50+ Burckhardt Compression Interview Questions and Answers

Questions related to pumps, flow meters, distillation column, and heat transfer modes.

• Pumps are devices used to move fluids by mechanical action.

• Flow meters are instruments used to measure the flow rate of fluids.

• The working of flow meters varies depending on the type of flow meter used.

• Increasing the reflux ratio in a distillation column increases the purity of the distillate.

• The modes of heat transfer are conduction, convection, and radiation.

Broaching is a machining process used for shaping a surface by removing material with a toothed tool.

• Broaching is a metal cutting process that uses a toothed tool called a broach to remove material from a workpiece.

• It is used for shaping internal or external surfaces, such as keyways, splines, and gears.

• Broaching can be used as a finishing process to achieve tight tolerances and smooth surface finishes.

• It can also be used as a roughing process to remove large amounts of mater...read more

There are two main types of IC engines: spark ignition (SI) engines and compression ignition (CI) engines.

• Spark ignition (SI) engines use a spark plug to ignite the fuel-air mixture, commonly used in gasoline engines.

• Compression ignition (CI) engines rely on the heat generated by compressing the air-fuel mixture to ignite it, commonly used in diesel engines.

• Other types include rotary engines, two-stroke engines, and four-stroke engines.

• Rotary engines, also known as Wankel eng...read more

Types of pumps include centrifugal, reciprocating, and rotary pumps. Heat exchangers transfer heat between two fluids. Material properties affect heat and mass transfer.

• Types of pumps: centrifugal, reciprocating, rotary

• Working of heat exchanger: transfers heat between two fluids

• Properties of material: affect heat and mass transfer

• Examples: stainless steel for heat exchangers, copper for pumps

A heat exchanger is a device used to transfer heat between two or more fluids.

• Heat exchangers are used in various industries such as chemical, power, and HVAC.

• They work by allowing two fluids to flow through separate channels, with heat transferring from one fluid to the other.

• Common types of heat exchangers include shell and tube, plate and frame, and finned tube.

• Heat exchangers can be used for heating, cooling, or both.

• Efficiency of a heat exchanger is determined by factors...read more

Flow meters measure the flow rate of fluids or gases. There are various types with different working principles.

• Differential Pressure Flow Meters: Measure flow by creating a pressure drop across an obstruction in the flow path (e.g., Orifice Plate, Venturi Tube). Advantages: Simple design, low cost. Disadvantages: Pressure loss, limited turndown ratio.

• Positive Displacement Flow Meters: Measure flow by dividing the fluid into known volumes and counting them (e.g., Piston, Oval...read more

Flow meters are devices used to measure the flow rate or quantity of a gas or liquid moving through a pipe.

• Differential pressure flow meters

• Positive displacement flow meters

• Velocity flow meters

• Mass flow meters

• Open channel flow meters

Blowing a balloon violates Boyle's Law because the pressure inside the balloon increases as the volume decreases.

• Blowing air into a balloon increases the pressure inside the balloon.

• Boyle's Law states that at constant temperature, the pressure of a gas is inversely proportional to its volume.

• By blowing air into the balloon, the volume decreases while the pressure increases, violating Boyle's Law.

Distillation is a process of separating components of a mixture based on their boiling points.

• It involves heating the mixture to vaporize the component with the lowest boiling point.

• The vapor is then condensed and collected as a separate liquid.

• This process can be used to purify liquids, separate different components of a mixture, and extract essential oils from plants.

• Examples include the distillation of crude oil to produce gasoline and the distillation of alcoholic beverag...read more

A boiler is a closed vessel in which water or other fluid is heated. 2 level control of boiler involves maintaining water level. Cv is a formula for valve capacity. Different types of pressure gauges include bourdon tube, diaphragm, and digital.

• Boiler is a closed vessel used to heat water or other fluids.

• 2 level control of boiler involves maintaining water level at two different points to ensure safe operation.

• Cv is the formula for valve capacity and is calculated as the flow...read more

Types of pumps include centrifugal, reciprocating, and rotary pumps. Heat exchangers transfer heat between two fluids. Centrifugal pumps use centrifugal force to move fluid.

