QC QUESTION & ANSWERS

INTRODUCTION:
It is the branch of engineering which deals with the measurement, monitoring, display etc. of the
several of energy exchanges 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):

1- SAES – J001 (Instrument Index)
2- SAES – J002(Regulated Vendor List for Instrument/Technically Acceptable Instrument)
3- SAES – J003 (Basic Design Criteria)
4- SAES – J004 (Instrument Symbol and Identification)
5- SAES – J005 (Drawing and Forms)
6- SAES – J100 (Flow Measurement)
7- SAES – J200 (Pressure Measurement)
8- SAES – J300 (Level Measurement)
9- SAES – J400 (Temperature Measurement)
10- SAES – J502 (Analyzer Shelter)
11- SAES – J505 (Combustible Gas and Hydrogen Sulfide in Air Detection System).
12- SAES – J600 (Pressure Relief Valve)
13- SAES – J700 (Control Valve)
14- SAES – J801 (Control Building)
15- SAES – J901 (Instrument Air Supply System)
16- SAES – J902 (Electrical System for Instrumentation)
17- SAES – J903 (Intrinsically Safe System
18- SAES _ J904 (FOUNDATION fieldbus system)
19-
NEC ARTICLE NUMBERS:

250 Grounding and Bonding.

300 Wiring Methods & Materials.
320 Armored Cable
344 Rigid Metal Conduits.
352 Rigid Nonmetallic conduits.
354 Nonmetallic Underground Conduits.
353 High Density Polyethylene Conduits.
360 Flexible Metallic Tubing.
362 Electrical Nonmetallic Tubing 358(EMT)
366 Power and Tray Cable.
392 Cable Tray
500 Hazardous Location
504 Intrinsically Safe System
700 Emergency System
727 Instrument Tray Cable
760 Fire Alarm System

IEEE ARTICLE NUMBER

518 guide for the installation of electrical equipment to minimize electrical noise inputs to
Controller from external source

1100 recommnded practice for powering and grounding electronic equipment

1
Meraj | QA/QC Notes
IEC- 60529 this standard describes a system for classifying the tegrees of protection provided by
the enclose of electrical equipment
NEMA ICS 6 INDUSTRIAL CONTROL AND SYSTEMS ENCLOSURES
NEMA 250- Enclosures for electrical equipment (1000 v maximum)
UL 94-THICKNESS OF TERMINAL BLOCK HIGH STRENTH MATERIAL
VARIOUS TYPE OF STANDARDS:
SAEP Saudi Aramco Engineering Procedure
SAES Saudi Aramco Engineering Standard
SAIC Saudi Aramco Inspection Checklist
SATIP Saudi Aramco Typical Inspection Plan
SATR Saudi Aramco Test Report
SASD Saudi Aramco Standard Drawing
SAIP Saudi Aramco Inspection Personal
SAMSS Saudi Aramco Materials System Specification
SASO Saudi Arabian Standards Organization
NEC National Electrical Code
NACE National American Corrosion Engineers
SCADA Supervisory Control and Data Acquisition
ANSI American National Standards Institute
ASTM American Society for Testing and Materials
ASME American Society of Mechanical Engineers
BS British Standards
IEEE Institute of Electrical and Electronic Engineers
ICEA Insulated Cable Engineers Associations
IEC International Electro Technical Commission
NEMA National Electrical Manufactures Associations
NFPA National Fire Protection Association

SOME ABBREVIATIONS:
FM Factory Mutual
IP Ingress Protection
UL Underwriters Laboratories
ITC Instrument Tray Cable
PLTC Power Limited Tray Cable
PVC Polyvinyl Chloride
XLPE Cross Linked Polyethylene
XLPO Cross Linked Polyolefin
HDP high Density Polyethylene
RTD Resistance Temperature Detector
SWA Still Wire Armored
MICC Mineral Insulation Copper Conductor
PILC Paper Insulation Copper Conductor
FOC Fiber Optical Cable
QCP Quality Control Plan
ITP Inspection Test Plan
AWG American wire gauge

CABLE SPECIFICATIONS AND CABLE INSTALLATION:

Group – 1: Single Twisted pair/Triad, Unshielded.

Conductor: Stranded, Circular Copper (Material) as per ASTMB3.
Conductor Size: 16 AWG
Primary Insulation Material: Flame Retardant PVC or XLPO or XLPE minimum temperature rating
is 90 oC (NEC 501-4 (b), NEC 502-4 (b).
2
Meraj | QA/QC Notes
 Primary Insulation Voltage Rating: 300V for Type PLTC and type IT cable, 600V for type
TC cable
Primary Insulation Thickness: (.38mm for PLTC and ITC Cable), (.64mm for TC cable).
Shield Thickness: 0.022mm

Group 2: Single twisted pair/triad shield.

Shield Material: Aluminum foil bonded to non hygroscopic polyester (Mylar) tape.
Shield Thickness: 0.022mm
Shield Application: Helical, Minimum 25% overlap, to provide 100% coverage and electrical
isolation from conductors.

Group 3: Multipair / Triad, Unshielded with or without overall shield overall shield thickness 0.022mm.
Communication Wire: Not required if required shall be manufacturer’s standard size, Insulation
same as primary insulation –Orange color.

Group 4: Multipair / triad, Individual and overall shields.

Group 5: Thermocouple Extension wire conductor – solid thermocouple extension wire as per ANSI
MC 96.1
Conductor Size: 16AWG for singal pair, 18 AWG for multipair.
Color Code: ANSI MC 96.1(Temperature Measurement Thermocouple), (Yellow and Red) Negative
shall be Red color and magnetic
Terminal Block: As per minimum thickness of terminal block shall be 5mm or higher with Spring type
terminal block are not acceptable, Terminal block shall be fire retardant halogen free, High strength
material such as polyamide on equivalent in accordance with UL94.

COLOR CODE:
AC Supply: Phase Black
Neutral White
Ground Green or Green with yellow tracer

DC Supply: Positive Red

Negative Black

Signal Pair: Positive Black

Negative White

Signal Tried: Positive Black

Negative White
Third Wire Red

Thermocouple: Positive as per ANSI MC 96.1 (Yellow)

Negative as per ANSI MC 96.1 (Red)

TYPE OF THERMOCOUPLE:
3
Meraj | QA/QC Notes
T Type Thermocouple Copper + Constant -185 ~ 371 oC Blue - Red
J Type Thermocouple Iron + Constant -190 ~ 750 oC White - Red
K Type Thermocouple Cromel + Alumel -190 ~ 1250 oC Yellow - Red
E Type Thermocouple Chromel + Constantan -196 ~ 982 oC Purple - Red
S Type Thermocouple Platinum/Rhodium-Platinum 18.0 ~ 1760 oC
R Type Thermocouple Pt87/Rh13 + Platinum -17.7 ~ 1704 oC

 Design and installation of power and wiring system for instrument shall be in accordance with
NFPA 70 and NEC.
 Fireproofing of cable in fire hazardous area shall be in accordance with SAES-B-006.
 Shielded cables shall be used as required to reduce Electrostatic noise. The shield shall be
grounded at one point only.

Cable Shield: Prevent Electromagnetic Electrostatic Interference from being endued into the inner
wire conductor.
Field Bus Cable shall Comply with IEC 61158-2 (Type A)

Puling tension of FOC = 600 Pounds.

Fir Resisting: (CI: Circuit Integrity), flame Retardant.
for transmission of analog or digital signals in instrument and control systems.
Insulation: Silicon Rubber
Armor: Zinc Coated round steel.
OTDR: Optical Time Domain Refrectometer.
RE: Instrument Cable
2G: Insulation of Silicon
SI: Collective Screen
H: Inner Jacket of LSZH
SWA: Round Steel wire armor
I/W: Outer Jacket of heat resistant PVC
FL: Reduced flame propagation
CI: Circuit Integrity
FB: Field Bus Cable
Min Bending radius: 10 x Cable Dia.
Y: Outer sheath of PVC
2X: Insulation of XLPE
PIMF: Pair Screen
HVAC: Heating Ventilation & Air Conditioning.
ISDN: Integrated Service Digital Network
LASER: Light Amplification by stimulated.

4
Meraj | QA/QC Notes
 Primary cable installation 350mm we can keep it open with instrument side otherwise have to
provide conduit or tray.
 Cable Insulation thickness .38 mm PLTC/ITC
 TC Cable thickness = 0.64mm
 Light blue color coding shall be used to identify intrinsically safe wiring the preferred practice is to
specify intrinsically safe interconnecting cable with blue outer jacket. Alternative blue sleeves
slipped over the jacket.
 At all the points of termination may used to identify I.S. wiring.
 If used for connections of equipment to ground rods or ground grid be min 25 mm2 (#4AWG)
 Intrinsically safe system shall only be used in zone 0 hazardous area.
Guide Lines to identify T/C and T/C Extension wires.
For Extension wires having insulation color to American National Standard Institute ANSI C96.1 the
negative wire is always RED colored as per American standard.

