QC Qustion and answer

8/16/2019 QC Qustion and answer

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INSTRUMENT NOTES FOR QA/QC

INTRODUCTION :

It is the branch of engineering which deals with the measurement, monitoring, display etc. of the several of energyexchanges which take place during process operations. "In short Instrumentation is the study of Instrument."

INSTRUMENT :

Instrument is a device which is used to measure, monitor, display etc. of a process variable.

SOME SAUDI ARAMCO STANDARDS (SAES):- S!S #-$$1 %Instrument Index&- S!S #-$$' %(egulated )endor *ist for Instrument+echnically cceptable Instrument&- S!S #-$$ %asic /esign 0riteria&- S!S #-$$ %Instrument Symbol and Identification&- S!S #-$$2 %/rawing and 3orms&- S!S #-1$$ %3low 5easurement&- S!S #-'$$ %7ressure 5easurement&- S!S #-$$ %*evel 5easurement&- S!S #-$$ %emperature 5easurement&$- S!S #-2$' %naly:er Shelter&1- S!S #-2$2 %0ombustible ;as and iring 5ethods @ 5aterials'$ rmored 0able (igid 5etal 0onduits2' (igid =onmetallic 0onduits2 =onmetallic ?nderground 0onduits28


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SOME ABBREVIATIONS:

A07 Auality 0ontrol 7lanI7 Inspection est 7lanA echnical AueryS!7 Saudi ramco !ngineering 7rocedureS!S Saudi ramco !ngineering StandardSI0 Saudi ramco Inspection 0hecklistSI7 Saudi ramco ypical Inspection 7lanS( Saudi ramco est (eportSS/ Saudi ramco Standard /rawingSI7 Saudi ramco Inspection 7ersonalS5SS Saudi ramco 5aterials System SpecificationSSB Saudi rabian Standards Brgani:ation

>0 rmor >ire 0able=!0 =ational !lectrical 0ode=0! =ational merican 0orrosion !ngineersS0/ Supervisory 0ontrol and /ata !Cuation

=SI merican =ational Standards Institute S5 merican Society for esting and 5aterials S5! merican Society of 5echanical !ngineersS ritish StandardsI!!! Institute of !lectrical and !lectronic !ngineersI0! Insulated 0able !ngineers ssociations

I!0 International !lectro technical 0ommission=!5 =ational !lectrical 5anufactures ssociations=37 =ational 3ire 7rotection ssociation

!D tmospheres !xplosibles35 3actory 5utualI7 Ingress 7rotection?* ?nderwriters *aboratoriesI0 Instrument ray 0able7*0 7ower *imited ray 0able7)0 7olyvinyl 0hlorideD*7! 0ross *inked 7olyethyleneD*7B 0ross *inked 7olyolefinire rmored5I00 5ineral Insulation 0opper 0onductor 7I*0 7aper Insulation 0opper 0onductor 3B0 3iber Bptical 0ableB/( Bptical ime /omain (eflectometer ( (eCuest for echnical pproval50 5aterial est 0ertificate

CABLE SPECIFICATIONS AND CABLE INSTALLATION :

Group – 1: Single wisted pair+riad, ?nshielded.Conu!"or: Stranded, 0ircular 0opper %5aterial& as per ASTM B#$Conu!"or S%&': E 14 >;

Pr%r* In+u,"%on M"'r%,: 3lame (etardant 7)0 or D*7B or D*7! minimum temperature rating is -.o C%=!0 2$1- %b&, =!0 2$'- %b&.

Pr%r* In+u,"%on Vo,"' R"%n: $$) for ype 7*0 and type I cable, 4$$) for type 0 0able.Pr%r* In+u,"%on T0%!n'++: %.$2# mm for 7*0 and I0 0able&, %.$34 mm for 0 cable&.S0%', T0%!n'++: .$.55 mm

Group 5: Single twisted pair+triad shield.S0%', M"'r%,: luminum foil bonded to non-hygroscopic polyester %5ylar& tape.S0%', T0%!n'++: .$.55 mm

(QA/QC Engineer) | QA/QC Notes2


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S0%', App,%!"%on:


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! ype hermocouple 0hromel K 0onstantan -194 L 98' o0 7urple (ed+ >hiteS ype hermocouple 7latinum+(hodium-7latinum -18.$ L 164$ o0 lack (ed+ >hite( ype hermocouple 7t86+(h1 K 7latinum -16.6 L 16$ o0 lack (ed+ >hite

Pu,,%n "'n+%on o FOC N 4$$ 7ounds.F%r R'+%+"%n: %0IO 0ircuit Integrity& 3lame (etardant, for transmission of analog or digital signal to instrumen

and control systems.In+u,"%on: Silicon (ubber Aror: Pinc 0oated round steel.RE: Instrument 0able5G: Insulation of Silicon

SI: 0ollective Screen;: Inner #acket of *SP<S6A: (ound Steel >ire rmor I/6: Buter #acket of heat resistant 7)0FL: (educed 3lame 7ropagationCI: 0ircuit IntegrityFB: 3ield us 0able

8: Buter sheath of 7)05


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covered are used because in refinery, hydrocarbon gases will damage the 7)0 insulation, for thispurpose lead cover is used, for these purpose plumbing type glands are used.

