Static Inspector Q&A – By Duruper

1. RT Selection (Radiographic Testing selection)

• Based on weld joint category, material thickness, and service requirements.

• Selected as per ASME Section VIII or project specs.

• Critical joints (e.g., Category A longitudinal seams) often require 100% RT.

• Thicker sections and pressure-retaining welds get higher RT coverage.

2. PUSHT

• Pressure, Utility, Service, Hydro, Tightness — sequence of pre-commissioning tests for

piping/equipment.

• Ensures all systems meet integrity requirements before commissioning.

3. Inspector responsibilities (static equipment)

• Verify fabrication & installation as per approved drawings/specs.

• Witness & record all hold points (material inspection, fit-up, welding, NDE, hydrotest).

• Check alignment, levelness, and plumbness of equipment.

• Ensure all documentation, certificates, and test reports are complete.

• Verify safety & quality compliance before handover.

4. Bolt torquing

• Use calibrated torque wrench or hydraulic tensioner.

• Follow manufacturer’s bolt tightening sequence & torque values.

• Perform in multiple passes (e.g., 30%, 60%, 100% of final torque).

• Cross-pattern tightening for uniform gasket compression.

5. RT Requirement

• Defined in project specs / ASME codes.

• Factors: joint category, thickness, material, service type.

 • API 650 / ASME VIII often specify % of welds to be RT.

6. PUSHTT requirement

• PUSHTT = Pressure, Utility, Service, Hydro, Tightness, Test.

• Requirement: complete all mechanical work, clean system, isolate sections, and fill/pressurize as
per spec.

7. Equipment alignment

• Level and align using precision tools (spirit level, laser).

• Check verticality for columns/towers.

• Check nozzle orientation and flange face alignment.

• Verify tolerances as per API/ASME.

8. Types of material inspected

• CS (Carbon Steel)

• SS (Stainless Steel)

• Alloy Steel (Cr-Mo, etc.)

• Duplex / Super Duplex SS

• Non-ferrous (Aluminum, Copper, etc.)

9. Types of tanks & commissioning

• Types: Fixed Roof, Floating Roof, Spherical, Horizontal Cylindrical, Cryogenic Tanks.

• Commissioning:

1. Final inspection & cleaning

2. Leak test / hydrotest

3. Drying & inerting (if required)

4. Initial filling procedure as per API 650/620.

10. ASME Codes (common for static equipment)

 • ASME Section VIII – Pressure Vessels

• ASME Section IX – Welding qualifications

• ASME Section V – NDE methods

• ASME B31.3 – Process Piping

11. Type of preservation

• Dry preservation (desiccants, nitrogen purge)

• Wet preservation (inhibitor fluids)

• Mechanical preservation (rotation of shafts, covering openings)

12. Different types of pressure vessels

• Vertical / Horizontal pressure vessels

• Reactors

• Columns / Towers

• Heat exchangers

• Air receivers

13. Installation procedures (static equipment)

• Check foundation readiness & anchor bolt positions.

• Rigging & lifting with approved method statements.

• Align and level equipment.

• Install nozzles/flanges with correct gaskets & torque.

• Connect to piping without imposing stress.

14. Construction requirements

• Comply with approved drawings/specifications.

• Follow welding, NDE, and inspection plans.

• Maintain traceability of materials.

• Ensure safety and quality control at all stages.

15. Storage tank types

• API 650: Welded tanks for oil storage (fixed/floating roof).

• API 620: Large low-pressure tanks.

• API 653: Tank inspection & repair standard.

• Cryogenic tanks for LNG/LPG storage.

 RTR Inspectors Q&A – by Duruper

1. What is RTR?

• Full form: Reinforced Thermosetting Resin.

• Definition: A type of piping system made from thermosetting resin (e.g., epoxy, polyester, vinyl
ester) reinforced with glass fibers.

• Use: Common in offshore, chemical, and industrial plants for corrosive fluids due to high
corrosion resistance, low weight, and durability.

