# Competency Question Answer

1 Technical Distillation What is fractional distillation? Explain the Fractional distillation is the separation of a liquid mixture into fractions differing in boiling point (and hence chemical
Knowledge fractional distillation process in crude or composition) by means of distillation. Petroleum refining is the process of separating mixtures present in crude or
condensate fractionation tower. condensate. The longer the carbon chain, the higher the temperature at which the compounds will boil. The crude or
condensate is heated and vaporized. The gases pass upward in the distillation column through the liquid filled trays,
gasses get cooler as they rise higher in the column. When a compound in the gaseous state cools below its boiling point,
it condenses into a liquid. The liquids may be drawn off the distilling column at various heights.

2 Technical Distillation What is the pump around in distillation column? Pump around is used to heat balance the column by drawing a stream off from a tray of higher temperature and pass it
Knowledge through a heat exchanger or train of heat exchangers and returned it to the trays above where the temperature is lower
to condense the heavier hydrocarbons and to reduce the heat duty of OH condensers.

3 Technical Distillation What is the purpose of reflux in distillation To maintain purity of overhead vapor, partial amount of condensed o/h vapor is sent back to column as a reflux. It will
Knowledge column? maintain top temperature constant

4 Technical Distillation In condensate or crude distillation column why Condensate or crude contains salt in form of chloride. In distillation column chloride will be carried over with water
Knowledge corrosion occurs at top section particularly? What (from Stripping steam) at top of the tower. Chloride will react with water and form HCL. In condenser HCL condenses
precautions are usually taken to avoid corrosion and corrosion occurs.
here? To neutralize HCL, dosing of Neutralizing amine or ammonia and corrosion inhibitor will be carried out in the O/H
system. In addition, continuous water wash to avoid formation of ammonium chloride in O/h system. O/H drum water
PH, iron and chloride content should be monitored to detect the degree of corrosion.

5 Technical Distillation What is the function of side cut stripper? Where The function of side cut stripper is to maintain IBP and flash point of the product by stripping light ends. Vapours are
Knowledge would the overhead vapour be routed? routed back to distillation column

6 Technical Specs What is flash point? What is the specification of The flash point is the minimum temperature at which liquid gives off enough vapors which will, in presence of air,
Knowledge flash point for Kerojet product? momentarily ignite. Flash point is related to the IBP of the liquid. The specification of Kerojet flash point is > 38°C.

7 Technical Specs What is the freezing point? What is the Freezing point is the temperature at which a liquid will begin to change its state of matter to a solid. Freezing point is
Knowledge specification of freezing point for Kerojet product? related to the FBP of the liquid. The specification of Kerojet product freezing point is -47°C.

8 Technical Distillation What is the function of stripping steam in Stripping steam in distillation column is used to help separation of components by reduction of partial pressure of
Knowledge distillation column? components.

9 Technical Hydrotreating Why catalyst is require in hydrotreating reaction? In presence of hydrogen catalyst will increase the rate of reaction to remove sulphur, nitrogen and oxygen from feed.
Knowledge

10 Technical Hydrotreating What is the chemical reaction for Mercaptan C-C-C-C-C-SH + H2 --------> C-C-C-C-C + H2S
Knowledge sulphur removal?
11 Technical General What mean by endothermic and exothermic When energy is required for the reaction, then reaction is endothermic (absorbes energy). When the reaction releases
Knowledge reaction? energy, then it is exothermic.

12 Technical Hydrotreating What are the main process variables for The main process variables are Reactor inlet and outlet temperature, System pressure, Hydrogen partial pressure,
Knowledge hydrotreating process? Recycle gas flow rate, Liquid hourly space velocity (LHSV) and fresh feed quality.
13 Technical Hydrotreating What mean by SOR & EOR of reactor? Why we SOR mean Start of run reactor inlet temperature. It is the temperature we maintain at reactor inlet when catalyst is
Knowledge require to increase reactor inlet temperature? fresh.
EOR means End of run reactor inlet temperature. It is the maximum allowable reactor inlet temperature we can operate
at.
As catalyst ages, we need to increase reactor inlet temperature to maintain product sulphur. We can increase max up to
EOR temperature of Reactor.

