90+ Interview Questions and Answers

Boiler maintenance and bowl mill are crucial for the efficient functioning of a thermal power plant.

• Boiler maintenance involves regular cleaning, inspection, and repair of the boiler to ensure its safe and efficient operation.

• Bowl mill is a type of grinding mill used in power plants to grind coal and convert it into a powder form that can be burned more efficiently.

• Regular maintenance of bowl mills is necessary to ensure their proper functioning and prevent breakdowns.

• Mainten...read more

Various emergencies were handled in the plant including fires, chemical spills, and equipment malfunctions.

• Fires were extinguished using fire suppression systems and evacuation procedures were followed

• Chemical spills were contained and cleaned up according to safety protocols

• Equipment malfunctions were addressed promptly to prevent further damage or safety hazards

• Emergency drills were conducted regularly to ensure preparedness

• Emergency response team was trained and equipped t...read more

Over-heating of Commutator in a DC motor can be caused by factors like excessive current, poor ventilation, dirty environment, and worn-out brushes.

• Excessive current flowing through the motor can cause the commutator to overheat.

• Poor ventilation around the motor can lead to inadequate cooling, resulting in overheating.

• A dirty environment can cause dust and debris to accumulate on the commutator, hindering heat dissipation.

• Worn-out brushes can create excessive friction and res...read more

The shunt motor will run at dangerously high speeds and may get damaged.

• The motor will run at its no-load speed, which is much higher than its rated speed.

• This can lead to overheating and mechanical stress on the motor components.

• The motor may get damaged or fail prematurely if directly connected to the supply line.

Light up procedure in thermal power plant involves starting up the boiler and turbine.

• The first step is to start the boiler and bring it to the required pressure and temperature.

• Once the boiler is ready, the turbine is started and brought to the required speed.

• The generator is then synchronized with the grid and power is gradually increased.

• During the light up procedure, various safety checks are performed to ensure smooth operation.

• The entire process can take several hours d...read more

Heat losses in a boiler occur due to various factors.

• Heat loss through flue gases

• Heat loss through radiation and convection from the boiler shell

• Heat loss through blowdown and steam leaks

• Heat loss through incomplete combustion

• Heat loss through unburnt fuel in ash

• Heat loss through moisture in fuel

• Heat loss through excess air

• Heat loss through soot and scale buildup on heat transfer surfaces

Causes of hot bearings include lack of lubrication, overloading, misalignment, and contamination.

• Lack of lubrication: Insufficient or degraded lubricant can cause increased friction and heat.

• Overloading: Excessive load on the bearing can lead to overheating.

• Misalignment: Improper alignment of the bearing can cause it to operate under stress and generate heat.

• Contamination: Foreign particles or debris in the bearing can hinder smooth operation and cause overheating.

DCDA process is used to produce high concentration sulphuric acid.

• DCDA stands for Double Contact Double Absorption process.

• It involves two absorption towers and two contact towers.

• Sulphur dioxide is oxidized to sulphur trioxide in the contact towers.

• Sulphur trioxide is then absorbed in the absorption towers to produce sulphuric acid.

• The process is highly efficient and produces high concentration sulphuric acid.

• DCDA process is widely used in the chemical industry for the produ...read more

The head required for pumping fluid to a 30 mtr high building depends on the specific gravity and flow rate of the fluid.

• The head required is equal to the sum of the elevation head and friction head.

• Elevation head is the height difference between the pump and the highest point of the building.

• Friction head is the energy loss due to fluid friction in the pipes.

• The specific gravity and flow rate of the fluid affect the friction head.

• The pump should be selected based on the requ...read more

Facing difficulties in mines requires staying calm, following safety protocols, and seeking help when needed.

• Stay calm and assess the situation before taking any action

• Follow safety protocols and use proper equipment to minimize risks

• Communicate with team members and supervisors for assistance and guidance

• Stay alert for any signs of danger such as gas leaks or cave-ins

• Seek immediate help if you encounter any problems or emergencies

Plant overview refers to a comprehensive understanding of the various aspects of a plant's operations.