CABLE GLAND:
For Hazardous & Non Hazardous locations shall be in accordance with BS 6121 or BS 50262

Fastener Torque Value:

M8 14~16NM
M10 26~33NM
M12 45~58NM

Sizing of Cable:
1mm2 18 AWG 1 mm2
1.5 mm2 16 AWG 1.5 mm2
2.5 mm2 14 AWG 25 mm2
4 mm2 12 AWG 35 mm2
6 mm2 10 AWG 50 mm2
10 mm2 8 AWG 70 mm2
16 mm2 5 AWG 120 mm2

GROUNDING SYSTEM:
 Ground rods 2.4M minimum length.
 Cathode protection material is used galvanized steel.
 Individual Ground rod maximum resistance should be less than 25Ω Ohm.
 For copper or copper jacketed steel rods is a min of 16mm in diameter and galvanized iron
19mm in diameters.
 From main grid ground grounding conductor connected trough termite weld and compression
connector after apply boatman paint and tap
 Earth Tester is used for measuring of earthling system.
 Underground wire to wire connections shall be Caldwell or thermoweld. Compression
connector shall not be used.
 Shields and armour of power cables shall be grounded at both ends.
 If used for connections of equipment to ground rods or ground grid be min 25 mm2 (#4AWG)
 Metallic cable trays shall be bonded at both end points and a min of every 25m to the local
ground grid.
 If buried and used for grids and or interconnections of ground rods be min 70mm2 (2/0AWG)
 Be copper or copper jacketed steel or galvanized steel copper jacketed steel shall meet the
requirements of UL 476 (Underwriters Laboratories).
5
Meraj | QA/QC Notes
  Power Applications: Metal cable trays must be grounded and eclectically continuous systems
per NEC article 318.
 Types of Testing Instruments
Ratio ohmmeter
Double-balance bridge
Single-balance transformer
Induced-polarization receiver and transmitter

 Method of Testing

Four Terminal Method

Variation of Depth Method
Two-Point Method

 Non-Power Applications: Cable tray systems containing conductors outside the scope of NEC
Article 250 (such as communications, data, signal cables, etc.)

TO GROUNDING SYSTEM ARE REQUIRED FOR INSTRUMENTATION:

1) Safety ground for personnel safety.
2) Instrument CKT ground.

TRAY INSTALLATION:

6
Meraj | QA/QC Notes
Cable Tray Installation: The publication is intended as practical guide for the proper installation of
cable system. Cable tray systems design and Installation shall comply with NEC Article – 392 & 318,
NEMA VE 1, NEME VE 2 and NEMA FG 1 and follow safe practices as described in NFPA 70E.

NSL: Noise susceptibility Level

Level 1: High to Medium susceptibility analog signals of less than 50v and discrete instrument signal
of less than 30v.
Level 2: Low susceptibility switching signal greater than 30V, analog signals greater than 50 V and
120 ~ 240 AC feeder less than 20 Amps.
Level 3: Power AC and DC buses of 0 ~ 1000 V with currents of 20 ~ 800 Amps.

Tray Spacing in mm (inches):

NSL 1 2 3
1 0 150 650

Tray Conduit Spacing:

NSL 1 2 3
1 0 100 450

Conduit Spacing:
NSL 1 2 3
1 0 75 300

Tray to Tray:
Level 1 to Level 2 gap should be 150mm
Level 2 to Level 3 gaps should be 200mm
Level 1 to Level 3 gaps should be 650mm

Tray to Conduits:
Level 1 to Level 2 gap should be 100mm
Level 2 to Level 3 gap should be 150mm
Level 1 to level 3 gaps should be 450mm

Conduit to Conduit:
Level 1 to Level 2 gap should be 75mm
Level 2 to Level 3 gap should be 150mm
Level 1 to level 3 gaps should be 300mm

7
Meraj | QA/QC Notes
 TIPS FOR CABLE TRAY INSTALLATION:
 1.Cable tray specification shall be per NEMA V1 the tray shall be per NEMA VE2.
 2.The distance between consecutive rungs shall not exceed 229mm (9 Inch)
 3.The cable tray system shall be installation with manufactures standards fittings.
 Such as Clamps, Splicer Plates, Connector, Hangers, Reducer Plates, Grounding Brackets
Blind, Nut Bolts, plastic nut,holding clamp ,Washers etc.
4.The elevation of the bottom of the lowest interior cable tray shall be a minimum of 2.67M
 Above the main substation floor[SAEC-P-3307]
 5.The channel cable tray material shall be copper free aluminum (Aluminum with max of 0.4%
copper)
6. All cable trays shall have a minimum of 300 mm clear space above the tray.[SAEC-P-3307]
7. Supports should be located within 2 ft. (600 mm) of each side of expansion splice
. (NEC 110.3, NEMA VE-2 Sec.4.3.2) [SAEC-P-3307].SUPPORT IN T AREA SHOULD BE AS PER NEMA
VE2

Cable tray length in ARAMCO is 6M[one length]

 All metal cable trays, enclosures used for intrinsically safe wiring shall be grounded to the
plant grounding system with a min of # 4AWG copper wire with green insulation.
 Cable Tray material shall be galvanized, carbon steel in indoor air condition area.]
 Bare copper cable does not used in or on aluminum cable tray.

 Channel cable tray width shall be 3, 4, or 6 inches with a minimum loading depth of 1-1/4 inch.
 Cable tray joint fitting name is splice plate
 Cable tray Expansion splice plate installed every 18M
 Expansion plate moving distance 25mm
 Ladder tray used for power cable and for home run cable also using ladder tray
 For field run cable channel cable tray using
 SS tray are using were fire propping area
 Non metallic cable tray permitted in corrosive area. Non metallic cable trays shall be made of
flame retardant material.
 Duct Banks: consist of either hot dip galvanized rigid steel or PVC conduit, incase in concrete.
 75 mm of concrete from the outside surface of the duck bank to any conduit or reinforcing
steel.
 Fabricated spacers shall be used at intervals not exceeding 2.4m.
 The spacers shall provide a min conduit separation of 50 mm for 2 inch and above conduit.
 For equipment, devices, or appropriates certified as intrinsically safe, only those that are
certified are category EEX or AEX “ia” shall be used.

TIPS FOR CONDUIT INSTALLATION:

Conduit fittings and accessories include conduits and pull boxes:
 Conduit cover and gaskets
 Conduit Seal
 Conduit Unions and Couplings
 Check pull box every 4 bends
 Check conduit fittings suitable for hazardous location [if installed in hazardous location]
 Check conduit to conduit distance as per SAES-J-902
 Check conduit installation as per IFC drawing and typical drawing
 Check support as per NEC
 Factory Elbows
 Check Seal fittings if required
 Check the thread joint

8
Meraj | QA/QC Notes
  Check the clamp, thread size it is approved or not or as per typical drawing
 Drain
 Breathers
 Plugs
 Conduit Connectors reducers
 Expansion fittings
 Straps and Clamps
 Bushing
 Cable and duct seal, etc.

TIPS FOR CONDUIT INSTALLATION:

 Conduit Expansion fitting shall be provided in indoor 30 mtr.
 Conduit Puller J/B shall be provided every 25 mtr.
 Pull Box to Pull Box maximum bends acceptable in 360 deg. without 90 deg. bend.
 Support (Bending) does not occur NEC-344
 Pull & JB are Installed & Securely fixed as per NEC-314.28
 When Eyes type sealing fittings are used to seal cables in conduit entering enclosures, a
conduit union shall be installed between the sealing fittings and the enclosure.
 Sealing fitting used in hazards are horizontal and vertical Eya and EYam type.
 NPT type accordance with UL34E 34997 or CSA (Canadian Standard) LR 9795.
 For Vertical Type: Eyed and Eydm drain seal fittings.
 Seal fitting shall not be less than 5/8”
 Sealing compound shall be 35 to 85 deg F.

Support for Rigid Metal Conduits:

½” ~ ¾” 3M
1” 3.7 M
1 ½” 1 ¾” 4.3 M
2” 6.0 M

 Seals are provided in conduit & cable system to minimize the passage of gases and vapors
and prevent the passage of flame from one portion the electrical installation the conduit.
 Bushings: where a conduit enters a box, fittings or other enclosure a bushing shall be
provided to protect the wire from abrasion.