In !xplosion proof areas double compression glands are used to avoid these gasses entering in the

electric at apparatus.FASTENER TORQUE VALUE :

58 1 L 14 =5

51$ '4 L =5

51' 2 L 28 =5

SIING OF CABLE:$.62 mm' 18 >;

1.$ mm' 16 >;

1.2 mm' 14 >;

'.2 mm' 1 >;

.$ mm' 1' >;

4.$ mm' 1$ >;

1$ mm' $8 >;

14 mm' $2 >;

'2 mm' $ >;

2 mm' $' >;

2$ mm' 1+$ >;

6$ mm' '+$ >;

1'$ mm' +$ >;

GROUNDING S 8STEM:

;round rods 5$4 '"'r minimum length.

0athode protection material is used galvani:ed steel.

Individual ;round rod maximum resistance should be 5$7 O0.

3or copper or copper Qacketed steel rods is a minimum of 13 5 in diameter or 1- 5 in diameters.

!arth ester is used for measuring of earthling system.

?nderground wire for grounding to wire connections shall be ! 9', or "0'ro 9',. 0ompression

connector shall not be used.

Shields wires shall be grounded only at the one point for the signal cables.

Shields and amour of power cables shall be grounded at both ends.

If used for connections of eCuipment to ground rods or ground grid be minimum 57 5 ( 4 A6G)

5etallic cable trays shall be bonded at both end points and a minimum of every 57 M'"'r to the loca

ground grid.

If buried + used for grids or interconnections of ground rods to be minimum @. 5 (5/.A6G)

e copper or copper Qacketed steel or galvani:ed steel or copper Qacketed steel shall meet the

reCuirements of UL 4@3 %?nderwriters *aboratories&. Po9'r App,%!"%on+: 5etal cable trays must be grounded and eclectically continuous systems as pe

NEC r"%!,' 21#$

NonPo9'r App,%!"%on+: 0able tray systems containing conductors outside the scope of NEC Ar"%!,'

57. %such as communications, data, signal cables, etc.&

TRA8 INSTALLATION:

C=,' Tr* In+",,"%on: he publication is intended as practical guide for the proper installation of cable system0able tray systems design and Installation shall comply with NEC Ar"%!,' – 2-5 21#



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NEMA VE1 NEMA VE5 and NEMA FG 1 and follow safe practices as described inNFPA @.E.

TIPS FOR CABLE TRA8 INSTALLATION:

0able tray specification shall be per NEMA VE1 the tray shall be per NEMA VE5.

he distance between consecutive rungs shall not exceed 55- %- In!0&.

0able ies for )ertical pplication shall be provided every 1# %n!0 %after one rung&.

0able ied for


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L'', 1:


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Bver 2 M) 1$6$ mm 64$ mm 4$ mm

IMPULSE TUBING INSTALLATION :

Impulse lines for remote device should be as short as possible, 2 ''" for close-coupled transmitters andpreferable not more than 5. ''" %3 '"'r+&. 3or liCuid measurement the lines should slope down at least 1 %n!0per foot from the orifice taps.

Tu=%n: Stainless steel tubing shall seamless, annealed, minimum wall thick 1$54 as per ASTM A53- Gr+IP – 213L$

IMPULSE TUBING INSTALLATION TIPS :

S,op o Ipu,+' "u=%n: 5inimum of 1%n!0 for every 1 '"'r towards tapping point.B'n: 5inimum bends length around 6$ mm.T'+" Pr'++ur' o Ipu,+' L%n': 1.2 imes of the working pressure with minute.In+"ru'n" Tu=%n +%&': H inch x $.89 mm %wall thickness& N $.$2 Inches.

P%p%n n Ipu,+' "u=%n +0,, =' +uppor" + o,,o9+:

S%&'M?%u D%+"n!'='"9''n +uppor"+

ube *ess than H inch $$ mm

H inch ube @ 7ipe 18$$ mm

inch 7ipe '$$ mm1 inch 7ipe $$$ mm

AIR DISTRIBUTION S 8STEM :

ll main and branch headers shall be sloped Uminimum 4 mm per $ 5eter %5$7 %n!0'+ p'r 1.. ''"&V

and provided with low point drains.

Supply takeoffs to individual instruments %a line serving up to a maximum of four devices& shall connect to

the top of the branch header through a takeoff-line-si:e, full-bore isolation valve.

he minimum si:e of supply takeoffs is %n!0$

wenty percent %5.& spare takeoff fittings and block valves shall be installed on the branch header.

Instrument air piping shall not be pocketed. Instrument air piping shall not be installed underground.

he 7iping route shall avoid a harmful effect from a heat source %''p 17. %n%u %+"n!'& andnot be under the process piping and eCuipment, which is covered by the hot or cold insulation materials.

A%r P%p%n M?%u +0,, =' No o U+'r+ + o,,o9+:

P%p' S%&' M?%u No o U+'r+

H inch 1 L

inch 2 L 9

1 inch 1$ L 12

1 H inch 14 L 8$

' inch 81 L 12$

inch 121 L $$

ENCLOSURES:

Inoor+ n Ou"oor+ P,n" Ar':

Inoor+: >ithin the 7erimeter of the 7rocess ?nit %NEMA 57. / NEMA ICS3&

Ou"oor: Butside the 7erimeter of 7rocess rea %IP74&

Severe 0orrosive !nvironment %Industrial rea& NEMA T*p' 4< or IP33.

