INSTRUMENT NOTES FOR QA/QC

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 – J-001 (Instrument Index)
2- SAES – J-002 (Regulated Vendor List for Instrument/Technically Acceptable Instrument)
3- SAES – J-003 (Basic Design Criteria)
4- SAES – J-004 (Instrument Symbol and Identification)
5- SAES – J-005 (Drawing and Forms)
6- SAES – J-100 (Flow Measurement)
7- SAES – J-200 (Pressure Measurement)
8- SAES – J-300 (Level Measurement)
9- SAES – J-400 (Temperature Measurement)
10- SAES – J-502 (Analyzer Shelter)
11- SAES – J-505 (Combustible Gas and Hydrogen Sulfide in Air Detection System).
12- SAES – J-600 (Pressure Relief Valve)
13- SEAS – J-601 (Emergency Shutdown and Isolation Systems)
14- SAES – J-700 (Control Valve)
15- SAES – J-801 (Control Building)
16- SAES – J-901 (Instrument Air Supply System)
17- SAES – J-902 (Electrical System for Instrumentation) – Cable tray Noise Susceptibility Levels (NSL)
18- SAES – J-903 (Intrinsically Safe System)
19- SAES – B-006 (Fire Proofing of Cable for Fire Hazardous Area)
20- SAES – B-068 (Electrical Area Classification)
21- SAES – P-104 (Wiring Methods and Materials)
22- SAES – P-111 (Grounding)
23- SAES – P-103 (UPS and DC System)
24- SAES – T-634 (Telecommunications - Cable Testing and Acceptance)
25- SAES – T-796 (Communications Facility Grounding Systems)
26- SAES – T-911 (Telecommunication Conduit System Design)

VARIOUS 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
358 High Density Polyethylene Conduits
360 Flexible Metallic Tubing
362 Electrical Nonmetallic Tubing (EMT)
366 Power and Tray Cable
392 Cable Tray
500/505 Hazardous Location
504 Intrinsically Safe System
700 Emergency System
727 Instrument Cable Tray
760 Fire Alarm System

(QA/QC Engineer) | QA/QC Notes 1

SOME ABBREVIATIONS:
QCP Quality Control Plan
ITP Inspection Test Plan
TQ Technical Query
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
AWC Armor Wire Cable
NEC National Electrical Code
NACE National American Corrosion Engineers
SCADA Supervisory Control and Data Equation
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
ATEX Atmospheres Explosibles
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 Single Wire Armored
MICC Mineral Insulation Copper Conductor
PILC Paper Insulation Copper Conductor
FOC Fiber Optical Cable
OTDR Optical Time Domain Reflectometer
RTA Request for Technical Approval
MTC Material Test Certificate

CABLE SPECIFICATIONS AND CABLE INSTALLATION:

Group – 1: Single Twisted pair/Triad, Unshielded.
Conductor: Stranded, Circular Copper (Material) as per ASTM B8.
Conductor Size: # 16 AWG
Primary Insulation Material: Flame Retardant PVC or XLPO or XLPE minimum temperature rating is 90o C
(NEC 501-4 (b), NEC 502-4 (b).
Primary Insulation Voltage Rating: 300V for Type PLTC and type IT cable, 600V for type TC Cable.
Primary Insulation Thickness: (0.38 mm for PLTC and ITC Cable), (0.64 mm for TC cable).
Shield Thickness: 0.022 mm

Group 2: Single twisted pair/triad shield.

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

(QA/QC Engineer) | QA/QC Notes 2

Group 3: Multipair / Triad, Unshielded or without overall shield thickness 0.022 mm.
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: # 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: ½ inch, ¾ inch, 1 inch, 1½ inch, 2 inch.

Thread Type: ET (Equal Thread), BSP (British Standard Pitch), NPT (National Pipe Thread).

