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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):
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SOME ABBREVIATIONS:
QCP
ITP
TQ
SAEP
SAES
SAIC
SATIP
SATR
SASD
SAIP
SAMSS
SASO
AWC
NEC
NACE
SCADA
ANSI
ASTM
ASME
BS
IEEE
ICEA
IEC
NEMA
NFPA
ATEX
FM
IP
UL
ITC
PLTC
PVC
XLPE
XLPO
HDP
RTD
SWA
MICC
PILC
FOC
OTDR
RTA
MTC
Shield Application:
Helical, Minimum 25% overlap, to provide 100% coverage and electrical isolation from
conductors.
Group 3: Multipair / Triad, Unshielded or without overall shield thickness 0.022 mm.
Communication Wire: Not required if required shall be manufacturers 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: # 16 AWG for signal 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 5 mm 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.
Lugs: Drawing / Color Codes / Ferruling will be done for easy identification with use of lugs. Lugs are two types.
One is crimping type and the other one is soldering type.
Type of Lugs: (1) Shanap Type (2) Pin Type (3) Ring Type (4) U Type
Gland Size: inch, inch, 1 inch, 1 inch, 2 inch.
Thread Type: ET (Equal Thread), BSP (British Standard Pitch), NPT (National Pipe Thread).
COLOR CODE:
AC Supply:
Phase
Neutral
Ground
Black
White
Green or Green with yellow tracer
DC Supply:
Positive
Negative
Red
Black
Signal Pair:
Positive
Negative
Black
White
Signal Tried:
Positive
Negative
Third Wire
Black
White
Red
Thermocouple:
Positive
Negative
TYPE OF THERMOCOUPLE:
T Type Thermocouple
J Type Thermocouple
K Type Thermocouple
Copper + Constant
Iron + Constant
Cromel + Alumel
-185 ~ 371 oC
-190 ~ 750 oC
-190 ~ 1250 oC
Blue Red/White
White Red/White
Yellow Red/ White
E Type Thermocouple
S Type Thermocouple
R Type Thermocouple
Chromel + Constantan
Platinum/Rhodium-Platinum
Pt87/Rh13 + Platinum
-196 ~ 982 oC
-18.0 ~ 1760 oC
-17.7 ~ 1704 oC
Design and installation of power and wiring system for instrumentation 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.
Field Bus Cable shall Comply with IEC 61158-2 (Type A)
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 to be minimum 25 mm2 (# 4 AWG).
For Hazardous & Non Hazardous locations shall be in accordance with BS 6121 or BS 50262.
Cable Gland: Cable glands are used to protect Mechanical damage. To give earth continuity and for
entering it a junction box & MCC etc. For PILC (Paper Insulation Copper Conductor) cables lead
(QA/QC Engineer) | QA/QC Notes
covered are used because in refinery, hydrocarbon gases will damage the PVC insulation, for this
purpose lead cover is used, for these purpose plumbing type glands are used.
In Explosion proof areas double compression glands are used to avoid these gasses entering in the
electric at apparatus.
FASTENER TORQUE VALUE:
M8
14 ~ 16 NM
M10
26 ~ 33 NM
M12
45 ~ 58 NM
SIZING OF CABLE:
0.75 mm2
18 AWG
1.0
mm2
17 AWG
1.5
mm2
16 AWG
2.5
mm2
14 AWG
4.0
mm2
12 AWG
6.0
mm2
10 AWG
10
mm2
08 AWG
16
mm2
05 AWG
25
mm2
04 AWG
35
mm2
02 AWG
50
mm2
1/0 AWG
70
mm2
2/0 AWG
120
mm2
4/0 AWG
GROUNDING SYSTEM:
For copper or copper jacketed steel rods is a minimum of 16 mm2 in diameter or 19 mm2 in diameters.
Underground wire for grounding to wire connections shall be cad weld or thermo weld. Compression
connector shall not be used.
Shields wires shall be grounded only at the one point for the signal cables.
If used for connections of equipment to ground rods or ground grid be minimum 25 mm2 (# 4 AWG)
Metallic cable trays shall be bonded at both end points and a minimum of every 25 Meter to the local
ground grid.
If buried / used for grids or interconnections of ground rods to be minimum 70 mm2 (2/0AWG)
Be copper or copper jacketed steel or galvanized steel or copper jacketed steel shall meet the
requirements of UL 476 (Underwriters Laboratories).
Power Applications: Metal cable trays must be grounded and eclectically continuous systems as per
NEC article 318.