• Plant overview includes understanding the production process, machinery, equipment, and personnel involved.

• It also involves knowledge of safety protocols, quality control measures, and environmental regulations.

• For example, in a manufacturing plant, an overview would include understanding the assembly line, the types of machinery used, the roles of different employees, and th...read more

The MCDR 2017 mining plan exploration quality refers to the quality standards set for mining exploration in the Mineral Conservation and Development Rules of 2017.

• MCDR 2017 sets guidelines for exploration activities in the mining sector

• The plan should focus on ensuring efficient and sustainable exploration practices

• Quality control measures should be implemented to meet regulatory requirements

• Regular monitoring and reporting of exploration activities is essential

A relief valve is a safety device used to control or limit pressure in a system by releasing excess pressure.

• Relief valves are commonly used in steam boilers, pressure vessels, and pipelines.

• They are designed to open and release excess pressure when the pressure inside the system exceeds a certain limit.

• This helps prevent damage to the system and ensures the safety of personnel working with the system.

• Relief valves can be set to open at a specific pressure or temperature, dep...read more

A process flow diagram of a plate rolling mill

• Raw materials are loaded onto the mill

• The plate is rolled to the desired thickness and length

• The plate is then cooled and cut to size

• The finished product is inspected for quality

• The product is then packaged and shipped to customers

MSDS of Sulphuric Acid provides information on its properties, hazards, and safety precautions.

• MSDS stands for Material Safety Data Sheet

• Sulphuric acid is a highly corrosive and hazardous substance

• The MSDS provides information on the physical and chemical properties of the substance, as well as its potential health effects and safety precautions

• Safety precautions may include wearing protective clothing and equipment, handling the substance in a well-ventilated area, and avoid...read more

The gravitational constant of Earth is approximately 9.81 m/s^2.

• The gravitational constant of Earth is a measure of the acceleration due to gravity on the surface of the Earth.

• It is commonly denoted as 'g' and has an approximate value of 9.81 m/s^2.

• This value can vary slightly depending on the location and altitude on Earth.

Legal requirements in a manufacturing establishment include compliance with occupational health and safety regulations, environmental laws, and labor standards.

• Compliance with Occupational Safety and Health Administration (OSHA) regulations

• Adherence to environmental protection laws and regulations

• Ensuring workplace safety measures are in place, such as proper training, safety equipment, and emergency procedures

• Compliance with labor standards, including fair wages, working hou...read more

Precautions and actions taken in emergency situations as a firefighter

• Assess the situation and determine the appropriate response

• Communicate effectively with team members and other emergency responders

• Wear appropriate personal protective equipment

• Establish a safe perimeter and evacuate nearby people

• Use appropriate firefighting techniques and equipment

• Provide medical assistance to injured individuals

• Maintain situational awareness and adapt to changing conditions

• Follow establis...read more

Quality control can be achieved through implementing standardized processes, conducting regular inspections, providing training to employees, and utilizing feedback mechanisms.

• Implement standardized processes to ensure consistency in product/service quality

• Conduct regular inspections to identify and address any quality issues

• Provide training to employees on quality standards and procedures

• Utilize feedback mechanisms from customers and employees to continuously improve quality...read more

Tungsten has a melting point of 3,422 degrees Celsius.

• Melting point of tungsten is 3,422 degrees Celsius

• Tungsten has one of the highest melting points of all metals

• It is commonly used in high-temperature applications such as light bulb filaments and aerospace components

Helix marks arise in sheet rolling due to misalignment or uneven pressure.

• Helix marks occur when there is misalignment between the rolls during sheet rolling.

• Uneven pressure distribution can also lead to the formation of helix marks.

• These marks appear as spiral-shaped patterns on the rolled sheet.

• Helix marks can negatively impact the quality and appearance of the rolled sheet.

• Proper alignment and uniform pressure are essential to prevent helix marks.

Escape velocity from Earth is approximately 11.2 km/s.