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:

T Type Thermocouple Copper + Constant -185 ~ 371 oC Blue – Red/White

J Type Thermocouple Iron + Constant -190 ~ 750 oC White – Red/White
K Type Thermocouple Cromel + Alumel -190 ~ 1250 oC Yellow – Red/ White
E Type Thermocouple Chromel + Constantan -196 ~ 982 oC Purple – Red/ White
S Type Thermocouple Platinum/Rhodium-Platinum -18.0 ~ 1760 oC Black – Red/ White

(QA/QC Engineer) | QA/QC Notes 3

R Type Thermocouple Pt87/Rh13 + Platinum -17.7 ~ 1704 oC Black – Red/ White
Pulling tension of FOC = 600 Pounds.
Fir Resisting: (CI: Circuit Integrity) Flame Retardant, for transmission of analog or digital signal to instrument
and control systems.
Insulation: Silicon Rubber
Armor: Zinc Coated round steel.
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
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.

Cable Bending Radius (= 10 x Cable Diameter

Tube Bending Radius (= 05 x Tube Diameter

Cable Shield: Prevent Electromagnetic Electrostatic Interference from being endued into the inner wire
conductor.

 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)
 Cable Insulation thickness 0.38 mm PLTC/ITC
 TC Cable thickness 0.64 mm
 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).
 Intrinsically safe system shall be used in zone 0 hazardous area.
 Thermal send have to use in trench before started send bedding.

Guide Lines to identify T/C and T/C Extension wires:

For Extension wires having insulation color as per ANSI MC96.1 (American National Standard Institute). The
negative wire is always RED colored as per ANSI.

CABLE GLAND:
 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
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.

(QA/QC Engineer) | QA/QC Notes 4

 
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:
 Ground rods 2.4 meter minimum length.
 Cathode protection material is used galvanized steel.
 Individual Ground rod maximum resistance should be 2.5 Ohm.
 For copper or copper jacketed steel rods is a minimum of 16 mm2 in diameter or 19 mm2 in diameters.
 Earth Tester is used for measuring of earthling system.
 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.
 Shields and amour of power cables shall be grounded at both ends.
 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,
NEMA VE1, NEMA VE2 and NEMA FG 1 and follow safe practices as described in
NFPA 70E.

(QA/QC Engineer) | QA/QC Notes 5

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 ¼ inch.
 Nonmetallic cable tray permitted in corrosive area. Nonmetallic cable trays shall be made of flame
retardant material.

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 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.

(QA/QC Engineer) | QA/QC Notes 6

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 150 mm
Level 2 to Level 3 gap should be 500 mm
Level 1 to Level 3 gap should be 650 mm

Tray to Conduits:
Level 1 to Level 2 gap should be 100 mm
Level 2 to Level 3 gap should be 350 mm
Level 1 to Level 3 gap should be 450 mm

Conduit to Conduit:
Level 1 to Level 2 gap should be 75 mm
Level 2 to Level 3 gap should be 225 mm
Level 1 to Level 3 gap should be 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.
 Fabricated spacers shall be used at intervals not exceeding 2.4 Meter.
 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.
 Bare copper cable does not used in or on aluminum cable tray.

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
 Bushing
 Cable and duct seal, etc.

(QA/QC Engineer) | QA/QC Notes 7

TIPS FOR CONDUIT INSTALLATION:
 Conduit Expansion fitting shall be provided in indoor 30 Meter.
 Conduit Puller J/B shall be provided every 25 Meter.
 Pull Box to Pull Box maximum bends acceptable in 360 degree without 90 degree bend.
 Support (Bending) does not occur NEC-344
 Pull & JB are Installed & Securely fixed as per NEC-314.28
 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).
Tips: 1- Drain to provide continuous, automatic drainage of condensate.
2- Large openings with threaded closures to provide easy access to conduit hubs for making dams.
3- Integral bushings to protect conductor insulation from damage.
4- Taper tapped hubs to ensure ground continuity.
 NPT type accordance with UL34E 34997 or CSA (Canadian Standard) LR 9795.
 Seal fitting shall not be less than ⅝ inch.
 Sealing compound shall be 35 oC to 85 oF.

Support for Rigid Metal Conduits:

Maximum Distance
Size
between Supports
½” ~ ¾ inch 3.0 Meter
1 inch 3.7 Meter
1 ½” ~ 1 ¾ inch 4.3 Meter
2 inch 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.
Conduit and cable sealing shall be installed in accordance with NEC-5050.10.
Conduit seals shall be installed within 450 mm (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.