• Types of pumps: centrifugal, reciprocating, rotary

• Heat exchangers transfer heat between two fluids

• Centrifugal pumps use centrifugal force to move fluid

The equation commonly used for transporting fluid from one place to another is the Bernoulli's equation.

• Bernoulli's equation relates the pressure, velocity, and height of a fluid along a streamline.

• It is commonly used in fluid mechanics to analyze the flow of fluids in pipes, pumps, and other systems.

• The equation is: P + (1/2)ρv^2 + ρgh = constant, where P is pressure, ρ is density, v is velocity, and h is height.

• It helps in understanding the energy balance of a fluid as it m...read more

Control valve and shutoff valve datasheet key points and their meanings.

• Control valve datasheet key points: flow capacity, pressure drop, valve type, actuator type, material, size, Cv value, rangeability.

• Shutoff valve datasheet key points: valve type, material, size, pressure rating, leakage class, end connections.

• Control valve datasheet key points meaning: Flow capacity - maximum flow rate through the valve, Pressure drop - pressure difference across the valve, Valve type - ...read more

The Stress-Strain curve in Strength of Materials and the Carnot cycle are both important concepts in engineering.

• The Stress-Strain curve shows the relationship between stress (force applied) and strain (resulting deformation) in a material.

• The Carnot cycle is a theoretical thermodynamic cycle that describes the most efficient heat engine possible.

• Both concepts are fundamental in understanding material behavior and thermodynamics in engineering.

• Examples: Steel has a linear str...read more

Temperature instruments include thermocouples, resistance temperature detectors (RTDs), and thermistors.

• Thermocouples are made of two different metals and work based on the principle of the Seebeck effect.

• RTDs are made of pure metals like platinum and operate on the principle of the change in electrical resistance with temperature.

• Thermistors are made of semiconductor materials and their resistance changes with temperature.

• Metallurgy for temperature instruments depends on the...read more

A pipe rack is a structure used to support pipes and other equipment in a plant or industrial facility.

• Pipe racks are typically made of steel and are designed to withstand the weight of the pipes and equipment they support.

• They are used to organize and route pipes throughout a facility, allowing for easy access and maintenance.

• Pipe racks can be located indoors or outdoors, and can be designed to accommodate a variety of pipe sizes and configurations.

• They are an essential comp...read more

The pump curve shows the relationship between flow rate and head. The Bernoulli equation relates pressure, velocity, and elevation in a fluid flow system.

• The pump curve is a graph showing the performance of a pump by plotting flow rate against head.

• The Bernoulli equation is a fundamental equation in fluid mechanics that relates the pressure, velocity, and elevation of a fluid at any point in a flow system.

• Questions from CV may include experience with process engineering, know...read more

Battery sizing calculation involves determining the capacity and voltage required for a specific application.

• Determine the power requirements of the application

• Calculate the energy required by multiplying power and time

• Select a battery with sufficient capacity and voltage to meet energy requirements

• Consider factors such as temperature, discharge rate, and cycle life

• Perform testing and validation to ensure the selected battery meets the application's needs

Assumptions of Bernoulli's equation in fluid dynamics

• Incompressible flow (density is constant)

• Steady flow (velocity does not change with time)

• No viscous effects (no friction losses)

• No heat transfer (adiabatic process)

• Flow along a streamline (no cross-flow mixing)

• Potential flow (irrotational flow)

• Negligible changes in elevation (no significant height differences)

The Bernoulli equation relates the pressure, velocity, and elevation of a fluid in a moving streamline.

• The Bernoulli equation is P + 1/2 * rho * v^2 + rho * g * h = constant

• P represents the pressure of the fluid

• rho is the density of the fluid

• v is the velocity of the fluid

• g is the acceleration due to gravity

• h is the height of the fluid above a reference point

• The equation is based on the principle of conservation of energy for flowing fluids

Internal testing of transformers involves various tests to ensure proper functioning and safety.

• Insulation resistance test to check for any insulation breakdown

• Polarity test to verify correct connections

• Turns ratio test to ensure proper voltage transformation

• Winding resistance test to check for any short circuits or open circuits

• Impedance test to determine the impedance of the transformer

• Dielectric tests to assess the dielectric strength of the insulation material

Flow meters measure the rate of fluid flow in a pipe or channel.