• Advantages:

o Corrosion resistance

o Lightweight

o Long service life

o Low maintenance

2. Process of RTR Inspection

A. Material Receiving Inspection

1. Verify Material Test Certificates (MTC) from manufacturer.

2. Check markings: pipe size, pressure class, resin type, manufacturer’s name, batch no.

3. Inspect for transit damage — cracks, delamination, blisters.

B. Pre-Installation Inspection

1. Verify pipe storage condition (away from direct sunlight, well-supported).

2. Ensure no sharp bending or point loads.

3. Check that tools and equipment for cutting/jointing are approved.

C. Installation Inspection

1. Joint Preparation

o Ends must be clean, square, and free from dust/oil.

o Check chamfering as per manufacturer spec.

2. Adhesive Mixing

o Verify correct resin/hardener ratio.

o Ensure pot life is within limit.

 3. Lamination or Adhesive Bonding

o Check proper glass mat/resin wrapping in lamination joints.

o Maintain curing time & temperature.

4. Alignment

o Check for correct alignment before bonding.

o Gap within tolerance.

D. Curing & Post-Installation

1. Verify curing time before handling or hydrotest.

2. Inspect for voids, cracks, or incomplete bonding.

3. Confirm supports are installed per drawing.

E. Pressure Testing

1. Normally hydrotest at 1.5 × design pressure.

2. Gradual pressurization and hold for specified time.

3. Check for leaks, bulging, or delamination.

F. Final Documentation

• Installation report

• Adhesive batch records

• Inspection & Test Reports

• Test Certificates
 Rotating Inspector Q&A from past interviews – By Duruper

1. Process of material inspections

• Verify MTCs (Material Test Certificates) against project specs.

• Check visual condition (no damage, corrosion, dents).

• Confirm dimensions & tolerances as per drawings.

• Inspect surface finish, coating/painting quality.

• Ensure correct markings/identification (serial no., tag no.).

• Witness NDE (if required) — PT, UT, MPI, etc.

• Approve and sign off inspection reports before installation.

2. Process of installation of pump

• Verify foundation readiness (levelness, dimensions, grouting).

• Place baseplate on foundation with shims for leveling.

• Grout and allow curing as per manufacturer instructions.

• Mount pump and motor as per GA drawing.

• Perform initial alignment (rough alignment).

• Connect piping with proper supports (avoid strain).

• Final precision alignment after piping completion.

• Tighten bolts to specified torque.

3. Which capacity use pump or compressor

• Pump → for liquids (capacity based on flow rate [m³/hr or GPM], head [m], and fluid properties).

• Compressor → for gases (capacity based on volumetric flow [m³/hr] or mass flow, discharge
pressure, and gas type).

• Selection depends on fluid state, required pressure, and application.

4. What is the process of commissioning

• Pre-commissioning checks:

• Verify installation records & alignment.

• Check lubrication oil levels & cleanliness.

 • Ensure all bolts are torqued, guards installed.

• Confirm electrical connections.

• Dry run (no load) to check rotation direction & vibrations.

• Load runs as per manufacturer’s start-up procedure.

• Monitor temperature, vibration, pressure, flow.

• Record all parameters and hand over with commissioning report.

5. Process of alignment of pump or compressor

• Use dial gauge or laser alignment tool.

• Check soft foot and correct before starting alignment.

• Perform rough alignment during installation.

• After piping is connected, perform final alignment.

• Measure both vertical and horizontal offset & angular misalignment.

• Adjust using shims and lateral moves.

• Ensure tolerances meet API / manufacturer specs.

6. Explain NCR (Non-Conformance Report)

• NCR is a formal report raised when work, material, or process does not meet project
specifications, codes, or approved procedures.

• Documents the issue, evidence, and corrective action required.

7. When we raise NCR?

• Material received is damaged or wrong specification.

• Installation not as per drawing or procedure.

• Test results not meeting acceptance criteria.

• Any deviation without approved concession.

8. What is job responsibility? (For rotating equipment inspector)

• Ensure installation is as per approved drawings & procedures.

• Witness inspections at every stage (foundation, installation, alignment, testing).

• Verify material certificates and inspection records.

 • Coordinate with construction, QA/QC, and vendors.

• Ensure safety and quality compliance.

9. What is preservation?

• Set of activities to protect equipment during storage or before commissioning.