(QA/QC Engineer) | QA/QC Notes 8

  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 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 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 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 ⅝ 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 mm (gap max)
 50 oF or 10 oC gap is 9.5 mm (Standard)

DUCT BANK INSTALLATION OR UNDERGROUND CABLE SYSTEM:

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

The minimum depth of burial requirements for underground installations shall be as per:
Direct Buried Direct Buried Duct Bank & Direct Buried
System Voltage
Cable PVC Rigid Steel
600V & Below 610 mm 460 mm 460 mm
600V to 35 KV 920 mm 610 mm 460 mm
Over 35 KV 1070 mm 760 mm 460 mm

IMPULSE TUBING INSTALLATION:

Impulse lines for remote device should be as short as possible, 3 feet for close-coupled transmitters and
preferable not more than 20 feet (6 meters). For liquid measurement the lines should slope down at least 1 inch
per foot from the orifice taps.
Tubing: Stainless steel tubing shall seamless, annealed, minimum wall thick 1.24 mm as per ASTM A269 Gras
IP – 316L.

(QA/QC Engineer) | QA/QC Notes 9

IMPULSE TUBING INSTALLATION TIPS:
Slop of Impulse tubing: Minimum of 1inch for every 1 meter towards tapping point.
Bend: Minimum bends length around 70 mm.
Test Pressure of Impulse Line: 1.5 Times of the working pressure with 3 minute.
Instrument Tubing size: ½ inch x 0.89 mm (wall thickness) = 0.035 Inches.

Piping and Impulse tubing shall be support as follows:

Maximum Distance
Size
between supports
Tube Less than ½ inch 300 mm
½ inch Tube & Pipe 1800 mm
¾ inch Pipe 2400 mm
1 inch Pipe 3000 mm

AIR DISTRIBUTION SYSTEM:

 All main and branch headers shall be sloped {minimum 64 mm per 30 Meter (2.5 inches per 100 feet)}
and provided with low point drains.
 Supply takeoffs to individual instruments (a line serving up to a maximum of four devices) shall connect to
the top of the branch header through a takeoff-line-size, full-bore isolation valve.
 The minimum size of supply takeoffs is ½ inch.
 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.

Air Piping Maximum shall be No of Users as follows:

Pipe Size Maximum No of Users
½ inch 1~4
¾ inch 5~9
1 inch 10 ~ 15
1 ½ 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.
 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 900 mm (36 Inch)
 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
(QA/QC Engineer) | QA/QC Notes 10
  Name Plate shall be made from laminate Plastic, white – Black – White (Information engraved into the
black core) with white surface.

HAZARDOUS AREA CLASSIFICATION:

ATEX: (Atmospheres Explosibles) – It came from Europe’s intrinsic safety regulation, European Union’s
commonly called ATEX. NEC-505 is similar to ATEX.

NEC 500 ATEX

Definitions
Divisions Zones
Zone ‘0’ In which an explosive gas / air mixture is continuously present for long period.
Division 1
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
Division 2 Zone ‘2’
occurs it exist only for short time.

Example 1: Class I (Zone 0 / Division1) 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 Zone–0 or Zone-1 and Ex ‘N’ or ‘n’, Ex ‘o’, Ex ‘q’.
Designation Technique Zone
Ex ‘d’ Flame proof or Explosion proof 1
Ex ‘e’ Increased Safety 1
Ex ‘N’ or ‘n’ None Sparking 2
Ex ‘ia’ Intrinsic Safety 0
Ex ‘ib’ Intrinsic Safety 1
Ex ‘p’ Pressurization 1
Ex ‘o’ Oil Immersion 1
Ex ‘q’ Sand or Powder filled 1
Ex ‘s’ Special Protection 0
GAS GROUP:

Representative Gas IEC USA

Methane I D
(QA/QC Engineer) | QA/QC Notes 11
 Propane IIA D
Ethylene IIB C
Hydrogen IIC B
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. That’s 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
Class I - Explosive gases or vapors are present.
Class II - Combustible dusts are present.
Class III - Ignitable fibers or flying are present.
A location where a hazardous concentration of gases or vapors exists approximately
Division 1 Zone 0
10 ~ 100 % of the time (subject to interpretation as above).
A location where a hazardous concentration of gases or vapors exists approximately
Division 1 Zone 1
1 ~10 % of the time (subject to interpretation as above).
A location where a hazardous concentration of gases or vapors exists approximately
Division 2 Zone 2
0.1 ~ 1 % of the time (subject to interpretation as above).
Group A Group IIC A hazardous atmosphere containing acetylene or other similar gases or vapors.
Group B Group IIC A hazardous atmosphere containing hydrogen or other similar gases or vapors.