=on Industrial rea IP24.



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=ame 7late Shall is attached to the cabinets using stainless screws.

Indoor 0abinets shall be made of metal.

he 0abinet shall be a NEMA T*p' 1 as per NEMA 57. and NEMA ICS3.

NEMA ICS3: !nclosures for Industrial 0ontrols and System.

he 5ax /oor >idth shall be 9$$ mm %4 Inch&

he 5arshaling cabinets from the front surface to the surface of rear terminal block, shall not be more

than 4 cm %1# In!0&

minimum of prime, undercoat @ finishing coat of enamel or polish is reCuired.

Interior cabined color shall be white or of light color such as light gray off.

=ame plate for cabinets and panels letter height and spacing shall follow IS (7 4$.4

=ame 7late shall be made from laminate 7lastic, white lack >hite %Information engraved into the

black core& with white surface.

;AARDOUS AREA CLASSIFICATION:

ATE


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!x WdG 3lame proof or !xplosion proof 1

!x WeG Increased Safety 1

!x W=G or WnG =one Sparking '

!x WiaG Intrinsic Safety $

!x WibG Intrinsic Safety 1

!x WpG 7ressuri:ation 1

!x WoG Bil Immersion 1

!x WCG Sand or 7owder filled 1

!x WsG Special 7rotection $

GAS GROUP:

R'pr'+'n""%' G+ IEC USA

5ethane I /

7ropane II /

!thylene II 0


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0lass I - !xplosive gases or vapors are present.

0lass II - 0ombustible dusts are present.

0lass III - Ignitable fibers or flying are present.

/ivision 1 Pone $ location where a ha:ardous concentration of gases or vapors exists approximately1$ L 1$$ F of the time %subQect to interpretation as above&.

/ivision 1 Pone 1 location where a ha:ardous concentration of gases or vapors exists approximately1 L1$ F of the time %subQect to interpretation as above&.

/ivision ' Pone ' location where a ha:ardous concentration of gases or vapors exists approximately$.1 L 1 F of the time %subQect to interpretation as above&.

;roup ;roup II0 ha:ardous atmosphere containing acetylene or other similar gases or vapors.

;roup ;roup II0 ha:ardous atmosphere containing hydrogen or other similar gases or vapors.

;roup 0 ;roup II ha:ardous atmosphere containing ethylene or other similar gases or vapors.

;roup / ;roup II ha:ardous atmosphere containing pentane or other similar gases or vapor.

;roup ! - ha:ardous atmosphere containing metal dust, such as aluminum.

;roup 3 - ha:ardous atmosphere containing carbon black, coal, or coke dust.

Q: >hat does XS!!3T stand for Y..ZA: ritish approval service for electrical eCuipment in flammable atmospheres.

Q: !xplain the meaning ofO %a& Pone $ %b& Pone 1 %c& Pone ' %d& =on-


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Q: !xplain the type meaning of !x-p.A: 7ressuri:ation + 0ontinuous dilution %7urge&.

Q: !xplain the type meaning of !x-o.A: Bil Immersion.

Q: !xplain the type meaning of !x-m.A: !ncapsulation + hermetically sealed.

Q: !xplain the type meaning of !x-C.A: Sand filled.

INGRESS RATINGS :

Q: !xplain the meaning of XINGRESS PROTECTIONTA: he appliances ability to keep out solids and liCuids, i.e.O /ust, Sand and >ater. he first number indicates

the protection against solids and the second number indicates the protection against liCuids.

Q: Is it allowable to modify an !!x XdT gland to fit and entry in an !!x XdT enclosure..ZA: =o.Q: State the minimum amount of threads needed to be installed on an !xWdG cable gland..ZA: %1& 2 full threads %minimum length 8 mm& for gas group ' apparatus.

%'& 4 full threads %minimum length 9.2 mm& for gas group '0 apparatus.

TEMPERATURE RATING OF EQUIPMENT :

Q: !xplain what is meant by Xemperature 0lassification of !Cuipment for use in hat is A+A0ZAn+: QA/QC means, XAuality ssurance + Auality 0ontrolT he purpose of this %A+A0& is to establish

the seCuence of reCuirement for the Cuality of material, Cuality of works, its inspection, and records '. >hat is the 55; Auality 0ontrol 5anagement SystemZ

An+: ISB 9$$1 L '$$$

. >hat is the Auality 0ontrolZAn+: Auality 0ontrol Xhose activities and techniCues used to achieve and maintain the Cuality o

product, process or serviceT.

. >hat is Auality 0ontrol 7lanZAn+: Auality 7lan X/ocument Specification which procedures and associated resources shall be applied

by whom and when to specific proQect, product, process or contractT.

2. >hat is non-conformityZAn+: =on-conformity X=on-fulfillment of reCuirementT. %0omplete failure of a system, or controls, which

result in completely unsatisfactory goods or services being provided&.

4. >hat is the SpecificationZ



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An+: ;overning /ocument cceptance 0riteria.

6. >ho are the responsible for AualityZAn+: !verybody within all organi:ation.

8. >hat is the basic responsibility of a A+A0 personalZAn+: o ensure execution of works and comply fully as per standard and approved specs.