14 Technical Hydrotreating What is the importance of Hydrogen partial Higher hydrogen partial pressure promotes the desired hydro treating reactions, and the saturation of olefins, aromatics,
Knowledge pressure in hydrotreating reaction? How we can and cracked hydrocarbons. It is also necessary to minimize coke formation. For this reason, running the unit for
improve Hydrogen partial pressure in recycle gas? extended periods of time at lower than design hydrogen partial pressure will result in increased catalyst deactivation
rate and shorter cycle lengths.
The major control variable for high hydrogen partial pressure is the recycle gas purity. Recycle gas purity can be increase
either by increasing make up hydrogen purity or venting the gas through separator or reducing the separator
temperature.

15 Technical Hydrotreating What is the Gas to Oil ratio? What is the effect on Gas to Oil Ratio = Nm3/Hr of Hydrogen Recycle gas (Including makeup gas) / m3/hr charge of feed to reactor
Knowledge a unit operated at less Gas to oil ratio than If the unit is operated at less than the design gas/oil ratio, the catalyst bed and charge heater skin temperatures will
required? increases, leading to accelerated coke formation and equipment wear.

16 Technical Hydrotreating What is the formula for LHSV? What is the effect LHSV = Total feed to reactor inlet, m3/hr / Total catalyst volume, m3 or (LHSV = Reactant Liquid Flow Rate/Reactor
Knowledge of increase feed to reactor on life of catalyst? Volume).
Increasing the fresh feed rate with a constant catalyst volume increases the LHSV and a corresponding increase in
catalyst temperature will be required to maintain constant product quality.
The increased catalyst temperature will lead to a faster rate of coke formation and, therefore, reduce the length of time
of catalyst. If the LHSV is run significantly higher than the design of the unit, the rate of catalyst deactivation may
become unacceptable.

17 Technical General Which substances could cause permanent poison Metals like; Nickel, vanadium, arsenic, lead, sodium, silicon and phosphorous are soluble in oil and will be a poison to the
Knowledge to reactor catalyst? Why it is important to control catalyst.
metal content of feed? Once a catalyst is poisoned by metals, its activity cannot be restored. Therefore, metals content of the feedstock is a
critical variable which must be carefully controlled.

18 Operator duties Hydrotreating In case of feed loss to Hydrotreating unit what In case of feed loss to hydro treating unit FG firing to charge heater to be shut off. Keep recycle gas compressor in
actions should to be taken? running condition with max possible flow rate to swipe liquid from reactor to avoid coke formation. Monitor Reactor
outlet temperature for any unusual increment. If any unusual increment found then reduce separator pressure.

19 Operator duties Hydrotreating In case of recycle gas loss to Hydrotreating unit In case of recycle gas loss to hydro treating unit, cut off feed completely and shut off FG firing in charge heater. Try to
what actions should to be taken? start recycle Gas compressor as soon as possible to swipe out liquid from reactor. Monitor reactor outlet and bed
temperatures for any unusual rise. If unable to start recycle gas compressor than decrease separator pressure. Change
line up of makeup hydrogen from recycle gas compressor suction to discharge and try to cool down reactor bed
temperature.
20 Technical Hydrotreating Why catalyst sulphiding is required for fresh It is required to activate catalytic base metals from oxide form to the active sufide form. Reaction is ‘’Metal Oxide + H2S
21 Technical Hydrotreating What is the importance of water wash? A supply of wash water is necessary to remove ammonium bisulfide (NH4HS) and ammonium chloride (NH4Cl) from the
Knowledge reaction products.
22 Technical Specs What is the sulphur limits for EURO 5 diesel? 10 ppm
23 Technical Hydrotreating What is the function of stripping section in The function of stripping section is to strip off H2S and light ends from hydrotreated product.
24 Technical Pumps In a centrifugal pump, how do we achieve A centrifugal pumps purpose is to convert energy of a prime mover (an electric motor or turbine) first in to velocity or
Knowledge pumping of liquid? kinetic energy and then into pressure energy of a fluid that is being pumped. The energy changes occur by virtue of two
main parts of the pump, the impeller and the volute or diffuser. The impeller is the rotating part that converts driver
energy into the kinetic energy. The volute or diffuser is the stationary part that converts the kinetic energy into pressure
energy and move liquid from one place to other place

