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VALLIAMMAI ENGINEERING COLLEGE

SRM Nagar, Kattankulathur – 603 203.

DEPARTMENT OF EIE

QUESTION BANK
SUBJECT: EI6003 - INSTRUMENTATION IN PETROCHEMICAL INDUSTRIES
SEM / YEAR: VI / Third Year

UNIT I OIL EXTRACTION AND PROCESSING

Techniques used for oil discovery - seismic survey - methods of oil extraction - oil rig system –
Primary and Secondary recovery - Enhanced oil recovery - separation of gas and water from oil –
control loops in oil gas separator - scrubber - coalesce
PART A Level Competence
1 What is absorption? BTL 1 Remember
2 What is adsorption? BTL 1 Remember
3 What is filtration? BTL 1 Remember
4 What is crystallization? BTL 1 Remember
5 Identify the chemical process involves endothermic reactions. BTL 1 Remember
6 Identify the chemical process involves Exothermic reactions. BTL 1 Remember
7 Discuss about the occurrence of precipitation. BTL 2 Understand
8 Differentiate Endothermic and Exothermic reactions. BTL 2 Understand
9 Give the steps involved in oil-gas separation. BTL 2 Understand
10 Name the different petroleum exploration sites in Tamilnadu. BTL 2 Understand
11 Illustrate the need for petrochemical. BTL 3 Apply
12 Relate the principle raw materials used in petroleum and BTL 3 Apply
petrochemical industry.
13 Illustrate the unit operations extensively used in the separative BTL 3 Apply
section.
14 Mention the instruments used in refining of crude oil. BTL 4 Analyze
15 Analyze the steps involved in processing wet gases? BTL 4 Analyze
16 Why is petrochemical preferred over other organic chemical? BTL 4 Analyze
17 Enumerate the various recovery techniques in petroleum BTL 5 Evaluate
processing.
18 Justify the need for petroleum recovery. BTL 5 Evaluate
19 Design the P and I diagram of a gas separation process in a BTL 6 Create
petroleum refinery
20 Compose the pros and cons in the formation of OPEC . BTL 6 Create

PART B

1 Describe in detail how a gas separation process in a petroleum BTL1 Remember

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refining is carried out with a aid of a neat P and I diagram. (16)

2 (i) Describe in detail the method to discover petroleum mines BTL1 Remember
under sea(8)
(ii) Name the different products that are obtained from the
refining crude oil. (8)
3 (i)What is the need for separation of oil and gases from crude BTL1 Remember
oil? (6)
(ii)With the neat block diagram describe the separation process.
(16)
4 Examine the various process involved in processing wet gases BTL1 Remember
and explain the process with necessary diagram. (16)
5 Discuss the control loops involved in the separation of gas and BTL2 Understand
water from crude oil. (16)
6 Discuss in detail the procedure involved in refining crude oil. BTL2 Understand
(16)
7 Give the P and I diagram of a gas separation process in BTL2 Understand
petroleum refineries and explain in detail. (16)
8 (i) Demonstrate how the distillation used in petroleum industry BTL3 Apply
(8)
(ii) Show the various techniques used to discover the petroleum
resources. Explain the seismic mass type in detail. (8)
9 (i)Illustrate in detail the seismic method used to discover BTL3 Apply
petroleum mines? (8)
(ii) Draw the illustrative diagram of petroleum mine and explain
how petroleum is lifted from the deposits in the mine? (8)
10 Analyze the various methods used in primary and secondary BTL4 Analyze
recovery in petroleum plants. Explain the measurements done in
those recovery process.
11 Explain the various recovery techniques in petroleum plant? BTL4 Analyze
(16)
12 (i)Point out the need for Coalescer in oil and refineries and BTL4 Analyze
explain the technology behind Coalescer.(8)
(ii)Differentiate the scrubber and separator.(8)
13 (i)Explain in detail the methods that are used to discover BTL5 Evaluate
petroleum mines (8)
(ii) Lists the percentage of output and use of the different
products obtained from refining crude oil. (8)
14 (i)Compose the need for Scrubber with respect to pollution BTL6 Create
control in petrochemical industries.(8)
(ii)Explain the design and working of Scrubber with neat
diagram.(8)