9. >hat is the basic reCuired document for a A+A0 personalZ

An+: he basic reCuired documents for a A+A0 personal are as following.ITP (In+p'!"%on T'+" P,n): o conduct the Cuality check %Inspection of >itness, Surveillance and

ork can be execute without clientGs inspection and it can be inspected some part of

them if it is reCuired.6%"n'++: >ork can be executed, without client inspection and then it can be inspected upon thecompletion of work.



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;o, Po%n": >ork canGt be executed without client inspection.

12. >hat is difference between ha:ardous and non-ha:ardous reasZAn+: ;&rou+: ha:ardous location is defined as an area where a potential for fire or explosion

exists due to the presence of flammable gases, liCuids or vapors, combustible dusts or fibers andflying in sufficient Cuantities to produce an explosion or ignitable mixture.Non0&rou+: n area where non risk of presence of any kinds exposition.

14. >hat are different kinds of certificationZAn+: >eather 7roof.

/ust 7roof >ater ight

!xplosion 7roof 3lame 7roof Intrinsic Safety 7roof etc

16. >hat is ISBZ !xplain some of its standardsZAn+: ISB means International Standard Brgani:ation, Some are them they are as below

ISBO 9$$1, ISBO 9$$', ISBO 9$$, etc.18. >hat are :one classificationsZ ;ive a briefZ

An+: Pone classification is to define the area of ha:ards, they are as belowon' – .: :one in which explosions gas+air mixture is continuously present or present for

extended periods, during normal operation.on' – 1: :one in which an explosive gas+air mixture is likely to occur in normal operation.on' – 5: :one in which an explosive gas+air mixture is likely to occur in normal operation.

on' – 1.: :one in which an explosive dust atmosphere is present continuously or for extendedperiods of time.on' – 11: :one in which there is a likelihood that explosive atmospheres my occur for shor

periods due to unsettled to unsettled dust layers.

19. >hat are areas 0lassificationZ ;ive a briefZAn+: s per =!0 and =0, following are the ha:ard classificationZ

C,++ I: *ocation in which flammable gases or vapors may be present in the atmosphere inCuantities sufficient to produce explosive or ignitable mixture.0lass I gases+)apors are divided into four following groupsOGroup A: 7resence of cetylene.Group B: 7resence of hat is loop checkZAn+: o ensure that the system wiring from field to control consol are functioning fine.

''. >hat is the logic gateZAn+: digital logic circuit with one or more input voltage but only one output voltage.



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'. >hat is the foundation fieldbus systemZAn+: fully digital control system is called foundation fieldbus system.

'. >hat are meant by 3, S, (ZAn+: FAT: 3actory cceptance est.

SAT: Site cceptance est.RAT: (un cceptance est.

'2. >hat is 5icroprocessor control systemZ ;ive a brief of 7*0, /0S and S0/ZAn+: 0omputer based control process system is called microprocessor control system. he brief of 7*0

DCS n SCADA r' + o,,o9%n:PLC: 7rogrammable *ogic 0ontrol System.7*0Gs are used in practice with the aim of achieving a higher degree of availability or faulttolerance. he types are as follow.Fu," To,'rn": 1 ou" o 5 +*+"' o='!"%': (educe the probability of losses of production by

switching to a standby system.F%, S': 5 ou" o 5 +*+"' o='!"%': 7rotect life, the environment and investment by safely

disconnecting to a secure XoffT position.DCS: /istribute 0ontrol System.SCADA: Supervisory 0ontrol and /ata cCuisition.

'4. >hat are inspection points for a cable tray installationZAn+: 5aterial check as per approved spec, si:e and type, trayGs hook-up, proper distance structure, tray

to tray i.e. power+control+and signal+low voltage and high voltage, support and fixed strongly notshaking.

'6. >hat are inspection points for field instruments with impulse tubingZAn+: 5aterials inspection as per approved spec material, type and si:e, Installation as per hat are inspection points for #unction ox and 5arshalling cabinetsZAn+: 5aterial Inspection, type, si:e as per approved specification, installation hook up for frame, bracketor stands, fixed properly means shaking free, =ame 7late, and tag no.

$. >hat are standards methods or ferrules addressing to and from a #unction oxZAn+: 3or to side only terminalGs address reCuired which shall be close to terminal either side and

complete information shall be of from side after or before as per left and right side.

1. >hat is final (3IZ >hen it shall be raised upZAn+: >hen the A+A0 department of contractor is satisfied that the work detailed in the construction

(3I is completed, then reCuest shall be submitted for inspection to the client A+0 department.

'. >hat is schedule AZAn+: Schedule A is an attachment to the contract, which is the provision of Auality ssurance and

0ontrol, Inspection and test plan.

. >hat are the various levels of InspectionZ !xplainZAn+: hey are as following.

L'', o In+p'!"%on or M"'r%,+:A: L'', . – /ocuments reCuirements only, no Inspection.B: L'', 1 – Inspection prior to shipping.C: L'', 5 – 5inimum reCuirements, pre-inspection meetings, one or more unspecified XinprogressT surveillance visits.



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D: L'', 2 – Same as level ', except that Xin progressT surveillance inspection shall be in regularbasis.E: L'', 4 – (esident Inspection 0ontinuously monitor the work.