Bends:
Number in one run: There shall not be more than the equivalent of four quarter bends (360 degree
total) between pull point to point.
Mandrel Testing: Testing of underground duct bank and bend radius of conduit is 90 deg.
When union cannot be avoided in underground conduit installation, unions shall be protected with
heat shrinkable sleeves.
Conduit and cable sealing shall be installed in accordance with NEC-5050.10.
Conduit seals shall be installed within 450mm (18 inches) from the enclosure.
PB: Pull Box
RGS: Rigid Galvanized Steel.
Split Conduits: Split conduit Installation shall be used to repair existing conduits which contains
existing cable these conduits shall be installed in accordance with the manufacturer’s
recommendations or NEMA TCB2 User manual for the installation of order ground plastic conduits.

 We can use maximum bend in one conduit (Point to Point) 360 degree, but we have to avoid
90 degree bend or sharp bends.
 If there is sharp bend so we can perform Mineral Test.
 Direct buried conduits (Underground) shall be threaded, rigid steel per accordance ANSI
C80.1 and addition it shall be hot dip galvanized and PVC coated as per NEMA RN1 (min
9
Meraj | QA/QC Notes
 thickness of PVC 40 mils) or PVC conduit type DB-120 (Minimum elasticity 500-000 PSI) as
per NEMA TC6 & TC8 type.
 Concrete incase conduit shall be threaded, rigid steel as per ANSI C80.1 and in addition it
shall be hot dip galvanized.
 Conduit Installed exposed (not embedded in walls) above grounding in outdoor industrial
facilities shall be threaded rigid steel per ANSI C80.1 and in addition it shall be sot dip
galvanized.
 Conduit above ground in severe corrosive environments shall be as threaded, rigid steel as
per ANSI C80.1, in addition shall be factory PVC Coated (min thickness of 40 PVC mils) as
per NEMA RN-1.
 Electrical Metallic tubing (EMT) is acceptable only in non-hazardous indoor locations. EMT
shall comply with the requirement of ANSI C80.3
 Intermediate metal conduit (IMC) is prohibited.
 The Min conduit size shall be ¾ inch, except for instrumentation wiring inside building.
 Conduit and threaded conduit fitting shall have tapered (NPT) threads in accordance with
ANSI/ASME B1.20.1

ANSI C80.1 Rigid Steel Conduit-Zinc Coated

ANSI C80.3 Electrical Metallic Tubing-Zinc Coated (for indoor only)

 Process Piping shall not be used to support conduits.

 Flexible conduit: shall be used at instrument end of the conduit to provide isolation from
vibration prate against thermal expansion of the rigid conduit systems
 Conduit sealing shall only be poured at temp between 35F and 85F
 The sealing compound shall provide a seal against passage of gas or vapors through the seal
fittings.
 The minimum thickness of the sealing compound shall not be less than 5/8 Inch.
 Conduit seal fitting plug is painted with red color and non poured seat fitting are painted with
green color.
 Gap selling of expansion splice palate 25.4 mm (gap max)
 50F or 10C gap is 9.5 mm (Standard)

DUCT BANK INSTALLATION:

Conduit size shall be as per design of duct bank to be installed with minimum gap from wall to wall
shall be 75mm. Support of Conduit to be fixed every 2.4 M. Support shall be PVC material anchor
type.

Duct Bank &

System Voltage Direct Buried Cable Direct Buried pvc Direct Buried Rigid
Steel
600V & Below 610 460 460
600V to 35 KV 920 610 460
Over 35 KV 1070 760 460

Impulse Tubing Installation:

Tubing: Stainless steel tubing shall seamless, annealed, min wall thick 1.24mm as per ASTM A269
Gras IP – 316L

Impulse Tubing Installation Tips:

1.Slop of Impulse tubing: Minimum of 1mm, for every 12mm towards tapping point. for gas service
2.Test Pressure of Impulse Line: 1.5 Times of the working pressure with 3 minute.
3.Instrument Tubing size = ½” x 0.89mm (Wall thickness) = 0.035 Inches.

1
Meraj | QA/QC Notes
 4.Tubing supports should be spaced not more than four feet apart.
Pressure and D/P instruments in liquid or condensable vapor service shall be self-venting (i.e., mounted
below the process connections) with all impulse lines sloping downward approximately 1:12 -minimum toward
the instrument
5.Pressure and D/P instruments in gas service shall be self-draining (i.e., mounted above the process
connections) with all lines sloping downward approximately 1:12 minimum toward the process connection.
6. Field instruments shall be mounted as close as possible to the process connection to minimize the length
of instrument impulse lines. Where practically possible, the length of the impulse line should not exceed 6 m
(20 ft.)

Enclosures:
Indoors and Outdoors Plant Area
Indoors: With in the Perimeter of the Process Unit (NEMA 250 / NEMA ICS6)
Outdoor: Out side the Perimeter of Process Area (IP54)
 Severe Corrosive Environment (Industrial Area) NEMA Type 4X or IP66.
 Non Industrial Area IP34.
 Name Plate Shall is attached to the cabinets using stainless screws.
 Indoor Cabinets shall be made of metal.
 The Cabinet shall be a NEMA Type 1 as per NEMA 250 and NEMA ICS6.
 NEMA ICS6: Enclosures for Industrial Controls and System.
 The Max Door Width shall be 900mm (36 Inch)
 The Marshalling cabinets from the front surface to the surface of rear terminal block, shall not
be more than 46 cm (18 Inch)
 A min of prime, undercoat & finishing coat of enamel or polish is required.
 Interior cabined color shall be white or of light color such as light gray off.
 Name plate for cabinets and panels letter height and spacing shall follow ISA RP 60.6
 Name Plate shall be made from laminate Plastic, white – Black - White (Information engraved
into the black core) with white surface.

Hazardous area zone Classification:

Zone ‘0’ – In which an explosive gas-air mixture is continuously present or present for long period.
Zone ‘1’ – In which as explosive gas air mixture is likely to occur under normal operation.
Zone ‘2’ – In which an explosive gas-air mixture is not likely to occur in normal operation and if it
occurs it exist only for short time.
Zone ‘10’-in which an explosive dust atmosphere is present continuously or for extended period of
time
Zone ‘11’—in which there is likelihood that explosive atmospheres may occur for short periods due
to unsettled dust layers

QUESTION AND ANSWER

1. What is QA/QC
Ans: QA/QC means, “Quality Assurance / Quality Control” The purpose of this (QA/QC) is to
establish the sequence of requirement for the quality of material, quality of works, its
inspection, and records.

2. What is the MMG Quality Control Management System

Ans: ISO 9001 ~ 2000

3. What is the Quality Control?

1
Meraj | QA/QC Notes
 Ans: Quality Control “Those activities and techniques used to achieve and maintain the quality
of product, process or service”.

4. What is Quality Control Plan?

Ans: Quality Plan “Document Specification which procedures and associated resources shall
be applied by whom and when to specific project, product, process or contract”.

5. What is non-conformity?
Ans: Non-conformity “Non-fulfillment of requirement”.

6. What is the Specification?

Ans: A Company mandatory (must do) Technical Document designed to Ensure project work
are carried out to the required standard.

7. Who are the responsible for Quality?

Ans: Everybody within all organization.

8. What is the basic responsibility of a QA/QC personal?

Ans: To ensure execution of works and comply fully as per standard and approved specs.

9. What is the basic required document for a QA/QC personal?

Ans: The basic required documents for a QA/QC personal are as following.
ITP (Inspection Test Plan): to conduct the quality check (Inspection / Witness / Surveillance)
etc.
WP (Work Procedure): Standard procedure to execute the works.
P & ID: As a reference to ensure that the work is as per standard drawing.
MTC: To ensure that material complies the PES standard specs.
Calibration Report: To ensure parameters are function checked as per IDS.
PP (Project Plan): To ensure that the instruments are installation as per P & ID and PP as
per convenience.
Hook-up: To ensure that the remote connection of pneumatic is done correctly.
Wiring Diagrams: To ensure that wiring is done correctly.
ILD: To ensure that the sequential wiring is done correctly.
IDS/ISS: To ensure that the instruments comply with the basic requirement.
RFI: To conduct the inspection of completed work.
QR (Quality Record): To maintain the quality records of completed works etc.
QCO: To issue a warning in case of little violation and observation.
NCR: To issue warning in case of serious violation of standard.
MDR: Material Discrepancy Report.
TQ : Tehnical Query

10. What are QA/QC’s ITP and QCP? Give brief?

Ans: ITP: This procedure informs about the kinds of quality check (surveillance, inspection,
witness or hold pints) means quality of works is being done in proper sequences.
QCP: This procedure addresses the activities and requirement in details.

11. What is NCR? Why does it need for a QA/QC personal?

Ans: NCR means Non-Compliance Report, QA/QC personal has reserve the right to issue a
warning if the contractor doesn’t comply or violate with the standard procedure.

