Electrosteel Casting Junior Engineer Production Interview Questions and Answers

Q1. Which type of pc firing
Ans. 
PC firing refers to the type of firing system used in a power plant's boiler to ignite the fuel.
• PC firing stands for Pulverized Coal firing, where coal is ground into fine powder before being injected into the boiler combustion chamber

• It is a common method used in coal-fired power plants to efficiently burn coal and generate steam for electricity production

• Other types of firing systems include fluidized bed combustion
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Q2. Witch type of cooler house
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The type of cooler house depends on the specific requirements of the production process, such as air flow, temperature control, and size.
• Cooling towers for large-scale industrial production

• Air conditioning units for smaller production facilities

• Evaporative coolers for energy-efficient cooling solutions

• Refrigeration units for temperature-sensitive production processes
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Q1. Witch stage of preheater
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The preheater stage in cement production is the calciner stage.
• The preheater typically consists of several stages including the cyclones and the calciner.

• The calciner stage is where the raw materials are heated to high temperatures before entering the rotary kiln.

• The calciner stage helps to reduce the energy consumption in the rotary kiln by preheating the raw materials.

• An example of a preheater configuration is a 4-st
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Q2. How much capacity
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Capacity planning is crucial for ensuring optimal production output and resource utilization.
• Capacity planning involves assessing current production capacity and forecasting future needs.

• Factors to consider include equipment capabilities, workforce availability, and production demand.

• Examples of capacity planning tools include production scheduling software and simulation models.
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Q1. Technical plant operations and job responsibilities
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Q1. Kiln operation and your organization
Ans. 
I have experience in kiln operation and have implemented efficient processes in my organization.
• Implemented temperature monitoring system to ensure optimal kiln operation

• Developed maintenance schedule to prevent breakdowns and minimize downtime

• Trained staff on proper kiln operation techniques

• Utilized data analysis to improve kiln efficiency and reduce energy consumption
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Q1. Plant and equipment knowledge and family background
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Q1. About heat treatment process
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Q2. About casting process
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Q3. Mechanical metallurgy
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Q1. Type of casting defect and it's solution.
Ans. 
Shrinkage defect caused by improper cooling. Solution is to increase cooling rate or add risers.
• Shrinkage defect occurs due to improper cooling causing the metal to shrink and leave voids in the casting.

• Solution is to increase cooling rate or add risers to provide additional molten metal to compensate for the shrinkage.

• Other types of casting defects include porosity, cold shuts, misruns, and hot tears.

• Porosity is cause...read more
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Q2. Getting design and die devlopment .
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Q3. Degassing process and why it's necessary.
Ans. 
Degassing is the process of removing dissolved gases from liquids to prevent defects and improve product quality.
• Dissolved gases can cause defects in products such as bubbles or porosity.

• Degassing is commonly used in the production of metals, plastics, and electronics.

• Methods of degassing include vacuum degassing, sparging, and membrane degassing.

• Degassing can also improve the shelf life and taste of food and beverages...read more
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Q4. Die casting process parameters and it's calculation.
Ans. 
Die casting process parameters include temperature, pressure, and cycle time.
• Temperature: affects the fluidity of the metal and the quality of the casting.

• Pressure: determines the filling speed and the density of the casting.

• Cycle time: affects the productivity and the quality of the casting.

• Calculation involves determining the optimal values for each parameter based on the specific alloy and part design.

• Factors such a...read more
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Q5. Mejor improvement project.
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Q6. Shrinkage defect and it's prevention process.
Ans. 
Shrinkage defect is a common casting defect caused by the solidification of metal.
• Shrinkage defect occurs when the metal solidifies and shrinks before filling the entire mold cavity.

• It can be prevented by increasing the pouring temperature, using risers, and modifying the mold design.

• Proper gating and venting can also help prevent shrinkage defects.

• Examples of shrinkage defects include shrinkage porosity and shrinkage
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Q7. HPDC pressure and velocity calculation.
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Q1. Why do you want to change this job.
Ans. 
Looking for new challenges and opportunities to grow professionally.
• Seeking a more challenging role that aligns with my career goals

• Interested in exploring new technologies and industries

• Want to work in a more collaborative and innovative environment

• Looking for better work-life balance and career advancement opportunities
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Q1. What made you think you will be employed? Ans: I have the right insights needed for the job
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Q2. Hope you won't quit a month after being employed? Ans: No,I won't
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Q3. What made you apply for this job? Ans: I really want to help this company grow.
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Q1. Technical questions related to Kiln operation, Shutdown planning, coal planning, Budget preparation etc
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Q1. Basic cement plant related questions
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Online exam with approximately 220 questions related to Aptitude, behaviour questions and General English language questions

Q1. With Plant manager discussion about management skills
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Q1. Salary negotiation and general family related questions
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Q1. What reason of pin hole in sanitary ware products.
Ans. 
Pin holes in sanitary ware products can be caused by various reasons.
• Presence of impurities in the raw materials used for manufacturing

• Inadequate mixing of raw materials

• Improper firing temperature or duration

• Poor glaze quality

• Inadequate cleaning of molds

• Inadequate drying time

• Inadequate pressure during casting

• Presence of air bubbles in the casting material

• Poor quality control measures

• Environmental factors such as humidi
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Q2. Howmany typs of crack
Ans. 
There are several types of cracks that can occur in materials.
• Fatigue cracks

• Corrosion cracks

• Thermal fatigue cracks

• Brittle cracks

• Overload cracks
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Q1. Cement precess technical data optimization
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Q1. Technical data and optimization
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