50+ Interview Questions and Answers

Effluent water treatment involves multiple processes to remove contaminants and make it safe for discharge into the environment.

• Effluent water treatment involves physical, chemical, and biological processes to remove contaminants.

• The treated water must meet regulatory standards before it can be discharged into the environment.

• The final effluent water may not be suitable for drinking due to residual contaminants.

• Additional treatment processes may be required to make effluent w...read more

Heat treatment types, difference between normalizing and annealing, and annealing temperature of 0.028%C.

• Heat treatment types include annealing, normalizing, quenching, and tempering.

• Annealing involves heating the material to a specific temperature and then cooling it slowly to make it softer and more ductile.

• Normalizing involves heating the material to a specific temperature and then cooling it in still air to make it stronger and more durable.

• Annealing temperature of 0.028%...read more

We maintain equipment history records through a computerized maintenance management system (CMMS).

• We use a CMMS to track maintenance activities, repairs, and replacements.

• Each equipment has a unique identification number and maintenance log.

• We record the date, time, and details of each maintenance activity.

• We also keep track of the cost of maintenance and replacement parts.

• The CMMS generates reports on equipment performance and maintenance costs.

• We review the equipment histor...read more

Impedance voltage of a transformer is the voltage drop that occurs across the transformer's impedance when a current flows through it.

• Impedance voltage is a result of the transformer's internal impedance.

• It is caused by the resistance and reactance of the transformer's windings and core.

• Impedance voltage can be calculated by multiplying the current flowing through the transformer with its impedance.

• It represents the voltage that is required to overcome the impedance and allow...read more

Accutval PM is a preventive maintenance program for mechanical equipment.

• Accutval PM is a comprehensive maintenance program that includes regular inspections, cleaning, lubrication, and replacement of worn parts.

• It is designed to prevent equipment breakdowns and extend the lifespan of mechanical equipment.

• Accutval PM can be customized to meet the specific needs of different types of equipment and industries.

• Examples of equipment that can benefit from Accutval PM include HVAC ...read more

Different quality control tools include Pareto chart, fishbone diagram, control chart, scatter diagram, and histogram.

• Pareto chart helps identify the most frequent problems or defects

• Fishbone diagram helps identify the root cause of a problem

• Control chart helps monitor and control a process over time

• Scatter diagram helps identify the relationship between two variables

• Histogram helps visualize the distribution of data

Steel is a metal alloy made primarily of iron and carbon.

• Steel is known for its strength, durability, and versatility.

• It is used in construction, manufacturing, transportation, and many other industries.

• Different types of steel can be created by varying the amount of carbon and other elements added to the alloy.

• Stainless steel, for example, contains chromium and nickel to resist corrosion.

• High-strength low-alloy steel (HSLA) contains small amounts of alloying elements to incr...read more

Production is the process of creating goods or services through various steps and techniques.

• Production involves transforming raw materials into finished products.

• Steel is prepared by melting iron ore and adding other elements to achieve desired properties.

• Raw materials are the basic substances used in production, such as iron ore for steel production.

• Thermodynamics is the study of energy and its transformations in physical systems.

• Steps of thermodynamics involve analyzing an...read more

SAP FICO transaction codes, stock valuation methods, tax codes, financial analysis techniques, and TDS codes.

• B/S-F.01 is a transaction code for balance sheet preparation

• FBL1N is a transaction code for vendor ledger

• MIGO is a transaction code for purchase entry

• MIRO is a transaction code for invoice verification

• Stock valuation methods include FIFO, LIFO, and weighted average

• AS-22 is a tax code for deferred tax

• Cash flow and fund flow analysis are techniques used for financial ana...read more

The SLD (Single Line Diagram) is a graphical representation of the electrical system of a plant.

• SLD shows the electrical components and their interconnections in a simplified manner.

• It helps in understanding the power flow and control of the plant.

• SLD includes transformers, generators, switchgear, motors, and other electrical equipment.

• It also depicts protection devices, control circuits, and communication systems.

• SLD is essential for troubleshooting, maintenance, and design ...read more

Controlling inventory of spare parts involves monitoring stock levels, forecasting demand, and optimizing procurement processes.

• Regularly monitor stock levels to ensure adequate inventory

• Forecast demand based on historical data and upcoming projects

• Optimize procurement processes to minimize lead times and costs

• Implement a system for tracking inventory and ordering parts

• Establish relationships with reliable suppliers

• Consider implementing a just-in-time inventory system

• Regularl...read more

The question is about the PLC installed, maintenance procedure for DC and AC motors, and how looper works.

• The company PLC installed is not specified in the question.