12. What is the general procedure (WP)?

Ans: The general sequence of activities will be as follows:
Receiving Drawing and Documents.
Reproduction of Drawings
1
Meraj | QA/QC Notes
 Issuing of drawing to site
New-Issuing new Revision
Shredding drawings
Transmittal of redlines to Client (As-built)
Restricted access to the DCO
Work Permit prior to starts the works
Records

13. What are the common PPE required? Give a brief?

Ans: Following are the common PPE for a safe and quality works-standard procedure.
Qualification: Awareness about all kinds of safety std/codes and work procedure.
Experience: Qualification for the work’s execution.
Use (PPE): Proper equipments and tools shall be used to avoid injuries/loss. Safety shoes,
Helmet, Glass, Gloves, Earplugs, Harness, Proper Tools and certification equipments.

14. What is redlining? Brief its color coding?

Ans: In case of any change occur to the standard approved drawing while the project is being
constructed or tested the relevant drawing will be “redlined”. Following color coding shall be
used for this purpose.
Red: If any addition required from the drawing.
Green: If any Deletion is required from the drawing.
Blue: If any comments is added.

15. What is difference between inspection (Surveillance), witness and Hold point?
Ans: Inspection: Work can be execute without client’s inspection and it can be inspected
some part of them if it is required.
Witness: Work can be executed, without client inspection and then it can be inspected upon
the completion of work.
Hold Point: Work can’t be executed without client inspection.

16. What is difference between hazardous and non-hazardous Areas?

Ans: Hazardous: A hazardous location is defined as an area where a potential for fire or
explosion exists due to the presence of flammable gases, liquids or vapors, combustible dusts
or fibers and flying in sufficient quantities to produce an explosion or ignitable mixture.
Non-hazardous: An area where non risk of presence of any kinds exposition.

17. What are different kinds of certification?

Ans: Weather Proof.
Dust Proof
Water Tight
Explosion Proof
Flame Proof
Intrinsic Safety Proof etc

18. What is ISO? Explain some of its standards?

Ans: ISO means International Standard Organization, Some are them they are as below;
ISO: 9001, ISO: 9002, ISO: 9003, etc.

19. What are zone classifications? Give a brief?

Ans: Zone classification is to define the area of hazards, they are as below;
Zone – 0: A zone in which explosions gas/air mixture is continuously present or present for
extended periods, during normal operation.
Zone – 1: A zone in which an explosive gas/air mixture is likely to occur in normal operation.

1
Meraj | QA/QC Notes
 Zone – 2: A zone in which an explosive gas/air mixture is not likely to occur in normal
operation.
Zone – 10: A zone in which an explosive dust atmosphere is present continuously or for
extended periods of time.
Zone – 11: A zone in which there is a likelihood that explosive atmospheres my occur for
short periods due to unsettled to unsettled dust layers.

20. What are areas Classification? Give a brief?

Ans: As per NEC and NACA, following are the hazard classification?
Class I: Location in which flammable gases or vapors may be present in the atmosphere in
quantities sufficient to produce explosive or ignitable mixture.
Class I gases/Vapors are divided into four following groups:
Group A: Presence of Acetylene.
Group B: Presence of Hydrogen, Butadiene, Ethylene oxide etc.
Group C: Presence of Ethylene, Glycol-propane, Carbon Mono-oxide etc.
Group D: Presence of gasoline, acetone. Butane, Propane, alcohol, Natural gas (Methane),
etc

Class II: Location in which the presence of combustible dust are in the air in sufficient quantity
to ignite or explode.
Class II conductive/non conductive dust is divided into three below.
Group E: Presence of metal dusts (aluminum, magnesium and chemical dust etc)
Group F: Presence of black carbon, charcoal, coal or coke dust etc.
Group G: presence of non-conductive dust (foam, starch, combustible plastics etc.)

Class III: Location in which easily ignitable fibers or flying are present but are not likely to be
in suspension in air in quantities sufficient to produce ignitable mixture.
Division – 1: The hazards are present continuously or periodically under normal operation
condition.
Division – 2: The Hazards are only presents during accidental or abnormal condition.

21. What is the standard height to install the instruments?

Ans: Standard height to install the instrument is 1.4 meter, but it can vary less or more as per
location’s convenience.

22. What is loop check?

Ans: To ensure that the system wiring from field to control consol console functioning fine.

23. What is the logic gate?

Ans: A digital logic circuit with one or more input voltage but only one output voltage.

24. What is the foundation fieldbus system?

Ans: A fully digital control system is called foundation fieldbus system.

25. What are meant by FAT, SAT, RAT?

Ans: FAT: Factory Acceptance Test.
SAT: Site Acceptance Test.
RAT: Run Acceptance Test.

26. What is Microprocessor control system? Give a brief of PLC, DCS and SCADA?
Ans: Computer based control process system is called microprocessor control system. The
brief of PLC, DCS and SCADA are as following:
PLC: Programmable Logic Control System.

1
Meraj | QA/QC Notes
 PLC’s are used in practice with the aim of achieving a higher degree of availability or fault
tolerance. The types are as follow.
Fault Tolerant: 1 out of 2 system objective: reduce the probability of losses of production by
switching to a standby system.
Fail Safe: 2 out of 2 system objective: protect life, the environment and investment by safely
disconnecting to a secure “off” position.
DCS: Distribute Control System.
SCADA: Supervisory Control and Data Acquisition.

27. What are inspection points for a cable tray installation?

Ans: Material check as per approved spec, size and type, tray’s hook-up, proper distance
structure, tray to tray i.e. power/control/and signal/low voltage and high voltage, support and
fixed strongly not shaking.

28. What are inspection points for field instruments with impulse tubing?
Ans: Materials inspection as per approved spec material, type and size, Installation as per
Hook-up, check line route to avoid any obstruction, check tube bending, and check tube
support, compression fitting or ferrules, and then pressure test (hydrostatic test) shall be done.

29. What are inspection points for a cable laying?

Ans: Material inspection as per approved materials, types and size, meggering, cable routing
drawing, completion of cable route ( tray, conduit or trench etc ) and cable numbering (Tag),
cable bending, use or proper tools and equipment for cable pulling.

30. What are inspection points for Junction Box and Marshalling cabinets?
Ans: Material Inspection, type, size as per approved specification, installation hook up for
frame, bracket or stands, fixed properly means shaking free, Name Plate, and tag no.

31. What are standards methods or ferrules addressing to and from a Junction Box?
Ans: For to side only terminal’s address required 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.

32. What is final RFI? When it shall be raised up?

Ans: When the QA/QC department of contractor is satisfied that the work detailed in the
construction RFI is completed, then request shall be submitted for inspection to the client
QA/AC department.

33. What is schedule Q?

Ans: Schedule Q is an attachment to the contract, which is the provision of Quality Assurance
and Control, Inspection and test plan.

34. What are the various levels of Inspection? Explain?

Ans: They are as following.
Level of Inspection for Materials:
A: Level 0 – Documents requirements only, no Inspection.
B: Level 1 – Inspection prior to shipping.
C: Level 2 – Minimum requirements, pre-inspection meetings, one or more unspecified “in
progress” surveillance visits.
D: Level 3 – Same as level 2, except that “in progress” surveillance inspection shall be in
regular basis.
E: Level 4 – Resident Inspection Continuously monitor the work.

Level of Inspection for construction phase:

1
Meraj | QA/QC Notes
 A: Hold Point (H): The inspection activities will not proceed without the presence of
inspection.
B: Witness Point (W): Inspection activities can be proceeding after issuing RFI.
C: Review (R): Verification of documentation (NMR) on its correctness as per spec and
approved drawings.
D: Surveillance (S): Inspection has right to conduct random inspection of works.
E: Inspection (I) / Perform (P) / Test (T): construction can be proceeding to next phase
without client inspection.

35. What is ITP’s? What are Hold and Witness Point?

Ans: ITP mean Inspection and Test Plan, details of work scope and required types of
inspections.
Hold Point (H): is the level of inspection that client inspection must require through RFI and
can’t be preceded until inspection is done by client.
Witness Point (W): is the level of inspection that inspection activity can be preceded without
client inspection or if client is not available as per RFI timing.

36. What is RFI? When an RFI will be raised?

Ans: Request for inspection (RFI), RFI shall be raised only when the status of the preliminary
inspection is satisfactory, and the works (items) are Hold or Witness Point.

37. What is Cable tray and how is it identified separately for Electrical and Instrumentation?
Ans: Cable tray is the device used to provide support and protection to the laid cable in side
the building or outside pipe rack.

38. What is name of fieldbus communicator?

Ans: FBT6 (Fieldbus Transducer 6)

39. What is Calibration and what is process calibration?

Ans: Checking / testing the equipment for its accuracy and serviceability are known as
calibration. Process calibration means carrying out calibration activity by following the adopted
authorized method linked with standardization.