• Examples:

o Filling pump casing with preservation oil.

o Periodic shaft rotation to avoid bearing damage.

o Covering openings to prevent ingress of dust/moisture.

o Maintaining nitrogen blanket for certain equipment.

10. Installation of pump and motor while erection

• Verify foundation & baseplate leveling.

• Set pump & motor in place with proper shimming.

• Bolt down as per torque requirements.

• Perform rough alignment.

• Connect coupling guard temporarily removed for final alignment.

• Final alignment after piping connection.

• Reinstall coupling guard and complete checklist.

11. Alignment of pump (summary)

• Check soft foot → correct.

• Measure initial readings → calculate required shimming.

• Adjust vertical (by adding/removing shims) and horizontal (by moving motor sideways).

• Re-check until readings are within tolerance.

• Tighten bolts and verify no shift in readings.

 Piping Inspector Q&A – By Duruper

1. Difference between torquing and tensioning

• Torquing → Tightening bolts using a torque wrench to apply rotational force (torque) so that bolt
tension is achieved indirectly.

• Tensioning → Applying direct axial stretch to the bolt using hydraulic tensioners; gives more
accurate and uniform preload.

• Key difference: Torquing twists; tensioning pulls. Tensioning is usually for large-diameter/high-
pressure flanges.

2. Before hydrotest — what to check

• Piping installation complete & supports in place.

• All welds completed, inspected, and accepted (RT/MPI/PT).

• All branch connections, vents, and drains installed.

• Flange bolts tightened to spec.

• Temporary blinds installed as per test limits.

• Instruments and sensitive equipment removed or isolated.

• Test pressure calculated as per ASME B31.3 (1.5 × design pressure, adjusted for temp).

• Calibration certificates for pressure gauges.

• Safety barricades and signage in place.

3. ARAMCO standard to tell (common ones for piping inspection)

• SAES-L-105 – Piping Fabrication, Inspection, and Testing.

• SAES-L-150 – Hydrostatic Testing of Plant Piping.

• SAEP-1160 – Welding Inspection Requirements.

• SAES-H-101 – Painting and Coating Requirements.

• SAMSS-001 – General Piping Requirements.

4. What are piping materials

• Carbon Steel (ASTM A106, A53, A234, A105, etc.).

• Stainless Steel (ASTM A312, A403, etc.).

• Alloy Steel (ASTM A335, A182, etc.).

 • Non-metallic (GRE, HDPE, PVC) — depending on service.

5. What are insulation kits

• Sets of insulating sleeves, washers, and gaskets used in flanged joints to prevent galvanic
corrosion or electrical continuity between dissimilar metals.

• Common in cathodic protection systems, offshore, and underground pipelines.

6. Procedure to carry out after hydrotest

1. Depressurize test section slowly.

2. Drain test water completely (dispose as per environmental rules).

3. Dry out the system (air blowing, nitrogen purging if required).

4. Remove blinds and reinstall permanent items.

5. Restore instruments and valves.

6. Perform visual re-inspection for leaks or damages.

7. Prepare and sign off hydrotest report.

 Mechanical Welding Inspector Q&A – by Duruper

1. Hydrotest procedure

• Ensure fabrication is complete & NDE done.

• Install blinds to isolate test section.

• Fill with water (de-aerated if required).

• Raise pressure gradually to test pressure (as per B31.3 = 1.5 × design pressure × temp factor).

• Hold for minimum duration (usually 10 min) & check for leaks/pressure drop.

• Depressurize slowly, drain, and dry.

2. B31.3

• ASME B31.3 → Process Piping Code.

• Covers design, fabrication, examination, testing, and inspection for piping in process plants.

3. Material receiving inspections

• Check quantity, size, and markings.

• Verify Material Test Certificate (MTC).

• Confirm heat number and traceability.

• Inspect for damage/corrosion.

4. What is MTC

• Material Test Certificate: Document issued by manufacturer showing chemical composition,

mechanical properties, and test results per standards (EN 10204 Type 3.1, 3.2).

5. What is NCR

• Non-Conformance Report — issued when work/material deviates from approved spec, code, or
drawing.

6. Stages of ITP

• H (Hold) — inspection cannot proceed without inspector.

• W (Witness) — inspector must be present but work can proceed if missed.