• Escape velocity is the minimum speed needed for an object to break free from the gravitational attraction of a planet.

• It is calculated using the formula: escape velocity = sqrt(2 * gravitational constant * mass of the planet / radius of the planet)

• For Earth, the escape velocity is approximately 11.2 km/s.

• Escape velocity varies depending on the planet's mass and radius.

The aluminum business involves the production, processing, and distribution of aluminum and its alloys.

• Aluminum is a lightweight and corrosion-resistant metal.

• It is widely used in various industries such as construction, transportation, packaging, and electrical.

• The aluminum industry includes mining and refining of bauxite ore, smelting, and fabrication processes.

• Major players in the aluminum business include companies like Alcoa, Rio Tinto, and Norsk Hydro.

• Aluminum products ...read more

The melting point of aluminum is 660.32 degrees Celsius.

• The melting point of aluminum is 660.32 degrees Celsius or 1220.58 degrees Fahrenheit.

• Aluminum transitions from a solid to a liquid state at its melting point.

• Maintaining the correct temperature is crucial when melting aluminum for casting or other processes.

To test voltage, use a multimeter set to the appropriate range. To test thermometer readings, use a calibrated thermometer.

• For testing voltage, set the multimeter to the appropriate range (AC or DC) and connect the probes to the circuit being tested.

• For testing thermometer readings, use a calibrated thermometer to compare the temperature readings with the known standard.

• Ensure proper safety precautions are taken while testing voltage to avoid electric shock.

• Calibrate the ther...read more

There are various types of boilers and different types of boiler mountings are used depending on the type of boiler.

• Types of boilers include fire tube, water tube, and electric boilers.

• Boiler mountings include safety valves, water level indicators, pressure gauges, and blowdown valves.

• The type of boiler and its application determine the type of boiler mounting used.

• For example, a fire tube boiler may have a different set of mountings compared to a water tube boiler.

Light is a form of electromagnetic radiation that is visible to the human eye. It is used for illumination, communication, and various other applications.

• Light is a type of electromagnetic radiation that is visible to the human eye.

• It can be produced naturally (sunlight) or artificially (light bulbs, LEDs).

• Light is used for illumination in homes, offices, streets, etc.

• It is also used for communication (fiber optics), photography, medical treatments (phototherapy), and many ot...read more

The least count of a micrometer is the smallest measurement that can be read on the scale of the micrometer.

• The least count of a micrometer is typically 0.01 mm or 0.001 mm depending on the type of micrometer.

• It is determined by the number of divisions on the thimble and the pitch of the screw.

• For example, a micrometer with 50 divisions on the thimble and a pitch of 0.5 mm would have a least count of 0.01 mm.

Ohm's law states that the current flowing through a conductor is directly proportional to the voltage applied across it, and inversely proportional to the resistance of the conductor.

• Ohm's law is represented by the formula V = I * R, where V is voltage, I is current, and R is resistance.

• It helps in calculating the current flowing through a circuit when the voltage and resistance are known.

• It can also be used to determine the resistance of a component when the voltage and curr...read more

Yes, I have prepared IND AS Financials.

• I have experience in preparing financial statements as per IND AS standards.

• I am familiar with the changes and updates in IND AS and have incorporated them in my work.

• I have worked on various financial reports such as balance sheet, income statement, cash flow statement, etc. as per IND AS.

• I have also ensured compliance with all the relevant laws and regulations while preparing the financial statements.

• For example, I have prepared IND AS...read more

MW stands for megawatt, a unit of power equal to one million watts.

• MW is a unit of power used to measure the rate at which energy is generated or consumed.

• 1 MW is equal to 1 million watts or 1,000 kilowatts.

• It is commonly used in the context of electricity generation and consumption.

• For example, a large wind turbine may have a capacity of 2 MW, meaning it can generate 2 million watts of power.

The maximum diameter of a dowel bar typically ranges from 1 inch to 2 inches.

• Typical maximum diameter of dowel bar is 1 inch to 2 inches

• Dowel bars are commonly used in concrete pavement joints

• The diameter of dowel bars can vary based on the specific project requirements

The maximum thickness of slab bar is typically around 32mm to 40mm.