40. What is the loop and how is the loop folder made?
Ans: Loop is the electro-mechanical presentation of the circuit concerning to flow of liquid or
gas, alarm system, control valve operation and other specific for which field installation
instrument involvement is considered.
There are certain condition and requirements to be fulfilled to complete the loop check. The
list of attachments including drawing, check list and punch list and other listed documents are
arrange in folder (loop wise) for having an easy access to carry out the loop check and final
hand over of the project. That folder with all possible documents is known as loop folder.

41. What is the specialty rather characteristics of loop check? How do you come to know that loop
check is completed
Ans: a. Loop check is a clear blue print of a successful system functioning (activity wise),
b. This emphasises the serviceability of each instrument installed either in field or inside the
building,
c. This exposes also the limitation of some systems functioning as per the attached filled
punch list,
d. One of the ready documents for final hand over of a project on completion,
e. It is always two team’s operation-one will be on field and the other will be in the control
room, After every successful completion of loop check it is marked with Red Colored Label
bearing the date of the loop check and the witnessing parties initial.

1
Meraj | QA/QC Notes
42. What is the standard and what is the Standardization?
Ans: The standard means the authenticated documented instruction to be followed during
execution of any specific project for which it is made.
Standardization means the method of execution of certain standard which is specific to the
one or more related activities in a project execution process.

43. What is Inspection?

Ans: This is a process of verifying the method application by means of following certain
documented and authenticated instruction i.e. standardization is known as inspection.

44. What are the responsibilities of QC Inspector?

Ans: The following are the phenomenal responsibililities which any QC Inspector is supposed
to execute at the time of carrying out any inspection.
a. Well versed with the technology for which the inspection is carried out.
b. Should have the reasoning capability to analysis the method.
c. Should have thorough knowledge about the procedure to be adopted for inspection
i.e. adopted standards.
d. Should be able to convey the irregularities found to the concerned authorities.
e. Should be absolute sincere about the job execution.
f. Should be vigilant all the time.

45. What should be the attitude of a QC Inspector while carrying out an Inspection activity?
Ans: Following are the characteristics of a perfect inspector:
a. Should never compromise with the quality at the time of performing inspection.
b. Should be sincere towards performing the responsibilities.
c. Should be punctual.
d. Should be exemplary in approach while carrying out inspection.
e. Should have the capabilities to convince the authorities about the irregularities with
knowledgeable representation.

46. What are the requirements for carrying out installation inspection of any instruments and
receiving inspection of the said equipment?
Ans: Following are the requirements at the time of execution of an inspection.
a. Instrument data sheet.
b. Test Instrument Certificate.
c. Vendor instruction manual.
d. Test Instrument instruction manual.

47. What is the CCTV System?

Ans: Close Circuit Television system used for establishing the alarm notification in case of
any unforeseen hazard takes place. It is a digitally controlled system which enables the
automatic notification of the happening in and around the plant and plant premises.

48. What are the differences between QA & QC activities?

Ans: The QA activity means adopted method for verification of the execution of QC activity in
turn it focuses towards the importance of implementation of QC role in the industrial and other
sectors related to maintenance, production and construction specially.
The QC activity means the direct involvement in maintaining quality standard as per the
adopted method/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 project’s quality
maintainability and process execution.

49. What is Schedule ‘Q’and how many appendices are there in schedule ‘Q’?

1
Meraj | QA/QC Notes
 Ans: Schedule ‘Q’ is the guidelines for the method application related to quality including the
distribution of manpower (quality field oriented) and the quality process execution including
quality control and quality assurance.
It has got six appendices covering all the process implementations related to execution of
project performance with the focus towards maintainability of quality control and quality
assurance.

50. What are the linked documentations carried out related to QC activity for oil & gas construction
project?
Ans: a. Application for inspection from construction department after completion of every
activity.
b. Production of drawing based on the planning.
c. Method application priority wise.
d. Procurement of item and equipments required for the execution of the project.

51. What is process control system?

Ans: 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 the production unit on operation.

52. What are QCP, QMP and ITP?

Ans: QCP – Quality Control Procedure, QMP – Quality Management Procedure, ITP –
Inspection and Test Plan.

53. Explain procedure related to Quality Control?

Ans: The quality procedure is the series of steps taken to maintain the quality standard as
per the adopted standard and other specific.

54. What do you know about NEC, NEMA VE 1, NEMA VE 2, NEMA RN?
Ans: NEC – National Electrical Code earlier used to be published under the statutory body of
NFPA since 1897, from 2005 edition it is categorized as an internationally accepted method
inspection procedure guidelines covering all most all the field related to Electrical,
Instrumentation and Communication Engineering.

NEMA VE 1 – National Electrical Manufacture Association VE 1.

NEMA VE 2 – Deals with Cable tray installation specification.

55. What are the articles refereed during carrying out the following activities?
(1) Grounding. (2) Installation of cable Tray. (3) Fire alarm System Installation. (4) Installation
Instrument Cable Tray etc,
Ans: (1) Grounding Article 250 (Chapter IX for instrumentation), (2) Installation of cable tray
Article 392, (3) Fire Alarm System Art 760, Installation of instrument cable tray art 727.

56. What is Duct bank?

Ans: It is concrete poured structure with conduits laid inside by maintaining certain specified
elevation as per the requirements for the laying of cable through this enabling protection,
support and safety to the cable.

57. What would be the thickness of the top layer of a Duct Bank and color?
Ans: 5mm and Red Dye.

58. What is the purpose of using paint/dye on top layer?

Ans: To give an anticorrosive protection, top layer painting is provided.

1
Meraj | QA/QC Notes
59. What are types of conduits used in electrical and instrumentation wiring circuits?
Ans: Rigid Metallic Conduit (RMC), Intermediate Metallic Conduit (IMC), Rigid Nonmetallic
Conduit (RNC).

60. What are the differences between a JB (Junction Box) and Terminal Box?
Ans: The purpose of JB (Junction Box) is used as a linkage between one or more inlet and
one or more outlet. Whether terminal box has inlet on or more but out let may be one for
earthen or it may not be. JB can be used in between the routing for providing support and
extra opening but TB is used as Termination means at the end of the routing.

61. What is ‘termination’ related to construction industry?

Ans: Termination is widely used term in case of construction industry. For electrical and
instrumentation work this is used for make the routing as a complete one.

62. What is the impulse line?

Ans: 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
generate equivalent electrical signal to get the indication of the status of the system working.

63. What is the check list?

Ans: It is the list of sequential activities to be performed by any QC Inspector during inspection
of any activity performed by construction. It is made separated with distinguished activities for
each construction activity.

64. What is punch list? What is requirement of making a punch list?

Ans: It the list generally identified as RA 60B, which is used at the time of finalization of any
activity. Means every activity should be stamped with a final and foolproof documentation
which shows the clear evidence of the all completed job. It is always signed by QC to ensure
the maintainability of the quality aspect of the job performed.

65. What is the role of QC during shut down?

Ans: QC has the major role to be played at the time of shut down. It is the responsibility of
QC to officially hand over any completed project to the client with all the documentations to
be provided with the real completed project. This including the records of completion (activity
wise) areas with limitations as shown in punch list, the processing and final inspection test
report of the actual functioning of the project by making it operational.

66. What do mean by Hazardous and Non Hazardous area?

Ans: The area classification is done as per area wise risk involvement (environmental). The
area with maximum percentage of risk in functioning any system is known as hazardous area
(NEC Art 500 – 510).

67. How are the hazardous and non hazardous areas classified?
Ans: Hazardous and non hazardous areas are classified according to the classifications and
zones.

68. What is the Expansion joint? What should be the standard gap maintained in expansion joint?
Ans: It I the breathing space provided to accommodate the expansion of horizontal cable tray
to suit with different climatic condition by maintaining a standard length wise distribution.
According to NEMA VE 2 it is after every 20 M with a spacing (expansion joint) of 25mm to be
maintained. It sometimes differs, but should not be more for the horizontal length of the cable
try.

69. How the metallic cable trays grounded?

1
Meraj | QA/QC Notes
 Ans: Metallic cable tray shall be bonded at both end points and minimum of every 25m local
ground grid or ground electrode or to structural steel bonded to local ground grid or ground
electrode.

70. How the metallic conduit grounded?

Ans: grounded at both end points by bonding to grounding conductor, grounded metal
enclosure or to grounded metal cable tray by using approved grounding clamps.
A grounding bushing must be used with PVC coated conduit.

71. How many connection points required for equipment ground?

Ans:
a) For equipments like (motor, generators and transformers) which operated at 1000 v or
greater shall have two connections to supplementary electrode.
b) If the motors, generators and transformers operating at nominal voltage 480 v shall
have a minimum of one connections to supplementary grounding electrode.