• DC motor maintenance involves checking the brushes, commutator, and bearings. AC motor maintenance involves checking the bearings, rotor, and stator.

• Looper is a device used in textile manufacturing to maintain tension in the fabric.

• The working of looper involves the use of two threads, one from above and one from ...read more

Time based maintenance is a maintenance strategy based on a predetermined schedule.

• It involves performing maintenance tasks at set intervals, regardless of the equipment's condition.

• It is often used for equipment that is not critical to operations.

• Examples include changing air filters every three months or replacing belts every six months.

• It can be less effective than condition-based maintenance, which takes into account the actual condition of the equipment.

• However, it can b...read more

Petrol in a diesel engine can cause serious damage to the engine.

• Petrol does not ignite in the same way as diesel, causing incomplete combustion and damage to the engine.

• The engine may start to make unusual noises and vibrations.

• The fuel injectors and fuel pump may also be damaged.

• It is important to drain the fuel tank and flush the fuel system as soon as possible.

• Prevention is key - always double-check the fuel type before filling up.

The equipment is in good health with regular maintenance and inspections.

• Regular maintenance and inspections are conducted to ensure optimal performance.

• Any issues or malfunctions are promptly addressed and repaired.

• The equipment is regularly cleaned and lubricated to prevent wear and tear.

• Performance data is regularly monitored and analyzed to identify any potential issues.

• Spare parts and backup equipment are available in case of emergencies.

To test IGBT in an a.c drive, perform insulation resistance test, gate voltage test, and current-voltage characteristics test.

• Perform insulation resistance test to check for any leakage or insulation breakdown.

• Conduct gate voltage test to ensure proper functioning of the gate driver circuit.

• Test the current-voltage characteristics to verify the IGBT's performance under different load conditions.

• Use an oscilloscope to analyze the waveforms and check for any abnormalities.

• Perfo...read more

The density of carbon steel is approximately 7.85 grams per cubic centimeter.

• The density of carbon steel is commonly measured in grams per cubic centimeter (g/cm³).

• The density of carbon steel can vary slightly depending on the specific composition and heat treatment.

• For example, the density of low carbon steel is typically around 7.85 g/cm³.

• Higher carbon steels may have slightly higher densities.

• Density is an important property to consider in engineering applications, as it a...read more

The P.I test in transformers is performed to determine the insulation condition and losses in the transformer.

• P.I test stands for Polarization Index test.

• It is a type of insulation resistance test.

• The test measures the ratio of insulation resistance at 10 minutes to the insulation resistance at 1 minute.

• The test helps in assessing the insulation condition and detecting any moisture or contamination in the transformer.

• A high P.I value indicates good insulation, while a low val...read more

The erection sequence of a continuous casting plant involves several steps. There are two types of casters: vertical and horizontal.

• The first step is to install the foundation and anchor bolts.

• Next, the columns and beams are erected.

• After that, the equipment such as tundish, mold, and rollers are installed.

• Finally, the electrical and hydraulic systems are connected.

• There are two types of casters: vertical and horizontal. Vertical casters are used for producing slabs, while ho...read more

Autonomous maintenance is a maintenance approach where operators take responsibility for routine maintenance tasks.

• Operators are trained to perform routine maintenance tasks

• Operators conduct inspections and minor repairs

• Autonomous maintenance reduces downtime and improves equipment reliability

• Operators become more familiar with equipment and can identify potential issues

• Autonomous maintenance is a key component of Total Productive Maintenance (TPM)

Total productive maintenance is a maintenance strategy that aims to maximize equipment effectiveness and minimize downtime.

• TPM involves regular maintenance and inspection of equipment to prevent breakdowns

• It emphasizes employee involvement and training to improve equipment performance

• TPM also includes continuous improvement efforts to optimize equipment and processes

• Examples of TPM techniques include autonomous maintenance, planned maintenance, and quality maintenance

Breakdowns are handled by identifying the root cause, prioritizing repairs, and implementing preventive measures.

• Conduct a thorough investigation to determine the cause of the breakdown

• Prioritize repairs based on the impact on production and safety

• Implement preventive measures to avoid future breakdowns

• Maintain a record of breakdowns and repairs for analysis and improvement

• Train and educate staff on proper maintenance and troubleshooting techniques

Predictive maintenance is a technique that uses data analysis to predict when equipment maintenance is needed.

• It involves monitoring equipment performance and collecting data

• Data is analyzed to identify patterns and predict when maintenance is needed

• This helps to prevent equipment failure and reduce downtime

• Examples include using sensors to monitor machine vibrations or oil analysis to detect wear in engines

Six Sigma is a data-driven methodology used to improve business processes by reducing defects and variability.