(QA/QC Engineer) | QA/QC Notes 12

 Group C Group IIB A hazardous atmosphere containing ethylene or other similar gases or vapors.
Group D Group IIA A hazardous atmosphere containing pentane or other similar gases or vapor.
Group E - A hazardous atmosphere containing metal dust, such as aluminum.
Group F - A hazardous atmosphere containing carbon black, coal, or coke dust.


Q: What does “BASEEFA” stand for …..?
A: British approval service for electrical equipment in flammable atmospheres.

Q: Explain the meaning of: (a) Zone 0 (b) Zone 1 (c) Zone 2 (d) Non-Hazardous.
A: (a) - In which an explosive gas-air mixture is continuously present or present for long period.
(b) - In which as explosive gas air mixture is likely to occur under normal operation.
(c) - 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.
(d) - An area which by implication is any area not classified as zone 0, 1 or 2.
i.e. control or switch room that is pressurized (HVAC) or an area that has no hydrocarbon inventory.

Q: Explain the type of protected equipment is required in the flowing zones: (a) Zone 0 (b) Zone 1 (c) Zone 2
A: (a) – Ex-ia, Ex-s: Must be specifically certified for zone 0 use.
(b) – Any type of equipment suitable for zone 0, Ex-ib, Ex-d, Ex-p, Ex-e.
(c) – Any type of equipment suitable for zone 0 and 1, Ex-n, Ex-o, Ex-q.

EQUIPMENT CLASSIFICATION:

Q: Explain the EEx ‘d’ iiB T6

A: EEx: Electrical Explosion Proof
iiB: Gas Group (Ethan)
T6: 85 oC

Q: Explain the type meaning of Ex-ia and Ex-ib.

A: Ex-ia is equipment that can withstand up to 2 faults in the circuit and still maintain the protection.
Ex-ib is equipment that can withstand 1 fault in the circuit and still maintain protection.

Q: Explain the type meaning of Ex-s.

A: Special protection (Proven by a series of approved tests to suitable for use)

Q: Explain the type meaning of Ex-d.

A: Flameproof (will withstand and internal explosion out damage or allowing any flammable gasses outside the
enclosure to ignite).
Q: Explain the type meaning of Ex-e.
A: Equipment that has been designed to give increases security against the possibility of sparks or excessive
temperatures.

Q: Explain the type meaning of Ex-n.

A: Non sparking equipment.

Q: Explain the type meaning of Ex-p.

A: Pressurization / Continuous dilution (Purge).

Q: Explain the type meaning of Ex-o.

A: Oil Immersion.
Q: Explain the type meaning of Ex-m.
A: Encapsulation / hermetically sealed.

Q: Explain the type meaning of Ex-q.

A: Sand filled.

INGRESS RATINGS:
Q: Explain the meaning of “INGRESS PROTECTION”

(QA/QC Engineer) | QA/QC Notes 13

 A: The appliances ability to keep out solids and liquids, i.e.: Dust, Sand and Water. The first number indicates
the protection against solids and the second number indicates the protection against liquids.

Q: Is it allowable to modify an EEx “d” gland to fit and entry in an EEx “d” enclosure..?
A: No.
Q: State the minimum amount of threads needed to be installed on an Ex‘d’ cable gland..?
A: (1) – 5 full threads (minimum length 8 mm) for gas group 2B apparatus.
(2) – 6 full threads (minimum length 9.5 mm) for gas group 2C apparatus.

TEMPERATURE RATING OF EQUIPMENT:

Q: Explain what is meant by “Temperature Classification of Equipment for use in Hazardous areas”).
A: It is the highest surface temperature that an appliance can attain under the worst condition (incl. overloads)
which is able to produce an ignition of any flammable gasses in the surrounding area.