25 Technical Pumps Explain how kinetic energy is transformed to The key idea is that the energy created by the centrifugal force is kinetic energy. The amount of energy given to the
Knowledge pressure energy inside a pump. liquid is proportional to the velocity at the edge or vane tip of the impeller. The faster the impeller revolves or the bigger
the impeller is, then the higher will be the velocity of the liquid at the vane tip and the greater the energy imparted to
the liquid.
This kinetic energy of a liquid coming out of an impeller is harnessed by creating a resistance to the flow. The first
resistance is created by the pump volute (casing) that catches the liquid and slows it down. In the discharge nozzle, the
liquid further decelerates and its velocity is converted to pressure according to Bernoulli’s principle.

26 Technical Pumps What is mean by NPSH? Why it is very important The NPSH is the pressure drop between the suction and minimum pressure in the pump. NPSH available should be
Knowledge for centrifugal pump operation? always greater than NPSH required to avoid cavitation.

27 Technical Pumps Explain how cavitation occurs in a pump. a) Formation of Bubbles inside pump casing: Liquid inside the pump casing will start vaporizing and formation of bubbles
Knowledge take place. Vapor bubbles form due to vaporization of the liquid being pumped when the local static pressure at any
point inside the pump becomes equal to or less than the vapor pressure of the liquid at the pumping temperature. It can
cause either by decrease in suction pressure or rise in suction liquid temperature.
b) Growth of bubbles inside pump casing: Unless there is no change in the operating conditions, new bubbles continue
to form and old bubbles grow in size.
c) Collapse of bubbles inside pump casing: As the vapor bubbles move along the impeller vanes, the pressure around the
bubbles begins to increase until a point is reached where the pressure on the outside of the bubble is greater than the
pressure inside the bubble. The bubble collapses. The process is not an explosion but rather an implosion (inward
bursting). Hundreds of bubbles collapse at approximately the same point on each impeller vane.
d) Cavitation inside pump: After the bubble collapses, a shock wave emanates outward from the point of collapse. This
shock wave is what we actually hear and what we call "cavitation".
28 Technical Pumps What is the purpose of spill back line in a The purpose of the spill back line in a centrifugal pump is to maintain minimum required flow of the pump to avoid
Knowledge centrifugal pump? damage to pump. If pump operate below required minimum flow then it can cause rise of temperature inside the pump
casing and will lead to cavitation.

29 Technical Pumps Why priming of the pump is required? The pump is designed to pump liquids. Priming of the pump is required to remove all vapour from the pump and make
Knowledge sure it is filled completely with liquid. If vapour remains inside the pump then it will lead to cavitation.

30 Technical Pumps Why would the pump suction line be of a wider Pump suction diameter is large to decrease liquid velocity and increase suction pressure to increase NPSH available.
Knowledge diameter than the discharge line? Pump discharge line less in diameter to convert velocity to pressure in order to transfer liquid from one place to other.
31 Technical Pumps What is the function of mechanical seal? The function of mechanical seal is to prevent pump fluid to come out from pump.
Knowledge

32 Technical Pumps Where reciprocating pumps are usually used? Reciprocating pumps are used when liquid is required to be pumped from one place to another with very high pressures
Knowledge and low flows. It is used normally for metering systems, chemicals injections ..etc

33 Technical Compressors What is the impact of a liquid in a compressor? A compressor is a machine which transfer a gas or vapor from a low pressure zone to a higher pressure zone. Liquid is
Knowledge not compressible and will damage the compressor.

34 Technical Compressors How liquid carryover is prevented in a By suction knock out drums. The primary function of this KOD is to remove liquid droplets from the compressor suction
Knowledge compressor? gases.