 • R (Review) — documents/data reviewed after work.

• S (Surveillance) — random monitoring without notice.

7. LTCS

• Low Temperature Carbon Steel — e.g., ASTM A333 Gr.6 — used in cryogenic/low temp service.

8. SS Welding

• Requires control of interpass temp, correct filler metal, purging for root pass, and avoidance of
contamination.

9. How is purging checked and calculated

• Checked using oxygen analyzer (O₂ < 0.5% or per WPS).

• Purge time = (Pipe volume × purge factor) / gas flow rate.

10. Hydro test process (same as #1 but short)

• Fill → Pressurize → Hold → Inspect → Depressurize → Drain/Dry.

11. Purging — how to perform

• Seal ends with purge dams/tape.

• Introduce inert gas (argon/nitrogen) into root area.

• Monitor oxygen level until acceptable limit.

• Weld while maintaining purge gas flow.

12. PWHT detail

• Post Weld Heat Treatment: Controlled heating after welding to relieve residual stress and
improve toughness.

• Done at specific temp (e.g., 600–700°C for CS) for specified soak time based on thickness.

13. What is porosity

• Small cavities/voids in weld metal caused by trapped gas during solidification.

14. Why porosity happens (causes)

• Moisture in electrode or base metal.

• Improper shielding gas flow.

• Contaminated joint surface (oil, rust, paint).

15. Rate of back purging

• Typically 10–15 L/min (argon) until root shield is stable; then reduced to 5 L/min for remainder.

16. Types to weld SS (stainless steel)

• GTAW (TIG), SMAW, GMAW, FCAW — GTAW preferred for root pass due to cleanliness.

17. Heat input

• Energy per unit length of weld = (Voltage × Current × 60) / (Travel Speed × 1000).

• Too high → coarse grain, too low → lack of fusion.

18. PWHT? (repeat)

• Already explained in #12.

19. Purging — need/why

• Prevents oxidation and sugar formation on root pass.

• Ensures clean, corrosion-resistant welds in stainless and exotic alloys.

20. Which material needs purging

• Austenitic stainless steels, duplex stainless steels, titanium, nickel alloys — any alloy prone to
oxidation during welding.
 Instrumentation Inspector Q&A – by Duruper

1. Types of Instruments

• Pressure instruments – Pressure gauge, transmitters, switches

• Temperature instruments – RTD, thermocouples, temperature transmitters

• Flow instruments – Orifice plate, turbine meter, ultrasonic meter, flow transmitters

• Level instruments – Level switches, transmitters, sight glass

• Control devices – Controllers, recorders, PLCs, DCS panels

• Vibration monitoring – Vibration sensors, analyzers

2. P&ID (Piping & Instrumentation Diagram)

• Shows piping system with equipment, instruments, and control loops

• Symbol legend for instruments

• Tag numbers, line numbers, valve types

• Flow direction and interconnections

3. Valves

• Types: Gate, globe, ball, butterfly, check, diaphragm, control valves, PSV (Pressure Safety Valve),
PZV (Pressure Zero Valve)

• Inspection focus: Material, rating, actuator type, seat leakage, certification

4. Documents to Carry for Installation

• P&ID

• Instrument data sheet

• Loop diagram

• Cable schedule

• Hook-up drawing

• Vendor manual

• ITP (Inspection & Test Plan)

5. Hazardous Area Classification

• Zones:

o Zone 0 – Continuous presence of flammable gas/vapour

o Zone 1 – Likely presence during normal operation

o Zone 2 – Not likely during normal operation

• Explosion-proof (Ex) and intrinsically safe (IS) equipment requirements

6. TAG Information

• Unique ID for each instrument

• Function code (as per ISA standards)

• Service location and loop number

7. PSV & PZV

• PSV: Relieves excess pressure automatically to prevent equipment damage

• PZV: Maintains near-zero pressure in a vessel (often for venting/blanketing)

8. Vibration Sensors

• Used for rotating equipment condition monitoring

• Types: Accelerometer, velocity sensors, displacement probes

• Parameters: RMS velocity, frequency spectrum, peak-to-peak displacement

 Electrical Inspector Q&A – by Duruper

1. Size of cable tray

• Determined by total cable diameter, number of cables, spacing, bend radius, and future
expansion (usually 20–30% spare space).