• The maximum thickness of slab bar is determined by the design requirements and load capacity of the structure.

• In general, the maximum thickness of slab bar is around 32mm to 40mm.

• Thicker slab bars may be used for heavy-duty structures or special design requirements.

M25 grade concrete ratio is 1:1:2 (1 part cement, 1 part sand, 2 parts aggregate)

• M25 grade concrete has a ratio of 1:1:2 for cement, sand, and aggregate respectively

• This means for every part of cement, there is an equal part of sand and double the part of aggregate

• For example, for 1 cubic meter of M25 grade concrete, you would need 1 cubic meter of cement, 1 cubic meter of sand, and 2 cubic meters of aggregate

SPL stands for Sound Pressure Level and SEL stands for Sound Exposure Level.

• SPL is a measure of sound intensity relative to a reference level.

• SEL is a measure of sound exposure over a period of time, typically in decibels.

• Both SPL and SEL are commonly used in the field of acoustics and noise control.

Alumina is manufactured through the Bayer process, which involves extracting aluminum oxide from bauxite ore.

• Bauxite ore is crushed and mixed with sodium hydroxide to form a slurry

• The slurry is heated and pressurized to dissolve the aluminum oxide

• The resulting solution is cooled and filtered to remove impurities

• The aluminum oxide is then heated at high temperatures to form alumina

• The temperature required for this process is typically around 1000-1200°C

A cooling tower is a specialized heat exchanger in which air and water are brought into direct contact to reduce the water's temperature.

• Used in HVAC systems to remove heat from a building or industrial process

• Water is circulated through the tower and exposed to air, causing evaporation and cooling

• Commonly seen in power plants, refineries, and large buildings

CRM stands for Customer Relationship Management. It is a strategy used by companies to manage interactions with customers and potential customers.

• CRM involves using technology to organize, automate, and synchronize sales, marketing, customer service, and technical support.

• It helps companies build and maintain relationships with customers, streamline processes, and improve profitability.

• Examples of CRM software include Salesforce, HubSpot, and Zoho CRM.

A megger is a portable instrument used to measure the insulation resistance of electrical equipment.

• Measures insulation resistance to detect any faults or breakdowns in electrical insulation

• Helps prevent electrical accidents and equipment failures

• Commonly used in maintenance and troubleshooting of electrical systems

Safety valve and NRV are important safety devices in a boiler system.

• Safety valve is used to release excess pressure in the boiler to prevent explosions.

• NRV (Non-Return Valve) is used to prevent backflow of water or steam in the system.

• Safety valve should be tested regularly to ensure proper functioning.

• NRV should be installed in the correct direction to prevent backflow.

• Both safety valve and NRV are required by law in most countries to ensure safe operation of boilers.

Mercury is a liquid metal at room temperature.

• Mercury is the only metal that is liquid at room temperature

• It has a silvery appearance

• Mercury is commonly used in thermometers and barometers

Turbine generator work involves converting mechanical energy into electrical energy using steam or water.

• Turbine generators use steam or water to rotate a turbine connected to a generator

• The rotating turbine spins magnets inside the generator, creating an electric current

• The electric current is then transmitted through power lines for use in homes and industries

Density of slurry is the mass of the slurry per unit volume.

• Density of slurry is typically measured in kg/m^3 or lb/ft^3.

• It is calculated by dividing the mass of the slurry by its volume.

• The density of slurry can vary depending on the concentration of solids in the liquid.

• For example, a slurry with a high concentration of solids will have a higher density.

The red area typically refers to a section or region that is highlighted or marked in the color red.

• Red area can indicate danger or warning.

• In engineering, red areas on diagrams or blueprints may signify areas of high risk or critical components.

• Examples: red area on a map indicating a fire hazard zone, red area on a circuit diagram highlighting a high voltage section.

Displacement is the change in position of an object, typically measured in a straight line from the initial to the final position.