Non-Power Applications: Cable tray systems containing conductors outside the scope of NEC Article
250 (such as communications, data, signal cables, etc.)
TRAY INSTALLATION:
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,
(QA/QC Engineer) | QA/QC Notes
NEMA VE1, NEMA VE2 and NEMA FG 1 and follow safe practices as described in
NFPA 70E.
TIPS FOR CABLE TRAY INSTALLATION:
Cable tray specification shall be per NEMA VE1 the tray shall be per NEMA VE2.
The distance between consecutive rungs shall not exceed 229 mm (9 Inch).
Cable Ties for Vertical Application shall be provided every 18 inch (after one rung).
Cable Tied for Horizontal application shall be provided every 27 inch (after two rungs).
Unless otherwise noted, the support interval shall be not more than 2.4 meters as per NEMA VE1.
For the Vertical Application cable ties must be 316SS with PVC coated.
The open gap between tray/conduit to the instrument maximum 350 mm.
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, Washers etc.
The channel cable tray material shall be copper free aluminum (Aluminum with max of 0.4% copper).
Channel cable tray width shall be 3, 4, or 6 inches with a minimum loading depth of 1 inch.
Nonmetallic cable tray permitted in corrosive area. Nonmetallic cable trays shall be made of flame
retardant material.
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 grater then 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 to Tray Spacing in mm:
NSL
1
2
3
1
0
150
650
Tray to Conduit Spacing in mm:
NSL
1
2
3
1
0
100
450
Conduit to Conduit Spacing in mm:
NSL
1
2
3
1
0
75
300
Tray to Tray:
Level 1 to Level 2 gap should be
Level 2 to Level 3 gap should be
Level 1 to Level 3 gap should be
150 mm
500 mm
650 mm
Tray to Conduits:
Level 1 to Level 2 gap should be
Level 2 to Level 3 gap should be
Level 1 to Level 3 gap should be
100 mm
350 mm
450 mm
Conduit to Conduit:
Level 1 to Level 2 gap should be
Level 2 to Level 3 gap should be
Level 1 to Level 3 gap should be
75 mm
225 mm
300 mm
DUCT BANKS:
Consist of either hot dip galvanized rigid steel or PVC conduit, in case in concrete.
75 mm of concrete from the outside surface of the duck bank to any conduit or reinforcing steel.
The spacers shall provide a minimum conduit separation of 50 mm for 2 inch conduit.
For equipment, devices, or appropriates certified as intrinsically safe, only those that are certified are
category EEx or AEx ia shall be used.
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.
CONDUIT INSTALLATION:
Conduit fittings and accessories include conduits and pull boxes:
Conduit cover and gaskets
Conduit Seal
Conduit Unions and Couplings
Factory Elbows
Drain
Breathers
Plugs
Conduit Connectors reducers
Expansion fittings
Straps and Clamps
(QA/QC Engineer) | QA/QC Notes
Bushing
Cable and duct seal, etc.
Pull Box to Pull Box maximum bends acceptable in 360 degree without 90 degree bend.
All connection of conduit shall be made by the pipe thread with engagement of at least 5 threads in the
effective threaded portion.
The connection part shall be painted by the zinc primer.
When EYS and EZS Series (Explosion proof Conduit Sealing Fittings only).
Tips: 1- Sealing fittings are used to seal cables in conduit entering enclosures; a conduit union shall be
installed between the sealing fittings and the enclosure.
2- Restrict the passage of gases, vapors or flames from one portion of the electrical installation to another
at atmospheric pressure and normal ambient temperatures.
3- Limit explosions to the sealed off enclosure.
4- Limit precompression or pressure "piling" in conduit systems
When EYD and EZD Series (Explosion proof conduit sealing fittings with drain).
inch.
Maximum Distance
between Supports
3.0 Meter
3.7 Meter
4.3 Meter
6.0 Meter
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 degree.
When union cannot be avoided in underground conduit installation, unions shall be protected with heat shrinkable
sleeves.
(QA/QC Engineer) | QA/QC Notes
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 (minimum thickness of PVC 1
mm) 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 hot 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 (minimum thickness of PVC 1 mm) 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 Minimum conduit size shall be 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
ANSI C80.3
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 35 oF to 85 oF
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 Inch.
Conduit seal fitting plug is painted with red color and non-poured seat fitting are painted with green color.