T1 = 450 oC
T2 = 300 oC
T3 = 200 oC
T4 = 135 oC
T5 = 100 oC
T6 = 085 oC


INSTRUMENTATION 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?

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”. (Complete failure of a system, or controls, which
result in completely unsatisfactory goods or services being provided).

6. What is the Specification?

Ans: Governing Document Acceptance Criteria.

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 of Witness, Surveillance and
Hold Point) etc.
RFI: To conduct the inspection of completed work.
QR (Quality Record): To maintain the quality records of completed works etc.

(QA/QC Engineer) | QA/QC Notes 14

 NCR: To issue warning in case of serious violation of standard.
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 comply 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.
QCO: To issue a warning in case of little violation and observation.
DR: Discrepancy Report.

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 with or violate 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
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 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.
14. 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.
15. 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.
16. What are different kinds of certification?
Ans: Weather Proof.
Dust Proof
Water Tight
Explosion Proof
Flame Proof
Intrinsic Safety Proof etc
(QA/QC Engineer) | QA/QC Notes 15
17. 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.
18. 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.
Zone – 2: A zone in which an explosive gas/air mixture is 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.

19. 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/nonconductive 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 fiber / 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.

20. 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.

21. What is loop check?

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

22. What is the logic gate?

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

23. What is the foundation fieldbus system?

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

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

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

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.

(QA/QC Engineer) | QA/QC Notes 16

 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.

26. 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.

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. 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.

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 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.

31. 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.

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

(QA/QC Engineer) | QA/QC Notes 17

 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.

35. 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.
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.
37. 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.
38. 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.

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 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.

40. 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.
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. What are the responsibilities of QC Inspector?
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.

(QA/QC Engineer) | QA/QC Notes 18

 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. 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.

46. 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.

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

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 equipment’s required for the execution of the project.

49. 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.

50. What are QCP, QMP and ITP?

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

51. 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.

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

(QA/QC Engineer) | QA/QC Notes 19

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. 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.

55. What would be the thickness of the top layer of a Duct Bank and color?
Ans: 5 mm and Red Dye.
56. What is the purpose of using paint/dye on top layer?
Ans: To give an anticorrosive protection, top layer painting is provided.

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. 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.

60. 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.
61. 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.

62. 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.

63. 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.

64. 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 function any system is known as hazardous area (NEC Art 500 –
510).

65. How are the hazardous and nonhazardous areas classified?

Ans: Hazardous and non-hazardous areas are classified according to the classifications and zones.

66. What is the Expansion joint? What should be the standard gap maintained in expansion joint?
(QA/QC Engineer) | QA/QC Notes 20
 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. How the metallic cable trays grounded?

Ans: Metallic cable tray shall be bonded at both end points and minimum of every 25 meter local ground
grid or ground electrode or to structural steel bonded to local ground grid or ground electrode.

68. 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.

69. How many connection points required for equipment ground?

Ans:
a) For equipment’s 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.

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

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

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. 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: WI thought Terminal block.

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. What is a Mandrel testing?

Ans: Testing of underground duct bank or sharp bend.

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

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

Ans: Bell end fitting or protective bushings.

78. 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.

79. What is the minimum conduit size excepted for instrumentation wiring inside building?
Ans: ¾ Inch.

80. What is the minimum conduit size excepted for prefabricated skids and in-industrial area?

(QA/QC Engineer) | QA/QC Notes 21

 Ans: ½ Inch.

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

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

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. 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.

84. What is the minimum distance from main door to marshaling panel?
Ans: Minimum shall be 3 meter from main door to marshaling panel.

85. What shall be the slop for impulse line?

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

86. What shall be having extra length for unistrut support?

Ans: 40mm should be extra.

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

Ans: 1.5 times of the working pressure.

88. What shall be minimum acceptable insulation resistance of instrument cable during Megger Test?
Ans: 100 Mega ohms

89. 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.

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. What shall be the maximum pulling tension of FOC?
Ans: 600 Pounds.
92. What is name of fieldbus communicator?
Ans: FBT6 (Fieldbus Transducer 6)
93. What is the Principle of Bimetal Thermometer?
Ans: Different Metal of Different Coefficient.