• Six Sigma aims to achieve a level of quality where the probability of defects is extremely low.

• It follows a structured approach called DMAIC (Define, Measure, Analyze, Improve, Control) to identify and eliminate the root causes of defects.

• It uses statistical tools and techniques to measure and analyze process performance.

• It is widely used in industries such as manufac...read more

Speed is the rate of change of distance while velocity is the rate of change of displacement.

• Speed is a scalar quantity while velocity is a vector quantity.

• Speed can be calculated by dividing distance by time while velocity can be calculated by dividing displacement by time.

• Speed has no direction while velocity has direction.

• For example, a car moving at a constant speed of 60 km/h has a speed of 60 km/h but its velocity depends on its direction of motion.

• If the car is moving ...read more

The type of pipe in steel can vary depending on its purpose and specifications.

• Common types of steel pipes include carbon steel pipes, stainless steel pipes, and alloy steel pipes.

• Carbon steel pipes are widely used in various industries due to their strength and affordability.

• Stainless steel pipes are corrosion-resistant and commonly used in applications where hygiene and durability are important, such as in the food and beverage industry.

• Alloy steel pipes are made from a com...read more

White metal bearing damage can be overcome by identifying the root cause and implementing proper maintenance practices.

• Identify the root cause of the damage, such as misalignment, improper lubrication, or contamination.

• Implement proper maintenance practices, including regular inspections, lubrication, and alignment checks.

• Consider upgrading to higher quality bearings or materials if necessary.

• Consult with experts or manufacturers for guidance on preventing future damage.

The casting shop requires utilities such as electricity, compressed air, natural gas, and water of specific quality and type.

• Electricity is required for powering the equipment and lighting.

• Compressed air is used for cleaning and operating pneumatic tools.

• Natural gas is used for heating the furnaces.

• Water of specific quality and type is required for cooling and cleaning purposes.

• Water quality should be free from impurities and hardness.

• Water type can be either fresh or recycle...read more

Type in section pipe refers to the classification or categorization of pipes based on their shape, size, and material.

• Types of pipes can include circular, rectangular, square, or oval shapes.

• Pipes can be classified based on their diameter, wall thickness, and length.

• Materials used for pipes can vary, such as steel, PVC, copper, or cast iron.

• Different types of pipes are used for various applications like plumbing, drainage, irrigation, or gas transportation.

Yes, I have a basic understanding of steel manufacturing.

• I know that steel is made by heating iron ore in a furnace with coke and limestone.

• I understand that the process involves removing impurities and adding alloys to create different types of steel.

• I am aware of the importance of quality control in steel manufacturing to ensure the final product meets industry standards.

The density of carbon steel is 7850 kg/m3.

• Carbon steel is a commonly used material in construction and manufacturing.

• The density of carbon steel can vary depending on the specific alloy and composition.

• The high density of carbon steel makes it a durable and strong material for various applications.

Main power work distribution involves managing the distribution of electrical power throughout a construction site.

• Coordinate with electricians to ensure proper installation and maintenance of power distribution systems

• Monitor power usage and troubleshoot any issues that arise

• Ensure compliance with safety regulations and protocols

• Plan for future power needs and upgrades

• Examples: overseeing the installation of temporary power distribution for a new construction project, troubl...read more

A steel plant is a facility where steel is produced from raw materials using various processes.

• Steel plants typically use blast furnaces or electric arc furnaces to produce steel

• Raw materials such as iron ore, coal, and limestone are used in the production process

• Steel plants can produce a variety of steel products, including sheets, bars, and pipes

• Steel is an important material used in construction, manufacturing, and transportation industries

There are several types of valves used in mechanical systems.

• Gate valve

• Ball valve

• Butterfly valve

• Globe valve

• Check valve

• Diaphragm valve

• Plug valve

• Needle valve

• Pressure relief valve

• Safety valve

Moment of inertia is the measure of an object's resistance to rotational motion.

• Moment of inertia depends on the mass and distribution of mass of an object.

• It is denoted by the symbol 'I'.

• It is used to calculate the torque required to rotate an object.

• Examples include a spinning top and a rotating wheel.

• Moment of inertia is important in engineering and physics applications.

Active end flow of steam refers to the flow of steam at the outlet end of a turbine or boiler.

• Active end flow of steam is the steam flow at the outlet end of a turbine or boiler.

• It is important to monitor and control the active end flow to ensure efficient operation.

• High active end flow can indicate issues such as turbine overload or boiler inefficiency.

• Examples of monitoring active end flow include using flow meters and pressure sensors.