• As per IEC 61537 / NEMA VE-2.

2. SF6 breaker testing parameters

• Contact resistance (µΩ range).

• Timing test (open/close, trip/close times).

• SF6 gas pressure & leakage rate.

• Insulation resistance (megger).

• Power factor / tan delta test.

• Mechanical operation test.

3. Cable connection criteria

• Correct lug size & crimping tool per manufacturer.

• Clean, oxide-free conductor surface.

• Tighten to torque spec (avoid over/under tightening).

• Use correct gland type (explosion-proof in hazardous areas).

4. Standard of cable

• IEC 60502 (LV/MV power cables).

• IEC 60228 (conductor).

• BS 5467, BS 6724 (armoured).

• IEEE/NEC for US specs.

5. Standard of grounding

• IEC 60364, IEEE Std 80, NEC Article 250.

• Ensure grounding resistance < 1–5 Ω (depends on project spec).

6. Standard of grating (assuming you meant “grating” for walkways)

• ASTM, OSHA 1910.23 for load capacity and safety clearance.

7. Standard of earthing

• Same as grounding (in most contexts).

• IEEE Std 80, IEC 60364.

8. Connection of control device

• As per wiring diagrams and terminal schedules.

• Use ferrules, correct cable numbering, and segregation (control vs power).

9. Cable trays

• Types: Ladder, perforated, solid bottom, wire mesh.

• Material: GI, Aluminum, FRP.

• Must comply with IEC 61537 / NEMA VE-1.

10. Transformers

• Types: Oil-immersed, dry-type, auto-transformer, instrument transformer.

• Tests: Insulation resistance, winding resistance, turns ratio (TTR), oil BDV (for oil type).

11. Substation work

• Civil foundation inspection.

• Equipment installation alignment.

• Cable routing, termination, and testing.

• Earthing network installation & measurement.

12. Oil & Gas experience

• Hazardous area classification (Zone 0, 1, 2).

• Explosion-proof equipment installation.

• Cable sealing and gland selection for gas group.

13. Industrial work experience

• High-load panel installation.

• Cable tray and conduit installation.

• Control and automation wiring.

14. Backup generator

• Pre-commissioning: Fuel, cooling, lubrication checks.

• Load test and automatic transfer switch (ATS) function.

15. Substation GIS (Gas Insulated Switchgear)

• SF6 gas filling and leak check.

• Functional testing of disconnectors, breakers, and protection relays.

• PD (partial discharge) measurement.

16. Transformer type

• Power, distribution, instrument (CT, PT), isolation, earthing transformers.

17. Distribution substation pre-commissioning activities

• Equipment visual inspection.

• Insulation resistance tests.

• Protection relay setting verification.

• SCADA signal testing.

18. IP ratings, hazardous area classification, corrosive

• IP (Ingress Protection) as per IEC 60529.

• Hazardous areas classified per IEC 60079 / NEC 500.

• Corrosive areas require anti-corrosion coated equipment or stainless steel.

19. Thermowell installation inspection activity

• Verify material & size per datasheet.

• Check thread/ flange connection.

 • Orientation and depth per drawing.

20. Termination inspection activity

• Verify lug size, crimping quality, insulation stripping length.

• Torque check on bolts.

• Check numbering/ferrule per cable schedule.

21. Switchgear testing

• Insulation resistance.

• Contact resistance.

• Functional testing of trip/close mechanisms.

• Interlock checks.

• Protection relay secondary injection.

 Communication Inspector Q&A – by Duruper

1. Telecommunication Room Safety

• Access control – only authorized personnel allowed, with sign-in/out log.

• Fire safety – fire-rated walls, fire suppression system (FM200 or similar), smoke detectors.

• Environmental controls – maintain temperature/humidity (typically 18–27°C, 40–60% RH).

• Cable management – avoid trip hazards, maintain clearance from power cables.

• No liquids – prohibit drinks and water sources inside.

• Proper lighting – adequate illumination for work without causing glare.

• Emergency exits – unobstructed, with visible signage.

2. Door Type

• Fire-rated door – minimum 1–2 hours fire rating.

