect to see the following items?
a. Temperature and pressure of a process stream: PFD
b. Overview of a multiple-unit process: BFD
c. Major Control Loop: PFD
d. Pressure Indicator: P&ID
e. Pressure-relief valve: P&ID
2. A problem has occurred in the measuring element of a level-indicating
controller in a batch reactor. To what principle diagram should you refer in
order to troubleshoot the problem? P&ID
3. Why is it important for a process engineer to be able to review a threedimensional model (actual or virtual/electronic) of the plant prior to the
construction phase of a project? To check for clearance, accessibility, layout
of equipment, piping, and instrumentation
4. Name five things that would affect the locations of different pieces of
equipment when determining the layout of equipment in a process unit.
a. Clearance for tube bundle removal on a heat exchanger
b. NPSH on a pump-affects the vertical separation of feed vessel and
pump inlet
c. Accessibility of an instrument for an operator
d. Separation between equipment for safety reasons
e. Crane access for removing equipment
f. Vertical position of equipment to allow for gravity flow of liquid
g. Hydrostatic head for thermosiphon reboiler-affects height of column
skirt
5. Why are accurate plant models (made of plastic parts) no longer made as
part of the design process? What function did these models play and how is
this function now achieved? No longer made because they are too expensive
and difficult to change/revise. The models have been replaced with virtual/Emodel using CAD. They allow revision of critical equipment and instrument
placement to ensure access, operability, and safety
6. In the context of process modeling tools, what does OTS and ITS stand for?
OTS-Operator Training Simulation; ITS-Immersive Training Simulation
7. What is augment reality? Give one example of it.
8. There are two common reasons for elevating the bottom of a tower by means
of skirt. One is to provide enough NPSH for the bottoms product pump to
avoid cavitation. What is the other reason? Provide enough hydrostatic head
driving force to operate a thermosiphon reboiler
9. What is the purpose of a pipe rack in a chemical process? Provides a clear
path for piping within and between processes. It keeps piping off the ground
to eliminate tripping hazards and elevates it above roads to allow vehicle
access
10.When would a structure-mounted vertical plant layout arrangement be
preferred over a grade-mounted, horizontal, in-line arrangement? When land
is at a premium and the process must have a small foot print. The
a.
b.
c.
d.
e.
PI
TR
Pressure Indicator
Temperature Recorder
Flow Indicator Controller
Level Alarm High
Pressure Alarm Low
FIC
LAH
PAL
15.
TI
PR
LIC
FAH
TAL
PAL
a.
b.
c.
d.
e.
Temperature Indicator
Pressure Recorder (panel)
Level Indicator Control
Flow Alarm High (panel)
Temperature Alarm Low
2.
3.
4.
5.
Administration (FDA)
c. usually standardized equipment is used for many pharmaceutical products
and campaigns are run to produce each product this lends itself to batch
operation.
c. Examples for doing this for a reactor are to: increase the reaction rate
or improve equilibrium for an endothermic reactor. An example for
doing this for a distillation column is: to provide a vapor-liquid system
for a heavy (high boiling point) component
5. Define a condition of special concern. Define two such conditions, and state
one possible justification for each. A condition of special concern is a
process condition that deviates from an ideal or low-cost operating
conditions. Operating at pressures outside the range of 1-10 atm or
temperatures outside of the range 45-250C/4000C are examples of conditions
of special concern. Justification for operating at high temperatures and
pressure might be to increase the rate of a desired reaction.
6. In the food and drug industries, many processes used to produce new active
ingredients (drugs) or to separate and purify drugs and foods occur at
vacuum conditions and often at low temperatures (less than room
temperature). What is it about these types of products that requires that
these conditions of special concern be used? Many of these products are
thermally liable meaning that they degrade at quite low temperatures. The
use of vacuum conditions allows vapor-liquid equilibrium and vapor0solid
equilibrium (freeze drying or lyophilization) to occur at temperatures below
which thermal degradation occurs.
7. For the separation of a binary mixture in a distillation column, what will be
the effect of an increase in column pressure on the following variables?
a. Tendency to flood at a fixed reflux ratio. Will decrease because the
density of vapor will increase and hence the superficial velocity in the
tower will decrease thus moving away from flooding
b. Reflux ratio for a given top and bottom purity at a constant number of
stages. Will increase with pressure. This is because as pressure
increases, the separation becomes more difficult and the equilibrium
line moves closer to the xy line. The only way to compensate is
therefore to increase the reflux ration that in turn increases the internal
flows in the column-hence the vapor flow and velocity will increase and
move the column towards flooding.
c. Number of stages required for a given top and bottom purity at
constant reflux ratio. The number of stages will increase with pressure
for the same reason given in (b) above.
d. Overhead condenser temperature. As pressure increases, the condenser
temperature will increase- this is consistent with Antoines equation
that as temperature increases so does the vapor pressure.