94. What is the color coding for accepted instrument or rejected instruments?
Ans:
Blue - Pre-installation Test (Calibrated)
White - Test Fail (written message may be added giving reason failure)
Red - Pre-commissioned
Green - Cable Test (Megger)
Yellow - Pressure Test

95. How do you calculate new factor from new range using old factor and old range?
Ans:
(QA/QC Engineer) | QA/QC Notes 22
96. Definition of Instrument Range and Span?
Ans:

97. Calculation of Resistance or Pt100?

Ans: Ro = 100 Ω
X for platinum = 0.00385 / C
To calculate resistance at 100 oC
R100 = 100 [1 + (.385 x 100)]
= 100 + (100 x 0.385)
R100 = 138.5
Resistance at 100 oC = 138.5 Ω

98. Calculation of oC to oF?

Ans:

99. Calculation of oF to oC?

Ans:

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

Ans: D = dm {1 + 0.55 (dm) 2 / dh}
Where: dm = Measured diameter of orifice
dh = Drain hole diameter
d = Corrected diameter orifice size

101. What is CV of a valve?

(QA/QC Engineer) | QA/QC Notes 23
 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. Why does control valve operate at is PSI?

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

103. How to calculate the Accuracy of Instrument?

Ans:

104. How to calculate the Resistance of Cable?

Ans: Generally voltage drop calculation is done for selecting the cable size for particular motor and the
distance involved. As distance increases voltage drop occurs due to increase in resistance of
cables for reason we should find the voltage drop.

105. How to calculate the Level Calculation?

Ans:
Elevation& Suppression:
LRV = Elevation – Suppuration
URV = Range – Suppuration + Elevation

Suppuration Calculation:
Span = Range – Suppuration = 100% {Range = 27.422}
LRV = Suppuration = 0% {Suppuration = 30.316}
URV = Span = 100 % Span / 4 = 25 %
0% -30.316
25% -23.460
50% -16.605
75% -9.749
100% -2.894

Elevation Calculation:

(QA/QC Engineer) | QA/QC Notes 24

 Span = Range + Elevation = 100% {Range = 5.814}
LVR = Span = 100% {Elevation = .971}
URV = Elevation = 0% Span / 4 = 25%
0% 0.971
25% 2.424
50% 3.878
75% 5.331
100% 6.785


ELECTRICAL QUESTION AND ANSWER

What is the Transformer?

Transformer is one kinds of electro static device which transformer energy from winding to another winding by
electromagnetic induction effect without changing frequency.

H. T. Motors?
Motors working with voltage with voltage 3.3KV and above are HT motors. This motor normally used for high
loads are the operating current can be reduced. Normally these motors are connected. These motors are having
some special cooling arrangements like forced air cooling, condenser type cooling in which water is circulated to
cool the temperature inside. Instead of a ball bearing, sleeve bearing are also used. For cooling the bearing,
separate oil is used.

The Following protection normally used:

1. Instantaneous over current: Settled normally 10 times the rated current. Operates only during short circuit.
2. Thermal overload relay: Set normally at 110% rated operates at motor overload.
3. Locked rotor prolonged start protection: Set normally at 125% the rated operates when the load got
jammed. Set at normal starting time 2 Seconds.
4. Negative phase sequence: Set normally at 25% the rated operates when phase unbalance occurs and
single phasing. (One phase failed).
5. Earth Fault: Set normally at 20% the rated operates when fault occurs between phase and earth.

Over Current relay, Ground fault relay: These are intended for detecting faults in the electric system connected
with the Transformer. A fault in the Transformer results in the function of these relays, which is always
accompanied by the actuation of protective devices of the Transformer.

Illumination: The illumination is defined as the luminous flux received per unit area.

Overload Relay Setting: Overload protection given for almost all motors. The overload relay setting will be of
110% in general.

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.

(QA/QC Engineer) | QA/QC Notes 25

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.

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.

(QA/QC Engineer) | QA/QC Notes 26

2. Why the oil samples test shall be taken from the transformer?
Ans: To check the conductivity, analyses and characteristics of the oil.

3. 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.

4. 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.

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

Ans: 5 Amperes.

6. 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.