Direct Buried
Cable
610 mm
Direct Buried
PVC
460 mm
600V to 35 KV
920 mm
610 mm
460 mm
System Voltage
Over 35 KV
1070 mm
760 mm
460 mm
Maximum Distance
between supports
300 mm
1800 mm
2400 mm
3000 mm
Twenty percent (20%) spare takeoff fittings and block valves shall be installed on the branch header.
Instrument air piping shall not be pocketed. Instrument air piping shall not be installed underground.
The Piping route shall avoid a harmful effect from a heat source (keep 150 mm minimum distance) and
not be under the process piping and equipment, which is covered by the hot or cold insulation materials.
Maximum No of Users
inch
1~4
inch
5~9
1 inch
10 ~ 15
1 inch
16 ~ 80
2 inch
81 ~ 150
3 inch
151 ~ 300
ENCLOSURES:
Indoors and Outdoors Plant Area:
Indoors: Within the Perimeter of the Process Unit (NEMA 250 / NEMA ICS6)
Outdoor: Outside the Perimeter of Process Area (IP54)
Severe Corrosive Environment (Industrial Area) NEMA Type 4X or IP66.
10
The Cabinet shall be a NEMA Type 1 as per NEMA 250 and NEMA ICS6.
The Marshaling cabinets from the front surface to the surface of rear terminal block, shall not be more
than 46 cm (18 Inch)
A minimum 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.
NEC 500
Division
s
Division 1
Division 2
ATEX
Zones
Definitions
Zone 0
In which an explosive gas / air mixture is continuously present for long period.
Zone 1
In which as explosive gas air mixture is likely to occur under normal operation.
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 2
Example 1:
AEx
ia
IIC
T6
Area classification
Symbol for equipment built to American
Standards
Type(s) of protection designation
Gas classification group (not required for protection
Techniques indicated in NEC 505.6, FPN No. 2)
Temperature classification
Example 2:
TYPE OF PROTECTION:
Zone 0 Ex ia and Ex s (Specifically certified for use in Zone 0).
Zone 1 Any type of protection suitable for Zone-0 and Ex d, Ex b, Ex p, Ex e.
Zone 2 Any type of protection suitable for Zone0 or Zone-1 and Ex N or n, Ex o, Ex q.
Designation
Technique
Zone
(QA/QC Engineer) | QA/QC Notes
11
Ex d
Ex e
Ex N or n
Ex ia
Ex ib
Ex p
Ex o
Ex q
Ex s
1
1
2
0
1
1
1
1
0
GAS GROUP:
Representative Gas
IEC
USA
Methane
Propane
IIA
Ethylene
IIB
Hydrogen
IIC
Carbon Disulphide
IIC
INTRINSIC SAFE METERS:
In hazardous area only I.S. meters such Meggers, Vibration meters and Temperature meters shall not be used
unless the hot permits obtained.
Safety Barriers: (Zenner Barriers) Diode shunt barriers are used in intrinsically safe zone to limit the current and
voltage.
GROUNDING SYSTEM:
Safety Ground Definition: All exposed and non-exposed non-current carrying by the metallic parts that could
be energized its hazards. Thats why all safety ground must connect to the plant
ground system.
Circuit / IS Ground Definition: Reduce the electrical Interruption being the signal transmission.
Signal / Circuit / IS Ground: G + Y (Green + Yellow)
Safety Ground: G (Green)
Comparing NEC 500 to ATEX
ATEX : EX II 2 G EEX ia IIC T4
II designates the tool is approved for all non-mining areas. 2 represents a rating for Zone 1
II 2 G
and above. G designates atmosphere, in this case gas vapors and mist.
EEX
Explosion protection based on European ex-regulation.
ia
The type of protection, the energy in a device is reduced to a safe value.
IIC
Gas Group IIC indicates compatibility with the most dangerous gas group.
Maximum temperature of a surface that may be in contact with the ex-atmosphere under fault
T4
conditions. T4 rating is 35 C.
FM Classification: N.I. Class 1. Div 2, Groups A-D
Non-incendive apparatus, internal energy is limited so a specified atmosphere cannot be ignited
N. I.
by its use.
Class I
For use of gases, vapors and liquids (not dust , fibers of filings)
Certified for use division 2, explosive atmospheres not normally present, may rarely exist for
Div 2
short duration.
Rated for use with explosive gasses as defined y group A-D, including acetylene, hydrogen and
Groups A-D
propane
Note: European ATEX and North America NEC-505 classification are nearly identical excepting the
AEx v/s EEx marking.