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UNIT II PETROLEUM REFINING

Petroleum refining process - unit operations in refinery - thermal cracking - catalytic cracking -
catalytic reforming - polymerization - isomerization - alkylation - Production of ethylene,
acetylene and propylene from petroleum.
PART A Level Competence
1 Define cracking. BTL 1 Remember
2 List the different types of cracking. BTL 1 Remember
3 Define catalytic cracking. BTL 1 Remember
4 Define catalytic reforming. BTL 1 Remember
5 What are free radicals? BTL 1 Remember
6 List the chemical products derived from acetylene and BTL 1 Remember
propylene.
7 Discuss about polymerization and give one example. BTL 2 Understand
8 What do you mean by Isomerisation? BTL 2 Understand
9 Discuss about Alkylation in a petroleum industry. BTL 2 Understand
10 Distinguish between catalytic cracking and catalytic reforming. BTL 2 Understand
11 Show acetylene is production from petroleum. BTL 3 Apply
12 Which type of cracking produces unsaturated gas? BTL 3 Apply
13 What is the temperature and pressure for cracking? BTL 3 Apply
14 How are industrial thermal cracking operations classified? BTL 4 Analyze
15 Why does the product of cracking have higher molecular weight BTL 4 Analyze
than the feed itself?
16 Why the fraction is subjected to a high temperature catalytic BTL 4 Analyze
treatment in reforming?
17 Summarize the process of production of ethylene. BTL 5 Evaluate
18 Evaluate catalytic reforming with example. BTL 5 Evaluate
19 Formulate the process of production of propylene from BTL 6 Create
petroleum.
20 Formulate the importance of thermal cracking. BTL 6 Create

PART B
1 (i) List the various low molecular weight products produced BTL 1 Remember
after cracking. (6)
(ii) Describe the fluidized bed catalytic cracking method with a
neat sketch. (10)
2 Define unit operation and discuss about any two unit operation BTL 1 Remember
of your choice. (16)
3 Write a detail technical note on polymerization techniques in a BTL 1 Remember
petroleum industries with examples. (16)
4 (i) With the help of P and I diagram describe how acetylene is BTL 1 Remember
separated from petroleum. (8)
(ii) Discuss in detail the preparation of ethylene from liquid
hydrocarbon. (8)

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5 Describe in detail with a neat sketch about thermal cracking and BTL 2 Understand
catalytic reforming. (16)
6 Summarize the petroleum refining process followed with BTL 2 Understand
respect to the quality of the crude oil.
7 (i) Discuss with neat P and I diagram production of ethylene BTL 2 Understand
from petroleum. (8)
(ii) Discuss about alkylation in petroleum industry. (8)
8 Illustrate the procedure followed in the production of BTL 3 Apply
ethylene.(16)
9 Demonstrate the experimental procedure followed in the BTL 3 Apply
production of acetylene.(16)
10 (i)Differentiate thermal and catalytic cracking. (8) BTL 4 Analyze
(ii)Explain about catalytic reforming. (8)
11 (i)Explain the steps involved in polymerization.(8) BTL 4 Analyze
(ii) List and explain the products obtained by polymerization.(8)
12 (i) Explain in detail with the relevant diagrams process control BTL 4 Analyze
system the propylene production plant. (8)
(ii) List the products produced after cracking and also explain
its use. (8)
13 (i)Compare the Isomerization and Alkylation.(8) BTL 5 Evaluate
(ii)Explain both with relevant diagram.(8
14 (i)Integrate the procedure followed in the production of BTL 6 Create
propylene, ethylene and acetylene. (8)
(ii)Formulate the common process associated with all the above
products. (8)

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UNIT III CHEMICALS FROM PETROLEUM