• Flow meters work by measuring the velocity of the fluid and the cross-sectional area of the pipe or channel.

• There are different types of flow meters such as differential pressure flow meters, positive displacement flow meters, and electromagnetic flow meters.

• Flow meters are used in various industries such as oil and gas, water treatment, and food and beverage.

• Examples of flow meters include turbine flow meters, u...read more

Headroom clearance is the vertical distance between the highest point of a piping system and the ceiling or any obstruction above it.

• Headroom clearance is important to ensure safe and efficient installation and maintenance of piping systems.

• It is typically specified in building codes and industry standards.

• The required headroom clearance may vary depending on the type of piping system and its location.

• For example, a steam piping system may require a larger headroom clearance ...read more

Ensure proper equipment, weight limits, clear path, and communication before lifting.

• Check weight limits of equipment being used

• Ensure proper lifting techniques are being followed

• Clear the path of any obstacles

• Communicate with others involved in the lifting process

Safety is a critical aspect of engineering that involves identifying and mitigating potential risks and hazards.

• Safety is a top priority in engineering to protect people, property, and the environment.

• Engineers must have knowledge of safety regulations, standards, and best practices.

• They should be able to identify potential hazards and design systems to minimize risks.

• Examples of safety considerations in engineering include fire safety, electrical safety, and structural safet...read more

Ammonia conversion involves the reaction of nitrogen and hydrogen to form ammonia. Reforming reaction is the process of converting hydrocarbons into hydrogen and carbon monoxide.

• Ammonia conversion is a process that involves the reaction of nitrogen and hydrogen to form ammonia.

• The reaction is exothermic and occurs at high pressure and temperature.

• Reforming reaction is a process that converts hydrocarbons into hydrogen and carbon monoxide.

• This reaction is used in the productio...read more

Pump suction head is calculated by adding the atmospheric pressure, the vapor pressure of the liquid being pumped, and the elevation difference between the pump and the liquid source.

• Calculate the atmospheric pressure at the pump location

• Determine the vapor pressure of the liquid being pumped

• Find the elevation difference between the pump and the liquid source

• Add the atmospheric pressure, vapor pressure, and elevation difference to get the pump suction head

A centrifugal pump uses centrifugal force to transfer fluid from one location to another.

• Centrifugal pumps have an impeller that rotates to create centrifugal force.

• The centrifugal force pushes the fluid towards the outer edges of the impeller.

• As the fluid moves towards the outer edges, it gains kinetic energy.

• The kinetic energy is then converted into pressure energy as the fluid exits the impeller.

• The pressure energy allows the fluid to be transferred to a higher elevation o...read more

Transformers have lower losses compared to induction motors due to their simpler design and operation.

• Transformers have core losses (eddy current and hysteresis losses) and copper losses (due to resistance in windings).

• Induction motors have similar losses but also include mechanical losses (friction and windage losses).

• Efficiency of transformers is typically higher than induction motors due to lower losses.

• Losses in transformers can be minimized by using high-quality material...read more

Load cases in Caesar 2 are combinations of loads and boundary conditions used to analyze stresses in piping systems.

• Load cases are used to simulate different operating conditions of a piping system

• They include combinations of internal and external pressure, temperature, weight, wind, seismic, and other loads

• Boundary conditions such as fixed supports, guides, and anchors are also included in load cases

• Each load case generates a set of stresses and displacements that can be ana...read more

Implemented energy-efficient lighting system in manufacturing plant

• Conducted energy audit to identify areas for improvement

• Replaced traditional lighting with LED fixtures

• Installed motion sensors to automatically turn off lights in unoccupied areas

A pump characteristic curve is a graphical representation of a pump's performance.

• It shows the relationship between the pump's flow rate and the head it can generate.

• The curve is typically plotted with flow rate on the x-axis and head on the y-axis.

• The curve helps in selecting the right pump for a specific application.

• It provides information about the pump's efficiency, power consumption, and operating range.

• Different pump types have different characteristic curves.

Transformer circuit diagram consists of primary and secondary coils connected by a magnetic core. Losses include core losses and copper losses.