Hazardous Location Classifications:
NEC
IEC
Environment
(QA/QC Engineer) | QA/QC Notes
12
Class I
Class II
Class III
Division 1
Zone 0
Division 1
Zone 1
Division 2
Zone 2
Group A
Group B
Group C
Group D
Group E
Group F
Group IIC
Group IIC
Group IIB
Group IIA
-
13
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.
3.
4.
5.
What is non-conformity?
Ans: Non-conformity Non-fulfillment of requirement. (Complete failure of a system, or controls, which
result in completely unsatisfactory goods or services being provided).
6.
14
8.
9.
10.
11.
12.
13.
14.
15
16.
17.
18.
19.
20.
21.
22.
16
23.
24.
25.
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.
PLCs 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.
26.
27.
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.
28.
29.
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.
30.
What are standards methods or ferrules addressing to and from a Junction Box?
Ans: For to side only terminals 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.
31.
32.
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.
33.
17
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:
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.
34.
35.
36.
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 inside the building
or outside pipe rack.
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.
37.
38.
39.
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 emphasis 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 teams 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.
40.
41.
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.
42.
18
Ans: The following are the phenomenal responsibilities 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.
43.
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.
44.
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.
45.
46.
47.
48.
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.
49.
50.
19
51.
52.
What do you know about NEC, NEMA VE1, NEMA VE2, 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 VE1 National electrical manufacture association VE1
NEMA VE2 Deals with cable tray installation specification
53.
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.
54.
55.
What would be the thickness of the top layer of a Duct Bank and color?
Ans: 5 mm and Red Dye.
56.
57.
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).
58.
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.
59.
60.
61.
62.
63.
20
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.
64.
65.
66.
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 VE2 it is after every 20 meter with a spacing (expansion joint) of 25 mm to be
maintained. It sometimes differs, but should not be more for the horizontal length of the cable try.
67.
68.
69.
70.
71.
What is the minimum thickness of concrete from outside surface of the duct bank to any conduit or
reinforcing steel?
Ans: 75 mm
72.
73.
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.
74.
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.
75.
21
76.
What should be done, when union cannot be avoided in underground conduit installation?
Ans: Unions shall be protected with heat-shrinkable sleeves.
77.
78.
79.
What is the minimum conduit size excepted for instrumentation wiring inside building?
Ans: Inch.
80.
What is the minimum conduit size excepted for prefabricated skids and in-industrial area?
Ans: Inch.
81.
82.
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.
83.
84.
85.
86.
87.
88.
What shall be minimum acceptable insulation resistance of instrument cable during Megger Test?
Ans: 100 Mega ohms
89.
90.
What shall be the maximum acceptable attention value of fiber during OTDR test?
Ans: 0.5Db/Km or less for wave length of 1310 nm and 0.3Db/Km or less .for wave length of 1550nm.
91.
92.
93.
94.
22
Red
Green Yellow -
Pre-commissioned
Cable Test (Megger)
Pressure Test
95.
How do you calculate new factor from new range using old factor and old range?
Ans:
96.
97.
98.
Calculation of oC to oF?
Ans:
23
99.
Calculation of oF to oC?
Ans:
100.
101.
What is CV of a valve?
Ans: 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.
102.
103.
104.
105.
24
Elevation& Suppression:
LRV = Elevation Suppuration
URV = Range Suppuration + Elevation
Suppuration Calculation:
Span = Range Suppuration = 100%
LRV
=
Suppuration
=
URV
=
Span
=
0%
-30.316
25%
-23.460
50%
-16.605
75%
-9.749
100%
-2.894
Elevation Calculation:
Span = Range + Elevation = 100%
LVR
=
Span
=
URV
=
Elevation
=
0%
0.971
25%
2.424
50%
3.878
75%
5.331
100%
6.785
0%
100 %
{Range = 27.422}
{Suppuration = 30.316}
Span / 4 = 25 %
100%
0%
{Range = 5.814}
{Elevation = .971}
Span / 4 = 25%
25
Starting Current: Starting current of a induction motor generally will be 6 times the rated current.
Single Phase: One of the supply lines gates disconnected due to rupturing of fuse or open circuit in one of the
three supply connection. In such cases the motor continues to run on a single phase supply of 440V. If the rotor is
locked to its rated full load, it will draw excessive currents on single phasing. The windings get overheated and
damage is caused.
Megger Value: The insulation resistance value of the winding of the motor shall be checked periodically during
preventive maintenance.
For 3.3 KV motor the IR value shall be checked with 1 KV Megger.
For 11 KV motor the IR value shall be checked with 5 KV Megger.