Duct Bank:

72. What type of conduit is used in duct bank?

Ans: Duct bank consists of either hot-dip galvanized rigid steel or PVC conduit, encased in
concrete.

73. What is the minimum thickness of concrete from outside surface of the duct bank to any
conduit or reinforcing steel?
Ans: 75mm

74. What is mean by Guwat and Guwa, where it is applicable for use?
Ans: You can use in conduit installation for lighting purpose.
Guwat: With terminal block.
Guwa: Withought Terminal block.

75. How the Metallic and PVC conduit entering from below of any equipment like switchgear
control cabinets and similar enclosures sitting?
Ans: The metallic conduit shall be cut and threaded 50mm above finished grade level and a
threaded insulated grounding bushing shall installed, also PVC conduit shall be cut flush with
finished grade level and shall have its inner edge filed to a smooth radius.

76. What type of sealing is used for all ducts inside all manholes and hands holes where permitted
inside hydrocarbon handling plants?
Ans: All ducts shall be sealed with 3M scotch cast brand 4416 cable duct sealing kits or other
methods approved by the electrical standards committee chairman.

77. What is a Mandrel testing?

Ans: Testing of underground duct bank.

78. What should be done, when union cannot be avoided in underground conduit installation?
Ans: Unions shall be protected with heat-shrinkable sleeves.

79. What shall be provided on each duct where it terminates?

Ans: Bell end fitting or protective bushings.

80. How many spare ducts in duct banks?

Ans: Duct bank shall have 20% spare ducts (minimum one), unless this number is decreased
by the facility proponent.
2
Meraj | QA/QC Notes
81. What is the minimum conduit size excepted for instrumentation wiring inside building?
Ans: ¾ Inch.

82. What is the minimum conduit size excepted for prefabricated skids and in-industrial area?
Ans: ½ Inch.

83. What the meaning of (EMT) and for what used?

Ans: Electrical Metal Conduit (EMT), you can use only indoor.

84. What are the conduit fittings for outdoor rigid steel conduit and liquid tight flexible metal
(LFMC)?
Ans: Shall be cast or forged steel, cast iron or malleable iron either hot-dip galvanized
(preferably) electroplated.

85. Can be use the aluminum fitting in outdoor?

Ans: No aluminum fitting or fitting accessories such as covers, sealing fitting plugs shall be
used outdoor only malleable iron sealing fitting shall be used.

86. What shall be the slop for impulse line?

Ans: a minimum of a 1mm, for every 12 mm towards tapping point.

87. What shall be having extra length for unistrate support?

Ans: 40 mm should be extra

88. What shall be the test pressure of instrument impulse line?

Ans: 1.5 times of the working pressure.

89. What is RTD stands for?

Ans: Resistance Temperature Detector.

90. 4What shall be minimum acceptable insulation resistance of instrument cable during megger
test?
Ans: 100 Mega ohms

91. Name some testing equipments used for instrument calibration?

Ans: Deadweight tester, Digital multimetter, Megger, Digital pressure calibrator, Temperature
calibrator, Temperature bath, Field communicator, Vibration meter.

92. What shall be the maximum acceptable attention value of fiber during OTDR test?
Ans: 0.5Db/Km or less for wave length of1310 nm and 0.3Db /Km or less .for wave length of
1550nm.

93. What shall be the maximum pulling tension of FOC?

Ans: 600 Pounds.

TRANSFORMERS:

94. What the accessories of transformers?

Ans: Fans, Radiators, Oil Pumps, Pressure Relief device, Oil Level gauge, Temperature
Gauges, Tap Charger, Bushings, Current Transformers, Voltage Transformers, Surge
arrestors, Surge Capacitors, Dust filter bar, Post insulators.

95. Why the oil samples test shall be taken from the transformer?
2
Meraj | QA/QC Notes
 Ans: To check the conductivity, analyses and characteristics of the oil.

96. What the factory tests shall be performed on the transformers?

Ans: 1. Ratio tests at the rated voltage connection and at all tap connections.
2. Polarity and phase relation tests on the rated voltage connection.
3. Applied potential tests.
4. No load and excitation current at rated voltage connection.
5. Impedance tests.

97. What are the transformers ratings?

Ans: 1. Primary and secondary KVA.
2. Voltage.
3. Taps.
4. Primary and secondary continuous current
5. Basic impulse level for equipment over 600 V
6. Impedance.
7. Insulation class and temperature rise.
8. Sound level.

98. What is the standard secondary rating of the CT?

Ans: 5 Amperes.

99. What is the symmetrical interrupting current rating fuse on the HV –side of transformers?
Ans: The symmetrical interrupting current rating of a fuse shall not be less than max
symmetrical sub transient fault current.

100. What is the meaning AWG?

Ans: American Wire Gage

101. What is the Principle of Bimetal Thermometer?

Ans: Different Metal of Different Coefficient.

102. How do you calculate new factor from new range using old factor and old range?

Ans:

2
Meraj | QA/QC Notes
 103. Definition of Instrument Range and Span?

Calculation of Resistance or Pt100.

Ro. = 100
x for platinum = 0.00385 /c.
To calculate Resistance at 100'c.
R100 = 100 [ 1+ ( .385 x 100 ) ]
= 100 + (100 x 0.385)
R100 = 138.5
Resistance at 100'c = 138.5

What is the effect of weep hole on calculation of orifice bore?

(dm)2 where: dm = Measured diameter of orifice.

d = dm { 1 + 0.55 } dh = Drain hole diameter.
dh d = Corrected diameter orifice size.

What is CV of a valve?

CV is the capacity of a valve and is defined as:

"No of gallons per minute of water which passes through a fully open valve at a pressure drop of 1
psi.
CV = q ( ▲P / G )

Where: CV = Valve co-efficient

q = Volumetric flow rate ( gallons minute )
▲P = Pressure drop across the valve in psi.
G = Specific gravity of flowing fluid.

Why does control valve operate at IS psi ?

On higher pressure the actuator sizes becomes bigger in area. The actual force produced by the
actuator.
Force = Pressure x Area.

2
Meraj | QA/QC Notes
 = 15 psi x Area, If Area = 15"
Force produced = 15 psi x 25 in2 = 375 pounds.
Actual force acting on a control valve = 375 pounds.

PRESSURE CONVERSIONS:

1psi = 27.74 " H2O

1 Kg/cm2 = 14.223 PSI
1 Bar = 14.504 PSI
1 Kpa = 0.145 PSI
1 Kg/cm2 = 10000 mm of H20
1 Bar = 1.0197 Kg/cm2
1 Kg/cm2 = 0.98 Bar
1 Torr = 1 mm of Hg.

Common Things:
Type of Lugs: (1) Shanap Type (2) Pin Type (3) Ring Type (4) U Type
Gland Size: ½” ¾” 1”1½” 2”
Thread Type: ET (Equal Thread), BSP (British Standard Pitch), NPT (National Pipe Pitch).

ELECTRICAL:
LT – (Low Tension) – 50VAC ~ 230VAC
HT – (High Tension) – 320VAC ~460VAC
MCC – (Main Control Connection (Motor Control Center)
PCC – Power Control Connection

Equipment used for no Load Run:

Tacho Hi-Tester (Hioki Model 3403) for motor speed.

True RAS Multimeter (John Fluke Model 87V)

Infrared Thermometer (John Fluke Model 66) Using to get the Temperature of.
1. Ambient Temperature
2. Bearing Drive End
3. Winding Temperature
4. Bearing non Drive End

Vibration Meter (Monarch instrument Model Examiner 1000) Using to get the Vibration (mm/s)  

Motor in Two Locations: 

1. Drive End (Horizontal-Vertical and Axial)
2. Non Drive End (Horizontal-Vertical and Axial)

Sound Level Meter (Extech Instrument Model 407703) Using to get the noise (dB) of motor in 3 locations: 

2
Meraj | QA/QC Notes
 1. Drive end.
2. Non drive end.
3. Winding.

NB: The Duration of the no load run is 4 Hrs, Every 30mm needed to get a reading.

Equipment using for testing the panel board:

Michroohmeter (Model: Programma MOM200A).

Used to test the contact resistance of bas bars, breakers etc..?

Digital Earth Tester (Model: 4105A).
Portable Double Bridge (Model: 2769).

Using for winding resistance tests of voltage transformer, current transformer, etc..?
DC Dielectric Test Set (Biddle Model 220123).

Used to hi pot the medium voltage cables?