• Transformer circuit diagram includes primary and secondary coils connected by a magnetic core

• Losses in a transformer include core losses (eddy current and hysteresis losses) and copper losses (due to resistance in windings)

• Efficiency of a transformer is affected by these losses

Shell and tube heat exchanger is a type of heat exchanger that uses multiple tubes enclosed in a shell to transfer heat between two fluids.

• Consists of a shell (outer vessel) and tubes (inner vessels)

• One fluid flows through the tubes while the other flows around the tubes in the shell

• Heat is transferred from one fluid to the other through the tube walls

• Commonly used in industrial processes, HVAC systems, and refrigeration

• Examples include condensers, evaporators, and oil cooler...read more

Productivity can be improved by streamlining processes, setting clear goals, providing training and incentives, and using technology.

• Streamline processes to eliminate inefficiencies

• Set clear goals and expectations for employees

• Provide training and development opportunities to improve skills

• Offer incentives and rewards for meeting or exceeding goals

• Use technology to automate tasks and improve communication

• Encourage collaboration and teamwork to increase efficiency

Anchor bay on rack is decided based on the load and the type of piping system.

• Calculate the weight of the piping system and the forces acting on it

• Determine the type of piping system and the required support spacing

• Consider the thermal expansion and contraction of the piping system

• Select the appropriate anchor type and location based on the above factors

• Ensure compliance with applicable codes and standards

Heat exchangers are devices used to transfer heat between two or more fluids, without them mixing together.

• Heat exchangers are commonly used in industrial processes, HVAC systems, and refrigeration systems.

• They work by transferring heat from one fluid to another through a solid wall, without the fluids coming into direct contact.

• Examples of heat exchangers include shell and tube, plate, and finned tube heat exchangers.

Quality can be achieved by implementing a comprehensive quality management system and continuously improving processes.

• Establishing clear quality objectives and metrics

• Implementing quality control measures

• Conducting regular audits and inspections

• Providing training and development opportunities for employees

• Encouraging a culture of continuous improvement

• Using customer feedback to drive improvements

• Ensuring compliance with relevant regulations and standards

Managing project scope changes and ensuring timely delivery are my biggest challenges.

• Managing scope changes and ensuring timely delivery

• Balancing competing priorities

• Dealing with unexpected issues and risks

• Communicating effectively with stakeholders

• Ensuring project team is aligned and motivated

Final OPOT of a column can be achieved through proper planning and execution.

• Ensure proper alignment and positioning of the column

• Check for any defects or damages in the column

• Ensure proper reinforcement and formwork

• Pour concrete in stages and compact it properly

• Allow sufficient time for curing

• Perform necessary tests and inspections before finalizing OPOT

Designing an exchanger involves determining the heat transfer area, fluid flow rates, and selecting appropriate materials.

• Determine the heat transfer area required based on the heat duty and the overall heat transfer coefficient.

• Calculate the fluid flow rates and pressure drops for both the hot and cold fluids.

• Select appropriate materials based on the process conditions and compatibility with the fluids.

• Consider factors such as fouling, corrosion, and erosion when designing t...read more

Radiation is the emission of energy as electromagnetic waves or as moving subatomic particles, especially high-energy particles that cause ionization.

• Radiation can be classified into ionizing radiation (e.g. gamma rays, X-rays) and non-ionizing radiation (e.g. visible light, radio waves)

• Ionizing radiation has enough energy to remove tightly bound electrons from atoms, creating ions

• Radiation is used in various fields such as medicine (radiation therapy), industry (sterilizatio...read more

Risk methodology is a process of identifying, assessing, and prioritizing risks to minimize their impact on a project or organization.

• Risk identification involves identifying potential risks that may occur during a project or in an organization.

• Risk assessment involves analyzing the likelihood and impact of identified risks.

• Risk prioritization involves ranking risks based on their likelihood and impact to determine which risks should be addressed first.

• Risk mitigation involve...read more

Base pressure diagram of foundation shows the distribution of pressure on the foundation base.

• Base pressure diagram helps in understanding how the load is distributed on the foundation base.

• It is important for designing foundations to ensure they can support the load effectively.

• The diagram typically shows higher pressure under the columns and lower pressure in between.

• It is used to determine the size and depth of the foundation needed for a structure.

• Base pressure diagrams a...read more

Improvement can be achieved through better communication, collaboration, and innovation.