7. Find out the full load current of a Single Phase motor 220 volt 600 watts?
Ans: I = P/V = 600/220= 2.727 Ans.

8. What are the main protections is required for a motor?

Ans: Over Current (Inst.), Thermal Over Load, Stalling Relay (Armature Jam), Earth Fault, Negative
Sequence, Temperature.

9. Why do you use a thermal relay in a starter?

Ans: When winding temperature high then thermal relay active.

10. How do you check whether the winding of a motor is good or bad?
Ans: WR (Winding Resistance), IR (Insulation Resistance).

11. Why should ground all electrical equipment?

Ans: To prevent the earth fault.

12. What are the two method of winding connection in 3-Phase motors?
Ans: Star Winding & Delta Winding.

13. What is the liquid in the battery called?

Ans: Lead Acid (H2S04) & Alkaline.

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

(QA/QC Engineer) | QA/QC Notes 27

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:

21. How to find the motor speed and write equation?

Ans:

22. Transformers Transformation Ration?

Ans:

23. What is the PI and how can found the PI value?

Ans:
PI = Polarity Index

PI = Current Value ten minute / Current Value one minute

24. Which kind of motor it’s required to check the PI value?

Ans: It’s required more than 100 KW motor.

25. What is the breather, Details about the Silica Get?

Ans: It is a small container, contains silica gel and oil. It absorbs the moisture from the atmospheric air
and allows the fresh air to the conservator.
26. What is the meant by short circuit braking current?
Ans: The rated short circuit breaking current of a circuit breaker is the highest value of short circuit
current which a circuit breaker is capable of breaking under specified condition of transient recovery
voltage and power frequency voltage. Expressed in K. A. RMS at contact separation

27. What is meant by short circuit making current?

Ans: Rated Making Current = 1.8 x root 2 x rated short circuit breaking current.
= 2.5 x rated short circuit breaking current

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
(QA/QC Engineer) | QA/QC Notes 28
 29. What is the different between star and delta connection with types of motor?
Ans:

30. Star Delta connection with 3 Phase Induction Motor?

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.

31. Why does control valve operate at IS psi?

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

1 PSI = 27.74”H2O
1Kg/cm2 = 14.223 PSI
1 Bar = 0.145 PSI
Kg/cm2 = 10000 mm of H2O
1 Bar = 1.0197 Kg/cm2
1 Kg/cm2 = 0.98 Bar
1 Torr = 1 mm of Hg
(QA/QC Engineer) | QA/QC Notes 29
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) 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, 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).

(QA/QC Engineer) | QA/QC Notes 30

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

Additional Question from daelim.

1. Please explain the required equipments, Tools and Consumables for Cable Pulling?

Ans: Wench (Motor) or Tagger (Motor), Lubricant Compound, Rop

2. Please write full description of the following abbreviations?

1) GIB
2) GIS
3) IPB

Ans:

3. Please choose and fill related item from the Illustration?

Illustration
1) Mark 87 a) Frequency Protection
2) Mark 50/51 b) Under Voltage Protection
3) Mark 64 c) Over Current Protection
4) Mark 27 d) Earth Fault Protection
5) Mark 81G e) Differential Protection

Ans: 1 = e, 2 = c, 3=? , 4 = b, 5=?

4. Please choose and fill related item from the Illustration?

Illustration
1) Chico Compound a) MIG Welding
2) EXP – D b) EYS, EYD
3) Stress-Cone, 3M, Raychem c) Arc Welding
4) Aluminum Bus d) Cable Termination Kit
5) Carbon Steel Bracket e) Flame Proof Type

Ans:

5. Please fill the applicable material to the following work?

1) Cable Entry Hole or conduit Stub-up shall be sealed with …………………. After completion of cable
work?
2) Explosion proof seal fitting to be filled with…………………………………………..?
(QA/QC Engineer) | QA/QC Notes 31
 Ans:

6. Please write the name of termination tools for cable (more than 5 items)?
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. What is the free space in one conduit?

Ans: As per NEC chapter 9
1 Cable should be 53 %
2 Cable should be 31 %
3 Cable should be 40 %

10. Illumination Test as per which standard?

Ans:

11. Torque Value as which standard?

Ans:

12. What is the different between guide clamp and holding clamp?
Ans:

(QA/QC Engineer) | QA/QC Notes 32