Instrumentation Inspection and quality Control Questioner 4, 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 the material , quality of works its inspection and records. 2 What are basic responsibilities of QA/QC person? Ans : To ensure execution of works and comply fully as per standard and approved specs. 3, What are the basic required document for QA/QC personal? Ans:The basic required document for QA/QC personal are as following: ITP: To conduct he quality check(inspection/witness/surveillance) etc. WP: Standard procedure to execute the works. PID: 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 check as per IDS. PP: To ensure that the instrument HOOK-UP: To ensure that the remote connection of pneumatic is done correctly. are installed as per P&ID and PP as per convenience. WIRING DIAGRAMS: To ensure that wiring is done correctly. ILD: To ensure that the sequential wiring is done correctly. IDS/ISS: To ensure that instruments comply with the basic requirement. RFI: TO conduct the inspection of completed work. QR: 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 serious violations of standard.4,What are QA/QC,s ITP,s andQCP ?Give abrief? Ans: ITP-This procedure informs about the kinds of quality check(surveillance, inspection,witness or hold points)means quality of works is being done in proper sequences QCP-This procedure addresses the activity and requirement in details. 5,What is NCR?Why does it need for a QA/QC personal? Ans: NCR means non-compliance report, QA/QC personal have reserve the right to issue a warning if the contractor does not comply or violate with the standard procedure. 6,What are general work procedure(WP)? Ans: The general sequence of activities will be as follow: :Receiving drawing and documents. :Reproduction of drawings. issuing of drawing to site. :New- issuing new revision. :Shreading of drawing. sRer line drawing. :Transmittal of redlines to client(as-built) :Work permit perior to start the work. :Record. 7,What are the common PPE required?Give a brief? Ans:Following are the PPE for a safe and quality works standard procedure; Qualification:Awamess about all kinds of safety std/codes and work procedure.Experience:Qualify the work execution. USE PPE:Proper equipment and tools shall be used to avoid injuries/loss. Safety shoes, Helmet,Glass,Gloves,Ear plug,Harness and proper tools and certified equipments. 8, What is redlining? Briwf its color codding? Ans: In case of any change occurred to the standard approved drawing while thee project is being constructed or testing the relevant drawing will be “red ined” following color codng shall be used for purpose. Red: If any addition required in the drawing. Green: If any deletion is required from the drawing. Blue. If any comment is added. 9, What is difference between inspection (Surveillance), witness and hold point? Ans: Inspection: Work can be execute without clients inspection and it can be inspected some of them if it required. Witness: Work can be execute, without clients inspection and then it can be inspected upon the completion of work. Hold point: Work cannot be execute without clients inspection. 10, What is difference between hazardous and non hazardous area? Ans: Hazardous; \a hazardous location is defined as an area where a potential for fire or explosion exists due to the reasons of flammable gases, liquid or vapors, combustible dust or fiber and flying in sufficient quantities to produce an explosion or ignitable mixture. Non Hazardous: An area where no risk of presence of any kind of explosion.44. What are different kinds of certification? Ans: weather proof, Dust proof, Water tight, Explosion Proof, Frame proof, Intrinsic safety proof etc. 42, What is 1S0? Explain some of its standards? Ans: ISO means International Standard Organization, some of them are 1S0:9001, ISO 9002,ISO 003 etc. 13. What is Zone Classification? Give a brief? Ans: Zone Classification is to define the area of hazards, they are Zone-0: A Zone in which an explosion gas/air mixture is continuously present or present for extended periods, during normal operation. Zone-1: A zone in which an explosion gas/air mixture is not likely to occur in the normal operation. Zone-2: A Zone in which an explosive gas/air mixture is not likely to occur in normal operation and, if it occurs, it will only exit for short time. Zone-0: A zone in which an explosion dust atmosphere is present continuously or for extended periodof time. Zone-14: A zone in which there is likelihood that explosive atmosphere may occur for short periods due to unsettled dust layers. 