L'', o In+p'!"%on or !on+"ru!"%on p0+':A: ;o, Po%n" (;): he inspection activities will not proceed without the presence of inspection.B: 6%"n'++ Po%n" (6): Inspection activities can be proceeding after issuing (3I.C: R'%'9 (R): )erification of documentation %=5(& on its correctness as per spec and approveddrawings.D: Sur'%,,n!' (S): Inspection has right to conduct random inspection of works.E: In+p'!"%on (I) / P'ror (P) / T'+" (T): construction can be proceeding to next phase without

client inspection.. >hat is I7GsZ >hat are itness 7ointZ

An+: ITP mean Inspection and est 7lan, details of work scope and reCuired types of inspections.;o, Po%n" (;): is the level of inspection that client inspection must reCuire through (3I and canGtbe preceded until inspection is done by client.6%"n'++ Po%n" (6): is the level of inspection that inspection activity can be preceded without clientinspection or if client is not available as per (3I iming.

2. >hat is (3IZ >hen an (3I will be raisedZAn+: (eCuest for inspection %(3I&, (3I shall be raised only when the status of the preliminary inspection

is satisfactory, and the works %items& are itness 7oint.

4. >hat is 0able tray and how is it identified separately for !lectrical and InstrumentationZ

An+: 0able tray is the device used to provide support and protection to the laid cable inside the buildingor outside pipe rack.6. >hat is 0alibration and what is process calibrationZ

An+: 0hecking + testing the eCuipment for its accuracy and serviceability are known as calibration.7rocess calibration means carrying out calibration activity by following the adopted authori:edmethod linked with standardi:ation.

8. >hat is the loop and how is the loop folder madeZAn+: *oop is the electro-mechanical presentation of the circuit concerning to flow of liCuid or gas, alarm

system, control valve operation and other specific for which field installation instrument involvementis considered.here are certain condition and reCuirements to be fulfilled to complete the loop check. he list ofattachments including drawing, check list and punch list and other listed documents are arrange infolder %loop wise& for having an easy access to carry out the loop check and final hand over of the

proQect. hat folder with all possible documents is known as loop folder.

2-$ >hat is the specialty rather characteristics of loop checkZ hat are the responsibilities of A0 InspectorZ



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An+: he following are the phenomenal responsibilities which any A0 Inspector is supposed to executeat the time of carrying out any inspection.$ >ell versed with the technology for which the inspection is carried out.=$ Should have the reasoning capability to analysis the method.!$ Should have thorough knowledge about the procedure to be adopted for inspection i.e. adopted

standards.$ Should be able to convey the irregularities found to the concerned authorities.'$ Should be absolute sincere about the Qob execution.$ Should be vigilant all the time.

. >hat should be the attitude of a A0 Inspector while carrying out an Inspection activityZ

An+: 3ollowing are the characteristics of a perfect inspectorO$ Should never compromise with the Cuality at the time of performing inspection.=$ Should be sincere towards performing the responsibilities.!$ Should be punctual.$ Should be exemplary in approach while carrying out inspection.'$ Should have the capabilities to convince the authorities about the irregularities with

knowledgeable representation.

. >hat are the reCuirements for carrying out installation inspection of any instruments and receivinginspection of the said eCuipmentZAn+: 3ollowing are the reCuirements at the time of execution of an inspection.

$ Instrument data sheet.=$ est Instrument 0ertificate.

!$ )endor instruction manual.$ est Instrument instruction manual.

2. >hat is the 00) SystemZAn+: 0lose 0ircuit elevision system used for establishing the alarm notification in case of any

unforeseen ha:ard takes place. It is a digitally controlled system which enables the automaticnotification of the happening in and around the plant and plant premises.

4. >hat are the differences between A @ A0 activitiesZAn+: he A activity means adopted method for verification of the execution of A0 activity in turn it

focuses towards the importance of implementation of A0 role in the industrial and other sectorsrelated to maintenance, production and construction specially.he A0 activity means the direct involvement in maintaining Cuality standard as per the adoptedmethod+standard by the way of carrying out inspection %activity wise& and making the

documentation related to that. It also involves the activity involving for the proQectGs Cualitymaintainability and process execution.

6. >hat is Schedule WAG and how many appendices are there in schedule WAGZAn+: Schedule WAG is the guidelines for the method application related to Cuality including the distribution

of manpower %Cuality field oriented& and the Cuality process execution including Cuality control andCuality assurance.It has got six appendices covering all the process implementations related to execution of proQectperformance with the focus towards maintainability of Cuality control and Cuality assurance.

8. >hat are the linked documentations carried out related to A0 activity for oil @ gas construction proQectZAn+: $ pplication for inspection from construction department after completion of every activity.

=$ 7roduction of drawing based on the planning.!$ 5ethod application priority wise.$ 7rocurement of item and eCuipmentGs reCuired for the execution of the proQect.

9. >hat is process control systemZAn+: It is the system adopted for the proper execution of the activity by maintaining the adopted

standards and other specific. It involves surveillance on day to day activities performed by theproduction unit on operation.

2$. >hat are A07, A57 and I7ZAn+: QCP – Auality 0ontrol 7rocedure, QMP – Auality 5anagement 7rocedure, ITP – Inspection and

est 7lan.



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21. !xplain procedure related to Auality 0ontrolZAn+: he Cuality procedure is the series of steps taken to maintain the Cuality standard as per the

adopted standard and other specific.

