State dairy development department posts · India · State public service commissions (e.g. Kerala PSC)
Original practice questions written to the published syllabus · not past papersSteam, water, compressed air and electricity in the milk plant, and how to audit and cut energy and water use.
In the exams: ICAR AICE subject 37 Unit 3 (water conservation) and subject 38 Units 4–5; ICAR AIEEA-PG group 18 Unit II (steam generation, compressed air, energy audit)
How our questions for State dairy development department posts spread across the units of Dairy Plant Utilities & Energy Management. Difficulty: 26 easy, 28 medium, 4 hard.
| Water conservation and reuse | 8 | |
| Electrical supply and power factor | 7 | |
| Energy audits | 7 | |
| Boilers: types, fittings, mountings and efficiency | 6 | |
| Compressed air systems | 6 | |
| Boiler and pressure-vessel safety rules | 6 | |
| Water supply, treatment and quality for dairy use | 6 | |
| Renewable energy in dairy plants: solar thermal, biogas | 5 | |
| Steam distribution and condensate recovery | 4 | |
| Heat recovery and cogeneration | 3 |
Choose an answer, then open the working. Each explanation says why the right answer is right and why the others are not.
Leaks take 5 kW of compressor power, 8,000 hours a year, with electricity at 8 currency units per kWh. What do they cost each year?
D. 320,000 currency units
5 × 8,000 = 40,000 kWh; × 8 currency units = 320,000. 40,000 currency units forgets the price; the others misplace a factor.
Further reading: Bureau of Energy Efficiency, energy manager guide books
Which trap type is usually preferred for a heat exchanger with a modulating steam supply?
A. Float-and-thermostatic
Float traps discharge condensate continuously at steam temperature and vent air, suiting modulating loads.
Further reading: Spirax Sarco, The Steam and Condensate Loop
Why are steam mains and fittings insulated?
C. Less heat loss
Bare pipes lose heat continuously, wasting fuel and adding condensate.
Further reading: Spirax Sarco, The Steam and Condensate Loop
What is the purpose of a backflow preventer or air gap on a water supply?
C. Stopping back-flow into potable lines
Back-siphonage or back-pressure could otherwise pull process or chemical solutions into potable water.
Further reading: Tetra Pak, Dairy Processing Handbook
Which dryer is needed when air lines pass through freezing areas?
B. Desiccant dryer
Desiccant dryers reach dew points well below freezing; refrigerated dryers stay above it.
Further reading: Tetra Pak, Dairy Processing Handbook
What is a main role of an air receiver?
C. Buffering demand
Receivers store air to smooth demand and let water settle for draining.
Further reading: Tetra Pak, Dairy Processing Handbook
How is a low power factor usually corrected?
A. Capacitor banks
Capacitors supply reactive power locally, cutting kVA drawn from the grid.
Further reading: Ahmad, Dairy Plant Engineering and Management
In a liquid milk plant, which is often the largest electrical user?
D. Refrigeration
Refrigeration for chilling and cold storage commonly leads electrical use.
Further reading: Tetra Pak, Dairy Processing Handbook
Which simple fitting saves hose water in washdown?
A. Shut-off nozzle
Trigger nozzles stop flow when the hose is put down.
Further reading: Tetra Pak, Dairy Processing Handbook
At what pressure are boiler safety valves set?
C. At or below the design pressure, sealed
Valves are set not above the allowed working pressure and sealed against tampering.
Further reading: Ahmad, Dairy Plant Engineering and Management
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