Winding Resistance: The winding resistance of the motor shall be checked during preventive maintenance with
the bridge. The winding resistance of the three windings should be equal.
Earthing:
Generally earthing means non-current carrying metallic part of electrical equips should be earthed to avoid danger
to human fife.
Grid Resistance: Grid resistance means in a industry or building the no. of earth pits joined parallel together to
get a minimum earth resistance value and the value should be less than 1.0 Ohms acceptable in the industry.
Pit Resistance: Individual pit resistance can vary according to the solid resistance and the value can be 5 Ohms
or more than that. But to get a minimum value all the pits should connect in parallel as grid.
Earth Pits: Earth pits are generally used by using charcoal, salt and G. I. pipe of 3 meters in length and 40 mm
diameter.
Another type of earth pits is plate earth electrode and mesh type electrode with copper or GI strip brought out.
Another type in gulf generally used is the solid rod of copper driven straightway into to earth to get minimum value
by driving to a depth of max 6 meters.
Earth Megger: For measuring the earth resistance earth Megger is used and the diagram given below how to
measure the earth resistance.
Safe Earth Resistance: Generally earth resistance of the total grid should be less than 1.0 Ohms which is
acceptable for safe operation in industries.
Ammeter: Load current is measured through ammeter only. In AC lower range are directly can be read through
ammeter kept in series. For larger current transformer are uses for measuring the current.
In DC Power current is measured through a shunt resistance.
Wattmeter: For measuring the power consumed by the circuit (any type of feeder) wattmeter is used and the unit
is in KWH.
Avometer: This AVO meter is used for checking the electrical circuits measuring voltage, current, resistance and
electronic components etc.
Shunt Resistance: In DC circuit is measured through this shunt resistance.
Transducer: They are used to change one varying parameter into other form energy. Like voltage to current to
pneumatic signals etc.
(QA/QC Engineer) | QA/QC Notes
26
Bus Coupler: Where two different bus sections connected through an breaker (ACB or VCB or OCB) so that both
bus section supply can have an alternative feeding arrangement.
1. 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.
2. Why the oil samples test shall be taken from the transformer?
Ans: To check the conductivity, analyses and characteristics of the oil.
27
14. What is the paint name which is the used in grounding cable?
Ans: Vetomens Paints.
15. What is the RPM of a 2 pole 60 HZ motor?
Ans: N = 120f/P = 120 x 60/2 = 3600 RPM
16. If the IR value of the motor winding is very low what would you do to improve it?
Ans: Motor need over hauling.
17. What is the name of the test equipment used to measure the following?
Ans:
Current: Ammeter
Voltage: Voltmeter
Resistance: Ohm
Insulation Resistance: Megger
18. What is the different between primary and secondary cell?
Ans: Primary Cell is Anode (+)
Secondary cell cathode (-)
19. If the current is 15A what will be the size of the cable?
Ans: 6 mm2 or 10 mm2
20. What is the max speed obtained by 3 phase induction motor with normal state supply?
Ans:
28
28. What is range of low voltage and medium voltage and high voltage?
Ans: Low Voltage: 110 ~ 380 VAC
Medium Voltage: 489 ~13.8 KV
High Voltage: 14.6 ~115 KV
29. What is the different between star and delta connection with types of motor?
Ans:
Ans: Star Delta Starter: If the starter winding is directly connected with the supply it will draw
high current to reduce this high current (to control starting current) Star/Delta starter is used.
=
=
=
27.74H2O
14.223 PSI
0.145 PSI
(QA/QC Engineer) | QA/QC Notes
29
Kg/cm2
1 Bar
1 Kg/cm2
1 Torr
=
=
=
=
10000 mm of H2O
1.0197 Kg/cm2
0.98 Bar
1 mm of Hg
Common Things:
Type of Lugs: (1) Shanap Type (2) Pin Type (3) Ring Type (4) U Type
Gland Size: 11 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) or (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:
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, VTs, cts, 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).
(QA/QC Engineer) | QA/QC Notes
30
Please explain the required equipments, Tools and Consumables for Cable Pulling?
Ans: Wench (Motor) or Tagger (Motor), Lubricant Compound, Rop
2.
3.
4.
5.
6.
Please write the name of termination tools for cable (more than 5 items)?
(QA/QC Engineer) | QA/QC Notes
31
Ans:
7.
Please draw the typical 3-wire control circuit with two start-stop push button starters?
Ans:
8.
Please draw the simple forward reversing starter control circuit using Either-or Interlock?
Ans:
9.
10.
11.
12.
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