• Displacement is a vector quantity, meaning it has both magnitude and direction.

• It can be positive, negative, or zero depending on the direction of the movement.

• For example, if a car travels 10 meters east and then 5 meters west, the total displacement is 5 meters east.

• Displacement is different from distance traveled, as it only considers the change...read more

Servo motor works on the principle of error-sensing feedback control system to achieve precise position control.

• Servo motor receives a control signal that represents the desired position

• The motor compares the actual position with the desired position

• Based on the error signal, the motor adjusts its position to minimize the error

• This closed-loop system ensures accurate and precise control of the motor

A transformer is a device that transfers electrical energy from one circuit to another through electromagnetic induction.

• Transformers consist of two coils of wire, known as the primary and secondary coils.

• The primary coil is connected to a power source, creating a magnetic field when current flows through it.

• This magnetic field induces a voltage in the secondary coil, allowing for the transfer of electrical energy.

• Transformers are commonly used in power distribution systems t...read more

Newton's 3rd law states that for every action, there is an equal and opposite reaction.

• Action and reaction forces are always equal in magnitude but opposite in direction

• These forces act on different objects

• Examples include a person walking (action) pushing the ground backward (reaction)

1 M3 of cement volume is equivalent to 1440 kg or 1.44 tonnes.

• 1 M3 of cement volume is equal to 1440 kg or 1.44 tonnes.

• This volume is commonly used in construction projects to calculate the amount of cement needed.

• It is important to accurately measure and calculate cement volume to ensure the structural integrity of the project.

Current is the flow of electric charge in a circuit.

• Current is measured in Amperes (A).

• It is the rate of flow of electric charge past a point in a circuit.

• There are two types of current - direct current (DC) and alternating current (AC).

• Current is calculated using Ohm's Law: I = V/R, where I is current, V is voltage, and R is resistance.

A breaker is an electrical switch designed to protect an electrical circuit from damage caused by overload or short circuit.

• A breaker automatically interrupts the flow of electricity when it detects an overload or short circuit.

• Breakers come in different types such as circuit breakers, fuse boxes, and ground fault circuit interrupters (GFCIs).

• They are essential for preventing electrical fires and protecting electrical equipment.

• Examples include miniature circuit breakers (MCB...read more

Na3PO4 is used as a pH buffer in boilers while DM water is used to prevent scaling and corrosion.

• Na3PO4 is added to boiler water to maintain a pH level between 10 and 11, which helps prevent corrosion and scaling.

• DM water, or deionized water, is used in boilers to prevent scaling and corrosion by removing minerals and impurities.

• Using DM water in combination with Na3PO4 can help maintain a clean and efficient boiler system.

Economiser and APH are used in boilers to increase efficiency and reduce emissions.

• Economiser preheats the feed water using exhaust gases, reducing fuel consumption.

• APH (Air Preheater) preheats the combustion air, reducing fuel consumption and emissions.

• Both are commonly used in large industrial boilers.

• Economiser can increase efficiency by up to 5%.

• APH can increase efficiency by up to 2% and reduce emissions by up to 20%.

Power factor is the ratio of real power to apparent power in an electrical system.

• Power factor is a measure of how effectively electrical power is being converted into useful work.

• It is calculated as the cosine of the angle between the voltage and current waveforms in an AC circuit.

• A power factor of 1 indicates all the power is being used for useful work, while a power factor of 0 means all power is reactive.

• Power factor correction is often used to improve efficiency and redu...read more

Pressure is the force applied perpendicular to the surface of an object per unit area.

• Pressure is force divided by area: P = F/A

• Pressure is measured in units such as Pascals (Pa) or pounds per square inch (psi)

• Examples of pressure include atmospheric pressure, tire pressure, and hydraulic pressure

Materials can be identified by their physical properties, labels, codes, and documentation.