2'. >hat do you know about =!0, =!5 )!1, =!5 )!', =!5 (=ZAn+: NEC – =ational !lectrical 0ode earlier used to be published under the statutory body of =37

since 1896, from '$$2 edition it is categori:ed as an internationally accepted method inspectionprocedure guidelines covering all most all the field related to !lectrical, Instrumentation and0ommunication !ngineering.

NEMA VE1 =ational electrical manufacture association )!1NEMA VE5– /eals with cable tray installation specification

2. >hat are the articles refereed during carrying out the following activitiesZ%1& ;rounding. %'& Installation of cable ray. %& 3ire alarm System Installation. %& Installation Instrument0able ray etc.,An+: %1& ;rounding rticle '2$ %0hapter ID for instrumentation&, %'& Installation of cable tray rticle 9',

%& 3ire larm System rt 64$, Installation of instrument cable tray art 6'6.

2. >hat is /uct bankZAn+: It is concrete poured structure with conduits laid inside by maintaining certain specified elevation as

per the reCuirements for the laying of cable through this enabling protection, support and safety tothe cable.

22. >hat would be the thickness of the top layer of a /uct ank and colorZAn+: 2 mm and (ed /ye.

24. >hat is the purpose of using paint+dye on top layerZAn+: o give an anticorrosive protection, top layer painting is provided.

26. >hat are types of conduits used in electrical and instrumentation wiring circuitsZAn+: (igid 5etallic 0onduit %(50&, Intermediate 5etallic 0onduit %I50&, (igid =onmetallic 0onduit

%(=0&.

28. >hat are the differences between a # %#unction ox& and erminal oxZAn+: he purpose of # %#unction ox& is used as a linkage between one or more inlet and one or more

outlet. >hether terminal box has inlet on or more but out let may be one for earthen or it may not

be. # can be used in between the routing for providing support and extra opening but is usedas ermination means at the end of the routing.

29. >hat is WterminationG related to construction industryZAn+: ermination is widely used term in case of construction industry. 3or electrical and instrumentation

work this is used for make the routing as a complete one.

4$. >hat is the impulse lineZAn+: It is line rather tubing connection made from the source %flow pipeline or vessel& to the transmitter

%sensing device& to create the feasibility to the transmitter to sense the flow and to generateeCuivalent electrical signal to get the indication of the status of the system working.

41. >hat is the check listZAn+: It is the list of seCuential activities to be performed by any A0 Inspector during inspection of any

activity performed by construction. It is made separated with distinguished activities for eachconstruction activity.

4'. >hat is punch listZ >hat is reCuirement of making a punch listZAn+: It the list generally identified as ( 4$, which is used at the time of finali:ation of any activity.

5eans every activity should be stamped with a final and foolproof documentation which shows theclear evidence of the all completed Qob. It is always signed by A0 to ensure the maintainability ofthe Cuality aspect of the Qob performed.

4. >hat is the role of A0 during shut downZ



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An+: A0 has the maQor role to be played at the time of shut down. It is the responsibility of A0 toofficially hand over any completed proQect to the client with all the documentations to be providedwith the real completed proQect. his including the records of completion %activity wise& areas withlimitations as shown in punch list, the processing and final inspection test report of the actuafunctioning of the proQect by making it operational.

4. >hat do mean by hat is mean by ;uwat and ;uwa, where it is applicable for useZ An+: Jou can use in conduit installation for lighting purpose.

Gu9": >ith terminal block.Gu9: >I thought erminal block.

6. hat type of sealing is used for all ducts inside all manholes and hands holes where permitted insidehydrocarbon handling plantsZAn+: ll ducts shall be sealed with 5 scotch cast brand 14 cable duct sealing kits or other methods

approved by the electrical standards committee chairman.

62. >hat is a 5andrel testingZAn+: esting of underground duct bank or sharp bend.



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64. >hat should be done, when union cannot be avoided in underground conduit installationZAn+: ?nions shall be protected with heat-shrinkable sleeves.

66. >hat shall be provided on each duct where it terminatesZAn+: ell end fitting or protective bushings.

68. hat are the conduit fittings for outdoor rigid steel conduit and liCuid tight flexible metal %*350&ZAn+: Shall be cast or forged steel, cast iron or malleable iron either hot-dip galvani:ed %preferably&

electroplated.

8. 0an be use the aluminum fitting in outdoorZ

An+: =o aluminum fitting or fitting accessories such as covers, sealing fitting plugs shall be used outdooronly malleable iron sealing fitting shall be used.

8. >hat is the minimum distance from main door to marshaling panelZAn+: 5inimum shall be meter from main door to marshaling panel.

82. >hat shall be the slop for impulse lineZAn+: minimum of a 1mm, for every 1' mm towards tapping point.

84. >hat shall be having extra length for unistrut supportZAn+: $mm should be extra.

86. >hat shall be the test pressure of instrument impulse lineZ

An+: 1.2 times of the working pressure.

88. >hat shall be minimum acceptable insulation resistance of instrument cable during 5egger estZAn+: 1$$ 5ega ohms

89. =ame some testing eCuipments used for instrument calibrationZAn+: /eadweight tester, /igital multimetter, 5egger, /igital pressure calibrator, emperature calibrator

emperature bath, 3ield communicator, )ibration meter.

9$. >hat shall be the maximum acceptable attention value of fiber during B/( testZAn+: $.2/b+Mm or less for wave length of 11$ nm and $./b+Mm or less .for wave length of 122$nm.

