UPL DCS Operator Interview Questions and Answers

Q1. Critical speed of ball mill
Ans. 
Critical speed of ball mill is the speed at which the centrifugal forces equal gravitational forces at the mill shell's inside surface.
• Critical speed is calculated by the formula: Nc = 1/(2*pi*sqrt(D/g)) where Nc is the critical speed, D is the diameter of the mill in meters, and g is the acceleration due to gravity (9.81 m/s^2).

• At critical speed, the grinding media in the mill starts rotating with the mill shell and n...read more
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Q2. Distillation column design principles
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Distillation column design principles involve understanding the separation process, heat transfer, and fluid dynamics.
• Understanding the separation process is crucial for designing an efficient distillation column.

• Consider the heat transfer requirements to ensure proper temperature control within the column.

• Fluid dynamics play a key role in determining the flow patterns and efficiency of the distillation process.
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Q3. Heat exchanger area calculation
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Q4. Square and rectangular pitch
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Q5. Bernouli's law and friction factor
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Q1. Types of Loop in DCS , explain cascade loop
Ans. 
DCS loops include feedback, feedforward, and cascade loops. Cascade loop involves two or more loops working together.
• Feedback loop: measures output and adjusts input to maintain desired output

• Feedforward loop: anticipates changes in input and adjusts output accordingly

• Cascade loop: involves two or more loops working together to control a process. The output of one loop is used as the setpoint for another loop.

• Example: ...read more
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Q2. MSDS of product you have handled
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I have handled MSDS of various chemicals including Xylene, Toluene, and Acetone.
• I have experience in reading and interpreting MSDS sheets

• I am aware of the hazards associated with the chemicals I have handled

• I have followed proper safety protocols while handling these chemicals

• Examples of chemicals I have handled include Xylene, Toluene, and Acetone
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Q3. Difference between PSV & PRV
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PSV is a pressure safety valve used in process industries while PRV is a pressure relief valve used in plumbing and HVAC systems.
• PSV is designed to protect process equipment from overpressure while PRV is designed to protect plumbing and HVAC systems from overpressure.

• PSV is typically set to open at a higher pressure than PRV.

• PSV is usually larger in size than PRV due to the higher flow rates in process industries.

• Exam...read more
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Q4. Which DCS you have handled and it's iOS capacity
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I have handled Honeywell Experion PKS DCS with iOS capacity of 50,000 points.
• I have experience working with Honeywell Experion PKS DCS.

• The iOS capacity of the DCS I handled was 50,000 points.

• I am familiar with the configuration and programming of the DCS.

• I have worked on various projects involving the DCS, including installation, commissioning, and maintenance.

• I have also provided training to operators and maintenance
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Q1. What is current salary ?
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Q2. How much CTC you expect ? why you want to leave your current organisation ?
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About your industrial training.
About your company experience.
About core subjects.

Topic about Working in chemical industries.

Q1. About company. About family details. About personal details.
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Q2. About qualification.
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Q1. What is distillation column
Ans. 
A distillation column is a piece of equipment used in chemical processes to separate mixtures into their individual components.
• Distillation columns use the principle of vapor-liquid equilibrium to separate components based on their boiling points.

• They consist of a vertical column with multiple trays or packing material to facilitate the separation process.

• The feed mixture is introduced at the bottom of the column, and ...read more
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Q2. What is open Loop
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Open Loop is a control system where the output is not fed back to the input for correction or adjustment.
• Open Loop control does not use feedback to make adjustments

• It relies solely on the input and predefined control actions

• Examples include automatic doors, traffic lights, and irrigation systems
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Q3. What is Reaction
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Reaction is the response or behavior triggered by a stimulus or event.
• Reaction is a response to a stimulus or event.

• It can be physical, emotional, or cognitive.

• Reactions can vary in intensity and duration.

• Examples include flinching when touched by something hot, feeling happy after receiving good news, or thinking critically when faced with a problem.
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Q1. Open Loop and close loop
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Q2. Types of heat exchanger
Ans. 
Heat exchangers are devices used to transfer heat between two or more fluids.
• Shell and tube heat exchanger

• Plate heat exchanger

• Double pipe heat exchanger

• Finned tube heat exchanger

• Regenerative heat exchanger
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Q1. DCS related question and technical
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Q2. DCS and technical related
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Q3. Plant related, Dcs related
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Q1. About Dcs and close loops , open loops , cascade loops
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Q2. What is cascade loops
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Q1. Why did you want to leave current company
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