14, What are area classification? Give brief? Ans::A zone classification is to define the area of hazards, they are as below, Zone-0:A zone in which an explosion gas/air mixture is continuously present or present for extended periods, during normal operation. Zone-1:A zone in which an explosion gas/air mixture is likely to occur in normal operation. zone in which an explosion gas/air mixture is not likely to only exists for a shot Zone-21 occur in the normal operation and,if it occurs ,it time.Zone-10:A zone in which explosive dust atmosphere is continuously or for extended periods of time.. Zone-14:A zone in which there is a likelihood that explosive atmospheres may occur for shorts period due to unsettled dust layé 15, What are area classification 7Give a brief? Ans:As per NEC and NACA, following are the hazards classification, Class1:Location in which flammable gases or vapors may be present in the atmosphere in quantities sufficient to produce explosive or ignitable mixture. Glass‘ gases/vapors are divided into four following groups: GroupA-Present of Acetylene. GroupB-Present of Hydrogen, butadiene,ethylene oxide etc. GroupC-present Ethylene,cyclo-propone,carbon mono-oxide etc. GroupD-Present of gasoline, acetone,butane,propone,alcohol,natural gas(METHANE) CLASS2:Location in which the presence combustible dusts are in the air in sufficient quatity to ignite or explode. Class 2 conductive non-conductive are divided into three as below GroupE-presence of metal dusts(aluminium,magnesium and chemical dust etc). GroupF-Presence of black carbon ,charcoal,coal or coke dust etc. GroupG-Presence of non-conductive dust(foam,starch,combustible plastics etc). CLASS,3: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 hazard are present countinuously or periodically under normal operation condiDivision-2: The hazard are only presents during accidental or abnormal condition. 16, What are the standard height to install the instrument? Ans:-Standard height install the instrument is 14,meters,but it can vary less or more as per locations’s convenience. 47, What are the standard nozzle orientation for process contro! system? Ans(a)Gas service-It should be 45 degree side of the pipe or vertical. ‘A Figure: (b)Liquid service Horizontal or 45 degree below of either pipe. ree 9 | (c)Steam service- Horizontal or above it 45 degree either side of pipe. Figure:- NI 18,What is loop check? Ans:-To ensure that the system wiring from field to control console functioning fine.49, What is different between open-loop or close-loop? Ans:-Open -loop:A loop system which operates direct without any feedback and it generates the out put in response to an input signal. Close-loop :A loop system which uses a measurement of the output signal through feedback and a comparison with the desired output to generate and error signal that is applied to the actuator. 20, What is feed forward and feed back ward control system? i/o 24, What is logic gate? h one or more input voltage but only one output Ans:-A digital logic circuit voltage. 22, What is foundation fi Idbus system? Ans:-A fully digital control system is called foundation fieldbus system. 23, What are meant by FAT,SAT,RAT? Ans:-FAT-Factory acceptance test,SAT-site acceptance test,RAT-Run acceptance test.24, What is micro processor control system? Give a brief of PLC, DCSand SCADA? ‘Ans:-Computer based control processor system is called micro processor system. ‘The brief of PLC,DCSand SCADA are as following: PLC-prgramable logic control system,PLC’s are used in practice with the aim of achieving higher degree of availability or fault tolerance.The types are as follow: Fault tollerent-1 out of 2 system objective: Reduce the probality of losses of production by switching to a stand by system. Fail Safe: 2 out of 2 system objectives : Protect life, the environment and investment by safely disconnecting to a secured “off” position DCS: Distributed Control System. SCADA: Supervisory control and data acquisition. 25, What are inspection point for a tray installation? Ans, Material check as per approved specification, size and type, trays 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. 26. What are inspection points for field instruments with impulse tubing? Ans: Material check as per approved specification, material size and type, installation as per hook up, check line route to avoid any obstruction, check tube bending, and check tube support, compression fittings of ferrules, and then pressure test shall be done. 27, What are inspection point for cable laying? Ans, Material check as per approved material, types and size, meggering, cable routing drawing, completion of cable route( trays, conduit or trenchetc), and cable numbering, cable bending, use of proper tools and equipments for cable pulling. 