Insulation Tester (Megger Model: BM11D)

Used to test the insulation resistance of cables, bus bars, breakers, VT’s, ct’s, etc…?
Digital Multimeter Model: 77iii
Programma (Freja 300)

Relay test unit for: (transformer management relay, feeder management relay, motor management relay,
also used to test the ATS of switchgear, ammeters and voltmeters
Torque wrench (model 64-046).
Power Clamp Meter (Model: Unites 93510).
True RMS AC/DC clamp meter (Tektronix Model: DCM910)
Relay Test Unit (Programma Model Sverker 750)

Voltage injections exp: test the lock out relay

Breaker Analyzer System (Programmed Model TM1600)

How to calculate the accuracy of Instrument

Accuracy = Actual Value – Measured Value/Full Span x 100

2
Meraj | QA/QC Notes
 INTERNATIONAL STANDARD AND CODES

NEMA 250 Enclosures for electrical equipment (1000 v maximum)

NFPA- National electrical code
70/NEC
NEMA- PVC Coated rigid metal conduit
RN1
NEMA Electrical PVC conduit
TC2
NEMA PVC fittings for RGS PVC conduit
TC3
NEMA PVC Plastic utilities duct for U/G installation (EB35 & DB120)
TC6 & 8
NEMA Copper free cast Aluminium enclosures
type 3&4
ANSI- RGS conduit
C80.1
ANSI- EMT
C80.3
NEC-250 Groundings and Bonding
NEC-392 Cable tray
NEC-504 Intrinsically safe system
NEC-501 Hazards Classification
NEC-300 Methods and materials
NEC table- Max.wire fill percentage % in conduit or duct bank
9
EEx or Aex Certified as intrinsically safe apparatus (marking)
Ia intrinsically safe for Zone “0” location (marking)
Ib intrinsically safe for Zone “1” location (marking)
UL 1277 Temperature ratings for cable 90deg.C dry and 75deg.C wet
NEMA ICS Enclosures for indoor and outdoor (marking)
6
NEMA Outdoor corrosive area enclosures (marking)
type 4X
ExnA Non sparking (marking)
ExnL Non incendive (marking)
EEx d & Ex Explosion proof (marking)
IEEE 518 Noise susceptibility level(NSL)
ASME Thermowell flange type and size(pipe flange and fittings)
B16.5
ISA Thermocouple shall comply with ISA MC96,1
MC96.1
IEC 60751 RTD shall comply with IEC 60751
NEC Bending radius of cable(8xODfor shielded)(12xOD non-
300.34 shielded)
ANSI Temperature Measurement Thermocouples
MC96.1
NEMA Cable tray material system specification
VE1

2
Meraj | QA/QC Notes
 NEMA Cable tray material installation guideline
VE2
ANSI Chemical plant and petroleum refinery pressure piping
B31.3
ANSI Pressure and vacuum gauges(Indicating dial type)
B40.1
API RP551 Process measurement instrumentation
API RP554 Process instrumentation and control
IEC 79-0 Electrical apparatus for explosive atmosphere.general
requirement
IEC 60529 Classification of degree of protection provided by enclosures(IP)
NFPA 72 National fire alarm code
ANSI/ISA Control valve response measurement from steps input
TR75.25.02
UL 94 thickness of terminal block, High strength material
ANSI/ISA Recommendations for the Preparation, Content, and
RP12.2.02 Organization of Intrinsic Safety Control Drawings
ISA RP12.6 Wiring Practices for Hazardous (Classified) Locations
Instrumentation Part 1: Intrinsic Safety

MANIFA ARAMCO [SAIPEM]

Interview questions

1. Signal cable grounded at both end true or false?

Ans false

2. What is the maximum permissible seat leakage rate of class IV control valve as per FCI 70.2?
Ans --0 .01% of rated capacity

3. Why flow measurement calculated in squire root?

Flow varies directly as the square root of different pressure F = K square root of D/P. Since this flow varies
as the square root of differential pressure the pen does not directly indicate flow. The flow can be determined
by taking the square root of the pen. Say the pen reads 50% of chart.
4. On top of orifice plate which is not mention?
D .Dia of the pipe
4a.Grounding resistance for substation grid should be less than?
Ans- 1 ohm
5. What shall be the cable radios of fiber optic cable?
Ans. 10 times of the cable diameter
6. How the transmitters installed in Gas Service?
On gas service the transmitter is mounted above the tapping point because Gases have a property
of self venting and secondly condensate formation.
7. What is mounting height of gas detector?
Ans--.305 mm

2
Meraj | QA/QC Notes
 8. For square edge orifice plate the upstream edge of the orifice must be square and sharp without defect
any sort .so that the beam of light is reflected by the upstream edge when viewed without magnification
TRUE OR FALSE
ANS—TRUE

9. PSIG=PSIA—ATMOSPARIC PRESS. TRUE OR FALSE

Ans –TRUE

9a.what is the maximum spar length of foundation field bus?

Ans-120 meters
10. What is the maximum segment length of foundation fieldbus
Ans—1900 meters
11. What is distance of the tray maintaining from ceiling
Ans-450mm
12. What is the width of marshalling panel?
Ans -900mm
13. What type of battery used in UPS SYSTEM?
Ans-1.lead acid 2.nickal cadmium
14. What is the maximum resistance value accepted when meggoring a cable?
Ans—50 Moms
15. For above grad equipments can be clamp using in grounding installation
Ans- No [clamp not allowed]
16.In a grounded thermocouple the shield can be connected to thermocouple head[ true or false]
Ans –false
17. What is the maximum length of conduit shall be left at each outlet, junction & switch point for splices
connection of fixture?
Ans-6 inch[150mm]
18. What are the suitable means /method of connecting grounding conductors & bonding to electrical
equipment and electrode?
Ans –compression type
19. What is the maximum value in OHM permitted for grounding equipment in industrial area connected
on a single electrode?
Ans –25 ohm
20. In analog signal system supply voltage shall be normally
24 v dc
21. As per NEC, how many degrees bend permitted in conduit installation?
4quarter bend 360 deg only permitted
22. As per NEC what is the maximum number of over current devices allowed in branch circuit panel.
42 [per NEC 408.15]

23. What type of Connectors is to be used for control wiring i

Pin type compression

24 .Fire alarm system shall be installed in accordance with

NEC 760

25. What is the minimum grounding conductor used for equipment grounding?
25 mm2

2
Meraj | QA/QC Notes
26. Flow meter installation shall comply with
API RPI-551

27. What is the type of grounding?

1. Safety grounding for person 2.circuite grounding

28. Explain how you inspect instrument installation?

1.As per approved material and specification ,2.As per location plan , 3.As per P&ID, 4.Mounting
height,5.Impuls tubing installation as per hook up drawing ,6.Tag installation, 7.Orientation of transmitter

29. What is the mounting height of the BICON LAMP?

2.4 Meters

30.As a minimum, all pressure devices shall be specified with over-range protection to ______ times the
maximum system operating pressure.

a) 1-1/2
b) 2
c) 3
d) 5
e) 8

31. All pressure instruments installations shall be equipped with _____

a) Vent/Drain valves.
b) Control valve
c) Glove valve
d) Shut down valve
e) Release valve

32. All the field termination cabinets (junction boxes) shall be _____

a) NEMA Type 3
b) NEMA Type 7
c) NEMA Type 4X
d) NEMA Type 9
e) NEMA Type 8

33. Pressure and D/P instruments in liquid or condensable vapor service shall be self-venting (i.e.,
mounted below the process connections) with all impulse lines sloping downward approximately ___
minimum toward the instrument in SAES-J-003

a) 1:12
b) 1:100
c) 1:20
d) 1:40
e) 1:50

2
Meraj | QA/QC Notes
34. Pressure and D/P instruments in gas service shall be self-draining (i.e., mounted above the process
connections) with all lines sloping downward approximately ___ minimum toward the process
connection.

a) 1:20
b) 1:100
c) 1:12
d) 1:40
e) 1:50

35. The loop document / Package shall at least comprise of the follow:
a) Instrumentation Calibration Records
b) Instrument Data Sheets
c) Instrument Loop Diagrams
d) Piping and Instrument Diagram
e) All of the above

36. All cable ties used in the field shall be ____

a) Nylon coated 316 stainless steel
b) PVC coated 316 stainless steel
c) 316 stainless steel
d) Plastic
e) Steel
37. Flow meter Installation shall comply with:

a) API RPI 551

b API RPI 531
c) API RPI 351
d) API RPI 552
e) ASME Sec. IV

38. Acceptable field signals are:

a) 3-15 psi, 4-20 mA, Hart and any Vendor Protocol

b) 0-12 psi, 0-16 mA, 0-5V
c) 0-30 psi, 0-20 mA, Hart
d) 0-15 psi, 0-25 mA, Vendor Protocol
e) None of the above

39. Design and Selection of Process Control & Instrumentation System should include:

a) Suitability
b) Reliability
c) Quality
d) Accuracy & Repeatability
e) All of the above

3
Meraj | QA/QC Notes
40... Instrument & Control system (Outdoor, unsheltered) shall be rated for operation for Outdoor
temperature of:

a) 10 deg. C to 35 deg. C.
b) 0 deg. C to 30 deg. C.
c) 0 deg. C to 55 deg. C.
d) 10 deg. C to 55 deg. C.
e) 0 deg. C to 65 deg. C.