• Check the physical properties such as color, texture, weight, and shape

• Look for labels or tags on the material indicating its type, manufacturer, and specifications

• Refer to codes or markings on the material for identification purposes

• Review documentation such as invoices, packing slips, or material safety data sheets (MSDS)

• Use tools like barcode scanners or RFID technology for quick ide...read more

Safety is a top priority in all aspects of our work to prevent accidents and ensure a safe working environment.

• Implementing safety protocols and procedures

• Providing proper training to employees on safety measures

• Regularly inspecting equipment and facilities for potential hazards

• Encouraging a culture of safety awareness among all staff members

FGD process is feasible for reducing air pollution from power plants.

• FGD (Flue Gas Desulfurization) process is used to remove sulfur dioxide from flue gases.

• It is a proven technology and has been used in power plants for decades.

• FGD systems can reduce sulfur dioxide emissions by up to 95%.

• The feasibility of FGD process depends on various factors such as the type of fuel used, the size of the power plant, and the cost of installation and maintenance.

• For example, FGD process is...read more

Rankine cycle is a thermodynamic cycle used in power plants to generate electricity.

• It involves four processes: heating, vaporization, expansion, and condensation.

• Water is heated in a boiler to produce steam, which is then expanded through a turbine to generate electricity.

• The steam is then condensed back into water and the cycle repeats.

• Efficiency can be improved by using superheated steam and reheating the steam before it enters the turbine.

• Rankine cycle is commonly used in...read more

Safety standards and procedures are crucial for ensuring a safe work environment.

• Regular safety training for employees

• Strict adherence to safety protocols and guidelines

• Proper use of personal protective equipment (PPE)

• Regular safety inspections and audits

• Prompt reporting and investigation of safety incidents

• Continuous improvement of safety procedures based on feedback and data

• Collaboration with regulatory agencies to ensure compliance with safety regulations

Extraction of aluminum involves the process of electrolysis of alumina.

• Aluminum is extracted from its ore, bauxite, through the Bayer process.

• The extracted alumina is then converted into aluminum through the Hall-Héroult process.

• Electrolysis is used to separate the aluminum from the oxygen in alumina.

• The process requires a large amount of electricity and is energy-intensive.

Voltage drop is the decrease in electrical potential along a conductor due to resistance.

• Voltage drop occurs when current flows through a conductor with resistance.

• It is measured in volts and can affect the performance of electrical devices.

• Voltage drop can be calculated using Ohm's Law: V = I * R, where V is voltage drop, I is current, and R is resistance.

• Excessive voltage drop can lead to overheating and inefficiency in electrical systems.

• For example, if a 12V battery is co...read more

The current industry trend is towards digitalization and automation.

• Digital transformation is a top priority for many companies.

• Automation is being used to streamline processes and increase efficiency.

• Artificial intelligence and machine learning are being integrated into various industries.

• Remote work and virtual collaboration are becoming more common.

• Sustainability and social responsibility are also important trends.

• E-commerce and online shopping are growing rapidly.

• Cybersec...read more

Hindalco aims to become a global leader in sustainable aluminum production, focusing on innovation and environmental stewardship.

• Investing in research and development for eco-friendly production processes

• Expanding renewable energy sources for manufacturing operations

• Implementing circular economy practices to reduce waste and improve resource efficiency

• Collaborating with partners and stakeholders to drive sustainability initiatives

• Exploring new markets and opportunities for gr...read more

Alumina is extracted from bauxite through a process called the Bayer process.

• Alumina is the primary component of aluminum production.

• The Bayer process involves crushing the bauxite ore, mixing it with sodium hydroxide, and heating it in a pressure vessel.

• The resulting solution is filtered to remove impurities, leaving behind alumina which is then processed into aluminum.

• Alumina is used in a variety of industries including automotive, aerospace, and construction.

The company's policy focuses on transparency, efficiency, and cost-effectiveness in procurement processes.

• The company emphasizes transparency in all procurement transactions to ensure accountability.

• Efficiency is a key factor in the company's policy to streamline the procurement process and reduce lead times.

• Cost-effectiveness is prioritized to ensure that the company gets the best value for money in all purchases.

• Compliance with regulations and ethical standards is a fundame...read more