Chemicals from methane, acetylene, ethylene and propylene - production routes of important
petrochemicals such as polyethylene, polypropylene, ethylene dioxide, methanol, xylene,
benzene, toluene, styrene, VCM and PVC.
PART A Level Competence
1 Enlist the chemicals products derived from propylene and write BTL 1 Remember
its uses.
2 Name the chemicals obtained from acetylene. BTL 1 Remember
3 List the products evolved by processing ethylene. BTL 1 Remember
4 What is PVC? BTL 1 Remember
5 State the properties of PVC. BTL 1 Remember
6 State the properties of VCM. BTL 1 Remember
7 Write the polymers obtained from petrochemicals. BTL 2 Understand
8 Give the products obtained from methane? BTL 2 Understand
9 Give any one application of acetylene derivatives. BTL 2 Understand
10 Discuss diesel index. BTL 2 Understand
11 Show the formula for benzene BTL 3 Apply
12 Demonstrate formula for toluene BTL 3 Apply
13 Give the structure of polyvinyl chloride. BTL 3 Apply
14 Mention the application of ethylene glycol. BTL 4 Analyze
15 Classify the different products derived from propylene. BTL 4 Analyze
16 Mention the various chemicals from petroleum. BTL 4 Analyze
17 Evaluate formula for Xylene BTL 5 Evaluate
18 Evaluate the production route for ethylene dioxide. BTL 5 Evaluate
19 Design the production route for polyethylene, polypropylene. BTL 6 Create
20 Discuss the design production route for VCM. BTL 6 Create
PART B

1 (i) List the various chemicals from methane and Explain. (10) BTL 1 Remember
(ii) Write note on suspension polymerization. (6)
2 (i) Describe the chemicals obtained from ethylene. (8) BTL 1 Remember
(ii) List the applications of ethylene derivatives. (8)
3 (i) Write down the physical and chemical properties of BTL 1 Remember
Propylene. (8)
(ii) What are the different methane derivatives and explain the
production and process control system for Ammonia Andruss
process.(8)
4 (i)What are the various operating variables involved in a reactor BTL 1 Remember
for the production of Ethylene.(8)
(ii)With a block diagram explain how the viscosity is measured
in a petroleum industry. (8)
5 Describe the derivatives from propylene and explain its BTL 2 Understand
procedure.(16)

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6 (i) Summarize the routes available for producing ethylene BTL 2 Understand
dioxide.(8)
(ii) Explain any one method of your choice with the required
controls and Instrumentation systems. (8)
7 Describe the process involved in the manufacturing process of BTL 2 Understand
methanol. Also mention the application of methanol. (16)
8 Illustrate the steps involved in the production of polyethylene BTL 3 Apply
and also explain with necessary P & I diagrams. (16)
9 Show the other chemical names for Styrene and also list the BTL 3 Apply
various manufacturing procedures and explain any one process
with neat diagrams. (16)
10 (i) Explain the acetylene derivatives with application. (10) BTL 4 Analyze
(ii) Explain about emulsion polymerization. (6)
11 Analyze the various production rules involved in producing BTL 4 Analyze
polypropylene and explain any one route with the
instrumentation systems required. (16)
12 (i) Classify the production procedures involved in VCM and BTL 4 Analyze
PVC and explain the best route.(8)
(ii) Compare the production procedures involved in VCM and
PVC and state the difference between VCM and PVC . (8)
13 Recommend the best production route available for the BTL 5 Evaluate
production of Benzene and Toluene. Also Justify your
recommendation.
14 Formulate the procedure involved in the procedure involved in BTL 6 Create
the production of Xylene with necessary P & I diagrams.(16)