91. >hat shall be the maximum pulling tension of 3B0ZAn+: 4$$ 7ounds.

9'. >hat is name of fieldbus communicatorZAn+: 34 %3ieldbus ransducer 4&

9. >hat is the 7rinciple of imetal hermometerZAn+: /ifferent 5etal of /ifferent 0oefficient.

9. >hat is the color coding for accepted instrument or reQected instrumentsZAn+:

B,u' - 7re-installation est %0alibrated&60%"' - est 3ail %written message may be added giving reason failure&



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R' - 7re-commissionedGr''n - 0able est %5egger&

8',,o9 - 7ressure est

92.


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99. 0alculation of o3 to o0ZAn+:

1$$. >hat is the effect of weep hole on calculation of orifice boreZAn+: / N dm U1 K $.22 %dm& ' + dhV

60'r': dm N 5easured diameter of orifice

dh N /rain hole diameter d N 0orrected diameter orifice si:e

1$1. >hat is 0) of a valveZAn+: CV %+ "0' !p!%"* o ,' n %+ '%n' +:

X=o of gallons per minute of water which passes through a fully open valve at a pressure drop of 17SIT0) N C %^7 + ;&60'r': 0) N )alve co-efficient

A N )olumetric flow rate %gallons+minute& ^7 N 7ressure drop across the valve in psi. ; N Specific gravity of flowing fluid.

1$'. >hy does control valve operate at is 7SIZAn+: Bn higher pressure the actuator si:es becomes bigger in area. he actual force produced by theactuator.3orce N 7ressure x rea.

N 12 psi x rea, If rea N 12"3orce produced N 12 psi x '2 in' N 62 pounds.

ctual force acting on a control valve N 62 pounds.

1$.


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E,'"%on Suppr'++%on:*() N !levation Suppuration?() N (ange Suppuration K !levation

Suppur"%on C,!u,"%on:Spn N (ange Suppuration N 1$$F U(ange N '6.''VLRV N Suppuration N $ F USuppuration N $.14VURV N Span N 1$$ F Span + N '2 F$F -$.14'2F -'.4$2$F -14.4$2

62F -9.691$$F -'.89

E,'"%on C,!u,"%on:Spn N (ange K !levation N 1$$F U(ange N 2.81VLVR N Span N 1$$F U!levation N .961VURV N !levation N $F Span + N '2F$F $.961'2F '.'2$F .86862F 2.11$$F 4.682

ELECTRICAL QUESTION AND ANS6ER

60" %+ "0' Trn+or'rransformer is one kinds of electro static device which transformer energy from winding to another winding by

electromagnetic induction effect without changing freCuency.

;$ T$ Mo"or+5otors working with voltage with voltage .M) and above are


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S"r"%n Curr'n": Starting current of a induction motor generally will be 4 times the rated current.

S%n,' P0+': Bne of the supply lines gates disconnected due to rupturing of fuse or open circuit in one of the

three supply connection. In such cases the motor continues to run on a single phase supply of $). If the rotor is

locked to its rated full load, it will draw excessive currents on single phasing. he windings get overheated and

damage is caused.

M''r V,u': he insulation resistance value of the winding of the motor shall be checked periodically during

preventive maintenance.3or . M) motor the I( value shall be checked with 1 M) 5egger.3or 11 M) motor the I( value shall be checked with 2 M) 5egger.

6%n%n R'+%+"n!': he winding resistance of the motor shall be checked during preventive maintenance with

the bridge. he winding resistance of the three windings should be eCual.

Er"0%n:;enerally earthing means non-current carrying metallic part of electrical eCuips should be earthed to avoid danger

to human fife.

Gr% R'+%+"n!': ;rid resistance means in a industry or building the no. of earth pits Qoined parallel together to

get a minimum earth resistance value and the value should be less than 1.$ Bhms acceptable in the industry.

P%" R'+%+"n!': Individual pit resistance can vary according to the solid resistance and the value can be 2 Bhms

or more than that. ut to get a minimum value all the pits should connect in parallel as grid.

Er"0 P%"+: !arth pits are generally used by using charcoal, salt and ;. I. pipe of meters in length and $ mm

diameter. nother type of earth pits is plate earth electrode and mesh type electrode with copper or ;I strip brought out. nother type in gulf generally used is the solid rod of copper driven straightway into to earth to get minimum value

by driving to a depth of max 4 meters.

Er"0 M''r: 3or measuring the earth resistance earth 5egger is used and the diagram given below how to

measure the earth resistance.

S' Er"0 R'+%+"n!': ;enerally earth resistance of the total grid should be less than 1.$ Bhms which is

acceptable for safe operation in industries.

A'"'r: *oad current is measured through ammeter only. In 0 lower range are directly can be read through

ammeter kept in series. 3or larger current transformer are uses for measuring the current.In /0 7ower current is measured through a shunt resistance.

6""'"'r: 3or measuring the power consumed by the circuit %any type of feeder& wattmeter is used and the unit

is in M>


27/32

Bu+ Coup,'r: >here two different bus sections connected through an breaker %0 or )0 or B0& so that both

bus section supply can have an alternative feeding arrangement.

1. >hat the accessories of transformersZAn+: 3ans, (adiators, Bil 7umps, 7ressure (elief device, Bil *evel gauge, emperature ;auges, ap0harger, ushings, 0urrent ransformers, )oltage ransformers, Surge arrestors, Surge 0apacitors, /ustfilter bar, 7ost insulators.