• Self-closing with automatic latch.

• Access control integrated (key card, biometric, keypad).

• Grounded metallic frame to prevent static discharge.

3. Safety Requirements for Network Room

• Static control – anti-static mats, wrist straps for handling devices.

• Proper grounding & bonding – per TIA/EIA-607 standard.

• Separation of power & data cables to avoid electromagnetic interference.

• Cable labeling – both ends, with clear ID.

• Adequate rack stability – racks anchored to floor/wall.

• UPS backup – to ensure safe shutdown in power outage.

4. Telecom Devices (Inspection Focus)

• Patch panels – properly terminated, labeled, tested with continuity tester.

• Switches/Routers – securely mounted, proper ventilation clearance.

• Fiber optic terminations – inspected for cleanliness, proper bend radius maintained.

• Racks & enclosures – locked, with grounding.

• CCTV/NVR equipment – secure mounting, correct cable routing.

• Server hardware – installed per manufacturer’s guidelines, with airflow clearance.

 Coating Inspector Q&A – by Duruper

1. Selection of coating and painting

• Based on service environment (onshore, offshore, immersion, atmospheric).

• Check project specifications and coating manufacturer’s data sheet (MDS).

• Consider surface preparation requirements, operating temperature, chemical exposure, and life
expectancy.

• Select compatible primer, intermediate, and topcoat system.

• Ensure coating system meets ISO/NACE/SSPC standards for the given environment.

2. How to perform the blotter test

• Purpose: Check air cleanliness in blast-cleaned area for oil/moisture contamination.

• Steps:

1. Place white blotter paper 3–12 inches from air nozzle.

2. Blow compressed air for 1 minute.

3. Inspect paper — no oil stains or moisture spots should be visible.

• If contamination is found, air supply must be cleaned/dried before blasting resumes.

3. Procedure of coating and painting

1. Surface preparation (blasting to required Sa grade / profile height).

2. Conduct environmental checks (dew point, humidity, temperature).

3. Blotter test for air cleanliness.

4. Apply primer within specified time window after blasting.

5. Measure WFT during application.

6. Allow curing as per MDS.

7. Apply intermediate/top coats after proper surface cleaning & roughening (if required).

8. Perform DFT checks for each coat.

9. Prepare final inspection & acceptance report.

4. If blasting and painting time exceeded, what will be your action as coating inspector?
 • If maximum allowable interval after blasting (usually 4 hours for steel in humid conditions) is
exceeded:

o Re-inspect surface for flash rust, dust, contamination.

o If rusting or contamination is found, re-blast or perform mechanical cleaning to the

required standard.

o Document NCR if contractor repeatedly fails to apply within time.

5. Which coating systems are used in offshore jackets?

• Three-layer epoxy + polyurethane topcoat for splash/atmospheric zones.

• Fusion Bonded Epoxy (FBE) or High Build Epoxy for submerged zones.

• Thermal Spray Aluminum (TSA) in high-corrosion risk areas.

• Often a zinc-rich primer + high build epoxy + polyurethane finish.

6. What is the minimum time to do primer after blasting?

• As per project spec and manufacturer’s data sheet — but typically within 4 hours (shorter in
humid/coastal conditions).

• Should be before visible rusting occurs.

7. If contractor not taking any action after exceeding 4 hours blasting? Scenario as inspector

• Record the time blasting completed.

• At 4+ hours, re-inspect surface.

• If flash rust/dust present → reject surface preparation.

• Instruct contractor to re-blast to required standard.

• Issue NCR if repeated or if work delays are impacting quality.

8. What to do when DFT is exceeded?

• If DFT (Dry Film Thickness) exceeds manufacturer’s maximum limit:

o Check for curing issues, cracking, or solvent entrapment risk.

o If serious → strip coat from affected area and re-apply.

o If minor → consult coating manufacturer for acceptance/rework procedure.

9. Is WFT necessary or DFT is only required to check?

• Both are important:

o WFT (Wet Film Thickness) → ensures correct thickness is applied during painting.

o DFT (Dry Film Thickness) → verifies final thickness after curing.

• WFT prevents costly rework later; DFT confirms compliance with spec.