41. At what temperature is Degree Centigrade = Degree Fahrenheit

a) 32
b) 0
c) -40
d) 40
e) 100
42. Rangeability of 10:1 is major requirement in flow measurement. Which of the following method will
be most appropriate?

a) Orifice
b) Positive Displacement
c) Turbine Meter
d) Variable Area
e) None of the above
43. Displacement type instruments may be used for level range up to and including:

a) 1800 mm
b) 1830 mm
c) 1500 mm
d) 2200 mm
e) 3000 mm

44. for temperature measurement requiring maximum accuracy, following shall be used:

a) T/C
b) RTD – 2 wire
c) RTD – 3 wire
d) RTD – 4 wire
e) Filled System Instrument

45. Range of Transmitter is 20 to 100. It is colled:

a) Elevated range
b) Suppressed range
c) Elevated zero range
d) Ultimate range
e) None of the above

3
Meraj | QA/QC Notes
46. For viscous liquid, following orifice shall be used:

a) Concentric
b) Segmental
c) Eccentric
d) Quadrant Edge
e) All of the above

47. Which flow meter is used for No Pressure Loss?

a) Orifice
b) Magnetic flow meter
c) Rotameter
d) Positive displacement meter
e) None of the above

48. in new grass root projects, cable trays extending between the process area and the control room or
process interface building, or trays installed beneath raised computer floors, in control rooms or PIB
shall be sized for a minimum of ___

a) 25% spare space in addition to the installed 25% spare cabling.

b) 40% spare space in addition to the installed 30% spare cabling.
c) 20% spare space in addition to the installed 20% spare cabling.
d) 10% spare space in addition to the installed 15% spare cabling.
e) 15% spare space in addition to the installed 35% spare cabling.

49. Cable tray fill shall comply with NEC Article ___

a) 392
b) 250
c) 500
d) 501
e) 503
50. Instrument Cables from Field Junction Boxes are generally connected to ___ at Control Room

a) Marshaling Cabinets
b) DCS Cabinets
c) ESD Cabinets
d) SCADA Cabinets
e) I/O Cabinets

51. Cable-tags shall be ___ with permanently marked alphanumeric characters:

a) 316 SS
b) 304 SS
c) Plastic
d) Steel
e) Nylon

3
Meraj | QA/QC Notes
52. The minimum size of supply takeoffs for instrument air shall be ____.

a) ½ inch
b) 1 inch
c) 2 inch
d) ¾ inch
e) 1-1/4 inch
53. In instrument air sub header ______ spare takeoff fittings and block valves shall be
Installed on the branch header.

a) 20 %
b) 40 %
c) 25 %
d) 30 %
e) 10 %

54. Fire Alarm systems shall be installed in accordance with NEC Article ____

a) 250
b) 760
c) 384
d) 500
e) 504

55. A conduit outlet box (e.g., GUAT) shall be installed within _____ inches of the field device

a) 12
b) 6
c) 18
d) 30
e) 10

56. All fasteners (i.e., nuts, bolts, washers, etc.) used to connect and assemble the cable tray system shall
be ____

a) 304 SS
b) 316 SS
c) Both a & b
d) Galvanized Steel
e) None of the above

57. The minimum size for multi-pair/triad cable should be ____

a) 12 AWG.
b) 18 AWG.
c) 16 AWG.
d) 10 AWG.
e) 8 AWG.

3
Meraj | QA/QC Notes
58. The minimum sizes for process sensing tubing (impulse line) shall be ____
a) 1/2 inch
b) 1/8 inch
c) 1/4 inch
d) 1 inch
e) 1-1/4 inch

59. The slope of all main and branch headers for instrument air shall be _____2.5 inches per 100 feet
b) 2.5 inches per 100 feet[64mm for every 30 meter]

59 what is the minimum distance between power cable 1000v and control cable under 1000v?
Ans -300mm
60. what is maximum allowable length of impulse tubing?

Ans. 6 mtrs
61. Threaded entries into explosion proof equipment shall be made up with at least __ threads fully
engaged.

Ans -5 threads
62. In Saudi Aramco standard corrosive area pvc conduit installation accepted in above ground?

Ans- false

63.What is the minimum distance for direct buried cable ?

Ans- 610mm

SAIPEM
Interview questions
What is the maximum acceptable length & diameter of the copper jacketed grounded rod as per SAES-
P-111?
Ans. 2.4 M long *16 mm dia
62. In conduit installation system how many threads are fully engaged?

Ans –5 threads

63 .What is wall thickness of SS tubing?

Ans-0.89mm

64.what type of fasners used to connect to assemble to the cable tray in sever corrosive area
Ans -316 SS

65. In ¾ air line how many user are permitted ?

Ans-5 to 9

3
Meraj | QA/QC Notes
66. What is the maximum permissible seat leakage rate of class IV control valve as per FCI 70.2?
Ans --0 .01% of rated capacity

67.what are the two types of grounding ?

m Ans -1personel safety grounding 2.instrument circuit grounding

68. how many foundation field bus device connected to each spur?
Ans –1[one]

69 .what is the color coding of field bus cable ?

Ans –orange

70. What is minimum thickness of red day on the duct bank ?

Ans—5mm

71.what is the maximum distance between each support in rigid metal conduit installation ?
Ans –3 meter

72.how many types of orifice plate ?

1.concentric ,2.eccentric,3.segmental,4.quadrant

73. what will happen if a level transmitter displacer have a hole on it ?

The output is minimum

74.cable tray file shell be comply with ---?

NEC article-392

75. All the field termination cabinets (junction boxes) shall be _____
NEMA Type 4X

76. In the conduit duct bank installation system what is the maximum allowable distance between each
spacer ?
Ans - 2.4 meter

77. What is the color code of analog signal tried cable

Positive –black
Negative –white
Common-red

79. What is QA/QC

QUALITY ASSURANCE /QUALITY CONTROL. Quality Control is the observation techniques and
activities used to fulfill the sequence of requirements for quality

80. What is the gauge pressure?

Above the atmospheric pressure is called gauge pressure

81. What is the minimum size of process sensing tubing?

Ans - ½ inch

3
Meraj | QA/QC Notes
 82. What is the minimum size of multi pair triad cable?
Ans –18AWG

83.Instrument control wires and cable system shell be designed and installed in accordance with?
ANSI/NFPA—70

84. as per SA standard what size of cable is to be used for two hole compression terminal connection
Ans-4/0[5AWG or 16 mm2]

85. In what SAS used for electrical area classification

Ans –SAES-B-68

86. What is PCB stands for ?

Ans—poly chlorinated biphenyl

87. In SAS what type of temperature sensors element used for measuring temperature ?
Ans –RTD & THERMOCUPLE

88.What is the seal liquid used for filling impulse line on crude & viscous liquid ?
Ans—glycol
89.What is the minimum distance for direct buried cable ?

Ans- 610mm

90. What is QMIS?

QULITY MANAGEMENT INFORMATION SYSTEM

                91. Minimum depth of burial for direct buried grounding conductors  
                   
                             460mm 
                92. The power cable tray in Saudi Aramco shall be
                       Ladder tray 
 93. Metallic cable trays shall be bonded at both end points and a minimum of every 
        25M 
94. Low voltage power system at saudi armco shall be solidly grounded TRUE OR FALS 
 
       REUE 
95. WHAT IS THE MINIMUM LENGTH OF GROUNDING RODS  
       2.4 meters
 
               96. The maximum cable fill in a conduit is: 
                       40%
               
               
 
 
             
3
Meraj | QA/QC Notes
 
             97. Insulation resistance of MCB pole to pole, line to load, and pole to ground shall not be less than  
         50 mega‐ohms._ when test voltage 1000 volts DC is applied
 
98.  Minimum grounding conductor size used for equipment connection to ground rods or ground grid
                                               25mm² (#4 AWG)
 
 
99. For a single grounding rod resistance to ground should be less than 
                                               25 ohms
 
100.  The  grounding  resistance  of  made  electrodes  (grounding  rods/or  ground  grid)  used  for  system             
grounding shall not exceed __1 ohm__ for solidly grounded systems above 600V
 
101. What is the outer enclosures drain and breather volume? 
            More than 2000cm3
 
102. The power cable tray in Saudi Aramco shall be 
          Ladder tray 
 
 
 
 
 
 
 
 
 
 

3
Meraj | QA/QC Notes