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UNIT IV CONTROL LOOPS IN PETROCHEMICAL INDUSTRY

Control of binary and fractional distillation columns - Control of catalytic and thermal crackers –
control of catalytic reformer - control of alkylation process - Control of polyethylene production
– Control of VCM and PVC production.
PART A Level Competence
1 List the parameters to be measured in the refinery process. BTL 1 Remember
2 Enlist the selection procedure for choosing the instrument for BTL 1 Remember
petroleum industry
3 What is the advantage of automatic control in an industry? BTL 1 Remember
4 Define the control process used in control of PVC production. BTL 1 Remember
5 What is octane number? BTL 1 Remember
6 Quote the controllers involved in the production of PVC. BTL 1 Remember
7 What is the need for composition controller in a petrochemical BTL 2 Understand
industry?
8 Discuss the control actions performed in catalytic cracking. BTL 2 Understand
9 Brief the use of controllers in thermal cracking .List the control BTL 2 Understand
parameters.
10 Brief about the control of thermal crackers and its process BTL 2 Understand
variables.
11 Show the expression relating internal and external reflux ratio of BTL 3 Apply
a distillation column in a petrochemical industry.
12 Discuss the control actions performed in alkylation process . BTL 3 Apply
13 Explain the automatic controls in the production polyethylene in BTL 3 Apply
brief.
14 State about enriching section in a distillation column. BTL 4 Analyze
15 Explain the function of gauge glass in a petroleum tank. BTL 4 Analyze
16 Analyze the control actions performed in VCM production. BTL 4 Analyze
17 Enumerate the controls used in petrochemical industry BTL 5 Evaluate
18 Higher the activity of the catalyst, higher the conversion. Justify BTL 5 Evaluate
19 Develop the block diagram of a distillation column control. BTL 6 Create
20 Design the process control instrumentation diagram for BTL 6 Create
alkylation process
PART B
1 (i)With the help of neat sketches describe the lead compensation BTL 1 Remember
in temperature sensor placed in a process environment. (8)
(ii) How is boiler feed rate measured in a refinery? Name the
various flow measuring instruments in a petroleum industry. (8)
2 (i) How is steam feed rate measured in a refinery? Name the BTL 1 Remember
various level measuring instruments in a petroleum industry. (8)
(ii) Describe in detail the various Alarms and Annunciators
circuits used in refinery. (8)

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3 (i)Write a detailed note on the selection and maintenance of BTL 1 Remember

measuring instruments in petrochemical industry. (8)
(ii) Explain with neat sketches the installation of sensors in
reactor
distillation column.(8)
4 (i)Describe the common methods of density measurement in BTL 1 Remember
petroleum evaporator station with the aid of neat sketch. (8)
(ii) With the help of neat sketches explain the lead compensation
in temperature sensor placed in a process environment. (8)
5 (i) Discuss the procedure involved in controlling the quality of BTL 2 Understand
the quality of the products in a distillation column . (8)
(ii) Write a detailed note on the control and instrumentations
involved in catalytic cracking.(8)
6 (i) Discuss the procedure involved in controlling the top product BTL 2 Understand
of distillation column.(8)
(ii) Give the principle and operation of automatic control of
polyethylene production.(8)
7 (i)Distinguish the procedures involved in controlling the bottom BTL 2 Understand
product and top product of distillation column.(8)
(ii) Write short notes on the control involved in the production of
poly vinyl chloride.(8)
8 Examine the advanced control strategies followed in control of BTL 3 Apply
binary and fractional distillation column and also explain how
the efficiency is improved . (16)
9 (i) Illustrate the Basic controls involved in Binary distillation BTL 3 Apply
column.
(ii) Explain the difference between binary and fractional
distillation. (8+8)
10 Analyze the instrumentation equipments selection procedures BTL 4 Analyze
involved in petrochemical industries and also explain in what
way it differs from other industries? (16)
11 Explain the control system used in the distillation column and BTL 4 Analyze
mention the components used in it with neat diagram. (16)
(i)Explain the basic principle behind the stripping and enriching Analyze
12 sections of distillation column. List the various products BTL 4
obtained using distillation. (8)
(ii) Write a note on control of vinyl chloride. (8)
Evaluate the control of alkylation process and also explain the BTL 5 Evaluate
13 control procedure involved in that process.(16)
14 List the control and instrumentation equipments involved in the BTL 6 Create
control of VCM and PVC production and Design the process
flow diagram.(16)

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UNIT V SAFETY IN INSTRUMENTATION SYSTEMS