'. >hy the oil samples test shall be taken from the transformerZAn+: o check the conductivity, analyses and characteristics of the oil.

. >hat the factory tests shall be performed on the transformersZAn+: 1. (atio tests at the rated voltage connection and at all tap connections.'. 7olarity and phase relation tests on the rated voltage connection.. pplied potential tests.. =o load and excitation current at rated voltage connection.2. Impedance tests.

. >hat are the transformers ratingsZAn+: 1. 7rimary and secondary M).'. )oltage.

. aps.. 7rimary and secondary continuous current2. asic impulse level for eCuipment over 4$$ )4. Impedance.6. Insulation class and temperature rise.8. Sound level.

2. >hat is the standard secondary rating of the 0ZAn+: 2 mperes.

4. >hat is the symmetrical interrupting current rating fuse on the hat are the main protections is reCuired for a motorZAn+: Bver 0urrent %Inst.&, hermal Bver *oad, Stalling (elay %rmature #am&, !arth 3ault, =egative

SeCuence, emperature.

9. >hy do you use a thermal relay in a starterZAn+: >hen winding temperature high then thermal relay active.

1$. ( %>inding (esistance&, I( %Insulation (esistance&.

11. >hy should ground all electrical eCuipmentZAn+: o prevent the earth fault.

1'. >hat are the two method of winding connection in -7hase motorsZAn+: Star >inding @ /elta >inding.

1. >hat is the liCuid in the battery calledZAn+: *ead cid %


28/32

1. >hat is the paint name which is the used in grounding cableZAn+: )etomens 7aints.

12. >hat is the (75 of a ' pole 4$

hat is the different between primary and secondary cellZAn+: 7rimary 0ell is node %K&

Secondary cell cathode %-&

19. If the current is 12 what will be the si:e of the cableZ

An+: 4 mm' or 1$ mm'

'$. >hat is the max speed obtained by phase induction motor with normal state supplyZ

An+:

'1. hich kind of motor itGs reCuired to check the 7I valueZAn+: ItGs reCuired more than 1$$ M> motor.

'2. >hat is the breather, /etails about the Silica ;etZAn+: It is a small container, contains silica gel and oil. It absorbs the moisture from the atmospheric air

and allows the fresh air to the conservator.

'4. >hat is the meant by short circuit braking currentZAn+: he rated short circuit breaking current of a circuit breaker is the highest value of short circuit

current which a circuit breaker is capable of breaking under specified condition of transient recovery

voltage and power freCuency voltage. !xpressed in M. . (5S at contact separation

'6. >hat is meant by short circuit making currentZAn+: (ated 5aking 0urrent N 1.8 x root ' x rated short circuit breaking current.

N '.2 x rated short circuit breaking current



29/32

'8. >hat is range of low voltage and medium voltage and high voltageZAn+: Lo9 Vo,"': 11$ L 8$ )0

M'%u Vo,"': 89 L1.8 M);%0 Vo,"': 1.4 L112 M)

'9. >hat is the different between star and delta connection with types of motorZAn+:

$. Star /elta connection with 7hase Induction 5otorZ

An+: Star /elta StarterO If the starter winding is directly connected with the supply it will draw

high current to reduce this high current %to control starting current& Star+/elta starter is used.

1. >hy does control valve operate at IS psiZAn+: Bn higher pressure the actuator si:es becomes bigger in area. he actual force produced by the

actuator.

3orce N 7ressure x rea. N 12 psi x rea, If rea N 12"3orce produced N 12 psi x '2 in' N 62 pounds.

ctual force acting on a control valve N 62 pounds.

7ressure 0onversionsO

1 7SI N '6.6T


30/32

Mg+cm' N 1$$$$ mm of inding emperature

earing non /rive !nd

)ibration 5eter %5onarch instrument 5odel !xaminer 1$$$& ?sing to get the )ibration %mm+s&

Mo"or %n T9o Lo!"%on+:1 /rive !nd %inding.

=O he /uration of the no load run is


31/32

rue (5S 0+/0 clamp meter %ektronix 5odelO /0591$&(elay est ?nit %7rogramma 5odel Sverker 62$&

)oltage inQections expO test the lock out relayreaker naly:er System %7rogrammed 5odel 514$$&

! 2> 4 > = 7>

. 7lease choose and fill related item from the IllustrationZI,,u+"r"%on

1& 0hico 0ompound a& 5I; >elding'& !D7 / b& !JS, !J/& Stress-0one, 5, (aychem c& rc >elding& luminum us d& 0able ermination Mit2& 0arbon Steel racket e& 3lame 7roof ype

An+:

2. 7lease fill the applicable material to the following workZ1& 0able !ntry


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An+:

6. 7lease draw the typical -wire control circuit with two start-stop push button startersZAn+:

8. 7lease draw the simple forward reversing starter control circuit using X!ither-orT InterlockZAn+:

9. >hat is the free space in one conduitZAn+: s per =!0 chapter 9

1 0able should be 2 F' 0able should be 1 F 0able should be $ F

1$. Illumination est as per which standardZAn+:

11. orCue )alue as which standardZAn+:

1'. >hat is the different between guide clamp and holding clampZAn+:

Date post:	05-Jul-2018
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QC Qustion and answer

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