35 Technical Compressors What is the function of diffuser in centrifugal The velocity of the gas expelled from the impeller is very high. Diffuser will reduce velocity and convert it to pressure
Knowledge compressor? energy. I

36 Technical Compressors What is surging in the compressor? How can we It is the operating condition of compressor when compressor discharge pressure increase at maximum condition and
Knowledge avoid it? flow become minimum, compressor condition become unstable and compressor flow will start reversing momentarily
from discharge to suction, which will damage the compressor. We can avoid by installing anti-surge controller which will
maintain require flow through compressor by recycling from discharge to suction.

37 Technical Compressors What is the critical speed in compressor? It is the angular velocity at which compressor shaft/parts will be excited at their natural frequencies which will results in
Knowledge vibration and adamage to the compressor

38 Technical Furnaces What are the types of furnaces? a) Natural Draft Heater b) Force draft Heater c) Induced draft heater d) Balance draft heater
Knowledge

39 Technical Furnaces What is the ideal value for excess air in heaters? Normally excess air maintain @ 2 - 3 %. It is required to maintain to ensure fuel is completely combusted inside the
Knowledge Where whithin the heater excess air is measured? heater. It is generally measured at arch zone of the heater.

40 Technical Furnaces What is lead-lag control in heater? Lead lag control: 1- To increase heater outlet temperature: first air will increase and then fuel. 2- To decrease heater
Knowledge outlet temperature: first fuel will reduce and then air.
41 Operator duties Furnaces In case of natural draft heater if O2 content In case of excess O2% become 0%, first decrease fuel and bring O2 content to more than 2%, then increase air dampener
become 0% then what will be your action? and then again increase require fuel.

42 Technical Furnaces Why fins are provided in convection section Fins are provided in convection section to increase heat transfer area.
Knowledge tubes?

43 Technical Furnaces What is cross over temperature? Cross over temperature is the convection outlet to radiation zone inlet process temperature.
Knowledge
44 Technical Furnaces Why skin temperature being monitored? If skin Skin temperature indicates any flame impingement on the tubes. If skin temperature increases then it may be an
Knowledge temperature increases what it indicates? indication of some impingements. If it is increases gradually then it indicates coking of the tubes.

45 Technical Furnaces How to reduce Nox content in the stack flue gas? To reduce Nox content we need to decrease the burner flame temperature. Burner flame temperature can be reduced
Knowledge by reduction of excess air content. Can also use Low-Nox burners.

46 Operator duties Furnaces Why Fuel gas individual burner valves should not If we throttle Fuel gas individual valve it will increase the header pressure and also it increases velocity of FG inside
be throttled in the heater? heater, which will result in rise in flame height. Some time it can reach up to convection section. Hence we have to
operate heater always with fully open valves.

47 Operator duties Furnaces How can you identify Hot Spots? Hot spot can be identified by checking from peap holes. They are red or silver spots on the surface of the tube. Also hot
spots can be identified by specialized IR thermography equipment.

48 Technical Furnaces What is BMS? BMS is a Burner management system. It is heater start up automatic sequence. It is to avoid human error during startup
Knowledge of the heater.

49 Technical Sat Gas What is RVP? Why is it important to control RVP of The RVP (Ried Vapour Pressure) test is the measurement of absolute pressure built up by the vapours of a given
Knowledge Naphtha product? petroleum product in a standardized bomb. The value of RVP is directly related to the amount of volatile components
contained in the product which have high vapour pressure.
The naphtha RVP is being control for safeguard of floating roof tanks. The spec for RVP of naphtha is <13 PSI.

50 Technical Sat Gas What mean by flooding in Distillation columns? Flooding is brought about by excessive vapour flow, causing liquid to be entrained in the vapor up the column. The
Knowledge What are the main causes of flooding in distillation increased pressure from excessive vapor also backs up the liquid in the down comer, causing an increase in liquid holdup
columns? How flooding can be detected in on the plate above. Depending on the degree of flooding, the maximum capacity of the column may be severely
distillation columns? reduced. The main cause for flooding in distillation column is too high reflux flow rate, too high vapor flow rate and too
high feed flow rate. Flooding is detected by sharp increases in column differential pressure and significant decrease in
separation efficiency
51 Technical Sat Gas What mean by weeping in distillation column? This phenomenon is caused by low vapor flow. The pressure exerted by the vapor is insufficient to hold up the liquid on
Knowledge How weeping in column identified? What is the the tray. Therefore, liquid starts to leak through perforations. Weeping is indicated by a sharp pressure drop in the
effect of weeping in distillation? column and reduced separation efficiency.