Area and material classification as per National Electric Code (NEC) - Classification as per
International Electro technical Commission (IEC) - Techniques used to reduce explosion
hazards -Pressurization techniques - Type X, Type Y and Type Z - Intrinsic safety -
Mechanical and Electrical isolation - Lower and Upper explosion limit
PART A Level Competence
1 What is an explosion? BTL 1 Remember
2 NEC stands for what? BTL 1 Remember
3 IEC stands for what? BTL 1 Remember
4 What is meant by LEL and UEL? BTL 1 Remember
5 Define flash point. BTL 1 Remember
6 When will an explosion occur? BTL 1 Remember
7 Associate the zones in area classification as per NEC. BTL 2 Understand
8 How area classification is done as per NEC? BTL 2 Understand
9 Discuss the material classification procedure as per NEC BTL 2 Understand
standard.
10 Discuss the area classification procedure as per NEC standard. BTL 2 Understand
11 Describe the methods used for classification of hazardous areas. BTL 3 Apply
12 Illustrate about sources and grades of release. BTL 3 Apply
13 Show the important techniques used to reduce explosion hazard. BTL 3 Apply
14 Point out the material classification as per IEC standard. BTL 4 Analyze
15 Analyze how hazardous areas are classified? BTL 4 Analyze
16 Differentiate surface temperature and self ignition temperature. BTL 4 Analyze
17 Evaluate the importance of Intrinsic safety. BTL 5 Evaluate
18 Define purged systems with the reducing division levels for BTL 5 Evaluate
Type X, Type Y and Type Z -
19 Formulate the advantages of the safety codes. BTL 6 Create
20 Sketch and explain the fire triangle. BTL 6 Create
PART B
1 Describe some of the safety instruments used in the BTL 1 Remember
petrochemical industry and mention its applications. (16)
2 (i) Describe the area classification as per National Electric Code BTL 1 Remember
-NEC.(8)
(ii) List how material classification is done as per National
Electric Code -NEC.(8)
3 (i)Tabulate the material classification in Hazardous area as per BTL 1 Remember
Electro technical commission.(8)
(ii) List the material classification in petrochemical industries as
per Electro technical commission.(8)
4 (i)What is meant by pressurization technique? (4) BTL 1 Remember
(ii)In what way it is used in the reduction of explosion hazards in
petrochemical industry? Describe with neat diagrams. (12)
5 Differentiate Type X, Type Y and Type Z in the safety of BTL 2 Understand

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petrochemical industries and explain all of the above.(16)

6 Discuss the techniques used to reduce explosion hazards in BTL 2 Understand
petrochemical industries an explain with necessary
diagrams.(16)
7 (i)Analyze the need for Electrical isolation in petrochemical BTL 2 Understand
industries.(8)
(ii)List the standard isolation techniques followed in such an
industry with relevant representations.(8)
8 (i) Demonstrate the methods followed in mechanical isolation BTL 3 Apply
petrochemical industries.(8)
(ii) Explain the mechanical isolation levels as per the NEC
standards.(8)
9 Illustrate the various protection techniques employed in BTL 3 Apply
minimizing the potential risks of explosion or fire from electrical
located in hazardous locations.(16)
10 Compare the intrinsic safety, explosion proof and pressurization BTL 4 Analyze
techniques in the different intrinsic zones based on safety, cost,
maintenance and flexibility. (16)
11 Differentiate the intrinsic safe zone 1 and zone 2. Explain the BTL 4 Analyze
ignition triangle. When is equipment said to be intrinsically safe?
(16)
12 Compare the extrinsic safety, explosion proof and pressurization BTL 4 Analyze
techniques in the different extrinsic zones based on safety, cost,
maintenance and flexibility. (16)
13 (i)Assess about lower and upper explosion limit followed in BTL 5 Evaluate
petrochemical industries.(8)
(ii) Explain the general safety precautions to be followed in
petroleum industry.(8)
14 (i)Prepare the design regulations for explosion proof electrical BTL 6 Create
equipment.(8)
(ii) List the sources of ignition and explain with example. (8)

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