• Improved communication channels between teams and departments

• Increased collaboration and knowledge sharing among team members

• Encouraging innovation and experimentation to drive continuous improvement

• Regular feedback and performance evaluations to identify areas for improvement

Various building codes are used depending on the project location and type, such as International Building Code (IBC), National Electrical Code (NEC), and American Society of Mechanical Engineers (ASME) standards.

• International Building Code (IBC) for structural design and construction

• National Electrical Code (NEC) for electrical systems

• American Society of Mechanical Engineers (ASME) standards for mechanical systems

• Local building codes may also apply depending on the project l...read more

Friction factor is a dimensionless quantity used in fluid mechanics to describe the amount of friction between a fluid and a surface.

• Friction factor is denoted by the symbol 'f'.

• It is commonly used in the Darcy-Weisbach equation to calculate pressure drop in pipes.

• The formula for friction factor varies depending on the flow regime, such as laminar or turbulent flow.

• For laminar flow, the formula for friction factor is 64/Reynolds number.

• For turbulent flow, the formula for fric...read more

Construction planning at site involves creating a detailed schedule of activities and resources required for the project.

• Identify project objectives and constraints

• Develop a work breakdown structure

• Estimate activity durations and dependencies

• Allocate resources and create a schedule

• Monitor and control progress

• Adjust plans as necessary

Flow meters are devices used to measure the flow rate of a fluid in a pipe or conduit.

• Differential pressure flow meters (e.g. Orifice plate, Venturi tube)

• Velocity flow meters (e.g. Turbine, Electromagnetic)

• Positive displacement flow meters (e.g. Piston, Oval gear)

• Mass flow meters (e.g. Coriolis, Thermal)

Stress strain diagram shows the relationship between stress and strain in a material under tension.

• Shows how a material deforms under stress

• Yield point is where material starts to deform permanently

• Ultimate tensile strength is maximum stress material can withstand

• Failure point is where material breaks

• Different materials have different stress strain curves

NPSH stands for Net Positive Suction Head and is a measure of the pressure available at the suction port of a pump.

• NPSH is important for ensuring that a pump does not cavitate, which can damage the pump and reduce efficiency.

• It is calculated by subtracting the vapor pressure of the liquid being pumped from the total suction head of the pump.

• NPSH is typically provided by the pump manufacturer and must be greater than the required NPSH for the pump to operate properly.

• If the NP...read more

Iron carbon diagram is a graphical representation of the phases of iron and carbon at different temperatures.

• Shows the phases of iron and carbon at different temperatures

• Includes regions for austenite, ferrite, cementite, and pearlite

• Helps in understanding the microstructure of steel

I have experience using tools such as Salesforce, HubSpot, and LinkedIn Sales Navigator.

• Salesforce

• HubSpot

• LinkedIn Sales Navigator

BMD of a frame refers to the bending moment diagram which shows the variation of bending moment along the length of a structural frame.

• BMD is a graphical representation of the variation of bending moment in a structural frame.

• It helps in analyzing the internal forces and stresses in the frame.

• BMD is typically plotted with the bending moment on the y-axis and the length of the frame on the x-axis.

• The BMD can be used to determine the maximum bending moment and critical sections...read more

I have over 10 years of experience in the petrochemical industry, working on various projects and processes.

• Managed process optimization projects to improve efficiency and reduce costs

• Developed and implemented new processes for product development

• Troubleshooted and resolved issues in production processes

• Collaborated with cross-functional teams to ensure project success

Types of controllers include PID, PLC, and DCS.

• PID controller: used in industrial control systems to regulate processes based on feedback

• PLC (Programmable Logic Controller): used in automation to control machinery and processes

• DCS (Distributed Control System): used in large industrial processes to control multiple systems from a central location

Creep is the slow, time-dependent deformation of a material under constant load, while fatigue is the weakening of a material due to repeated loading and unloading.

• Creep is a time-dependent phenomenon, while fatigue is a cyclic phenomenon.

• Creep occurs at elevated temperatures, while fatigue can occur at any temperature.

• Creep leads to permanent deformation, while fatigue can lead to crack initiation and propagation.

• Examples: Creep in a turbine blade at high temperatures, fatig...read more