52 Technical Sat Gas What is the function of Naphtha Absorber in The function of the Naphtha absorber in saturation gas unit is to recover C3 & C4 content from Debutanizer and De-
Knowledge saturation gas unit? ethanizer overhead gases. It is for the recovery of C3 and C4 going to fuel gas.
53 Technical Sat Gas Which parameter will favour absorption? High pressure and Low temperature will favour absorption process.
Knowledge

54 Technical Sat Gas How to remove H2S from LPG? H2S removed from LPG in LPG amine absorber.
Knowledge

55 Technical Sat Gas Why difference between Lean amine and Fuel Gas The Lean amine is fed to the column at a temperature higher than the fuel gas by about 5°C in order to avoid
Knowledge temperatures maintained at 5°C? If foaming condensation of the heavier hydrocarbon components of the fuel-gas. Condensation of the hydrocarbons might lead to
occurs what steps to be taken? foaming of the amine solution.
Start antifoam injection in the FG absorber. Ensure DT between lean amine and fuel gas maintained at 5°C.

56 Technical Sat Gas How can we eliminate amine carryover from LPG In LPG water wash drum, amine carry over to LPG is eliminated by continuous injection of water. At regular intervals this
Knowledge amine absorber to LPG? water will be replaced.

57 Technical Sat Gas What is the function of LPG dryer? The function of LPG dryer is to remove water and small amount of H2S from LPG product.
58 Technical Sat Gas What is the function of De-butanizer? The function of debutanizer is to remove C1, C2, C3, C4 & H2S from hydro treated naphtha.
Knowledge

59 Technical Sat Gas How we can increase Naphtha RVP? We can increase Naphtha RVP by dropping LPG in to Debutanizer bottom.
Knowledge

60 Technical Sat Gas What is the function of De-ethanizer? The function of de-ethanizer is to remove C1, C2 and H2S from LPG.
Knowledge

61 SHE Chemicals What is a COSHH cabinet? What do you expect to A cabinet containing all MSDSs of all chemicals used in the area/plant. It also includes all relevant PPEs expected to be
Handling find there? used when handling these chemicals.

62 SHE Chemicals How would you approach filling a chemical into First, should know about chemical to be handled by reading approved MSDS, then check the specific procedure for this
Handling the system. task. Observe experienced operator performing, then perform supervised, then alone when allowed. Initiate
communication with PO and update progress regularly.

63 SHE Emergency What would you if you see a small fire/smoke in Inform PO/Fire immediately. Depending on the situation, I may also try to extenguish the fire using appropriate media
response your area. while in communication with PO.
64 SHE Emergency What would you do if you see spillage in your area. Report to PO/SS. Try to identify source and isolate. When permitted, clean the area.
response

65 Operator duties PTW What steps do you take before issuing a permit. Ensure PTW is valid/authorized. Understand the job. Ensure all hazards associated with job are identified and mitigation
measure are implemented. Check all associated documents (isolations/By-pass-overrides..etc) for implementation of
requirements. Communicate with SO/PO and issue the PTW.

66 Operator duties Safety devices What are steam traps? What are your A steam trap is a device used to discharge condensate and non condensable gases with a negligible consumption or loss
responsibilities w.r.t. steam traps. of live steam. Most steam traps are automatic valves. They open, close or modulate automatically. Operator duty is to
ensure that all traps are functionning well, by observing the traps for a while, or for some, check external valve
temperature.

67 Initiatives Initiatives have you made recommendations that were

considered / implemented
68 Problem Problem Tell me when you solved a problem or contributed
Solving Solving to better operations.

69 Basic Maths Basic Maths convert ppm to % and/or vice versa

70 Basic Maths Basic Maths for a given density, convert mass to volume and or
vice versa