28. What are inspection points for JB and marshalling cabinats? Ans. Material inspection, size, type as per approved specification, installation hook-up for frame, bracket or stands, fixed properly means shaking free, name plate and tag number. 29, What are standard method of ferrules addressing to and from a JB? Ans. For two side terminal address required which shall be closed to terminal either side and complete information shall be of from side after or before as per left and right side. 30, What are standards of installing a DP Transmitter in GAS service and why? Ans, Installing DP Transmitter in GAS service shall be above the process to avoid the malfunctioning and drain the liquid(condensate)into the process easily. 31. How do you determine the correct installation of flow orifice? Ans. The orifice data shall be punched in the up stream of orifice, the data side shall be in the up stream of flow direction . 32. Explain why shield of signal cable is not earthed on both side? Ans.To avoid the current noise(resonance). 33,What is final RFI?When it shall be raised up? Ans. When the QA/QC department of contractor is satisfied that the work details in the construction RF! is completed ,then request shall be submitted for inspection to the client QA/QC department. 34,What the required document for an inspection? Ans.Following are the required for an inspection: -RFl(request for inspection)-Pand ID for line verification -PP for location ‘Wiring diagram for wiring details -Data sheet for calibration and pressure test -Hook-up etc for remote tubing/air line -QR for maintaining record -WP, work procedure,to check each and every steps as per specification -QCO, for issuing incase of little violation -NCR, for issuing incase of major violation etc. 35,What are the required document for a remote loop folder? Ans. Following are the required document for a remote loop folder, -Loop package check list -ILD(instrument loop diagram) -Instrument loop acceptance record(UR test record) -P and 1D(piping and instrument diagram) -ISS/IDS(ins.spec.sheet/data sheet) -Alarm list -Calibration record(TR) -Cable meger report(primary to pulling) -Cable meger report (secondry after pulling) -Pressure test record(IR) -MC check record(remote loop)(green col -MC punch listLoop check punch list. 36,What are the required document for a local loop folder? Ans. Following are the required document for a local loop folder, -Loop package check list -ILD(if not mechanical loop) -Cable meyger report(primary prior to pulling) if not mechanical loop -Cable megger report(secondary after pulling) if not mechanical loop -Alarm list(if not mechanical loop) -P&ID Iss/IDS -Calibration report(TR) Pressure test record(TR) if required MC check record(local loop)(green color) -MG punch list -Visual check punch list/loop check punch list 37. What is schedule Q? Ans, Schedule Q is attachment to the contract, which is the provision of Quality Assurance and Control, Inspection and Test Plan 38. What are the various levels of inspection? Explain Ans. They are a- Level 0- Document required only, no inspection b- Level-1 Inspection prior to shipping ¢ Level-2 Minimum requirements, pre-inspection meetings, one or more d “in progress” surveillance visitsLevel 3- Same as level 2 except that “in progress” surve inspection shall be in regular basis e- Level 4- Resident Inspector continuously monitor the works -Level inspection for construction phase: a- Hold points(H) The inspection activity will not proceed without the presence of inspector b- Witness Points(W) Inspection activities can be proceeded after issuing RFI. c Review (R) Verification of documentation (NMR) on its correctness as per spec approved drawings d- Surv without Client Inspection jance (S) Inspector has right to conduct random inspection of works 39. What is !TP’s? What are hold and witness point? Ans, ITP mean Inspection 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 cannot proceeded until inspection is done by client Witness Point(W) is the level of inspection that inspection activity can be proceeded without ciient inspection or if ciient is not available as per RFi timing 40. What is RFI ? When an RFI will be raised 7 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 Points.