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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 ABBREVIATIONS :
FM Factory Mutual
IP Ingress Protection
UL Underwriters Laboratories
ITC Instrument Tray Cable
PLTC Power Limited Tray Cable
PVC Polyvinyl Chloride
XLPE Cross Linked Polyethylene
XLPO Cross Linked Polyolefin
HDP high Density Polyethylene
RTD Resistance Temperature Detector
SWA Still Wire Armored
MICC Mineral Insulation Copper Conductor
PILC Paper Insulation Copper Conductor
FOC Fiber Optical Cable
QCP Quality Control Plan
ITP Inspection Test Plan
AWG American wire gauge
| QA/QC Notes 2
Group 3: Multipair / Triad, Unshielded with or without overall shield overall shield thickness
0.022mm.
Communication Wire: Not required if required shall be manufacturer’s standard size,
Insulation same as primary insulation –Orange color.
Group 5: Thermocouple Extension wire conductor – solid thermocouple extension wire as per
ANSI MC 96.1
Conductor Size: 16AWG for singal pair, 18 AWG for multipair.
Color Code: ANSI MC 96.1(Temperature Measurement Thermocouple), (Yellow and Red)
Negative shall be Red color and magnetic
Terminal Block: As per minimum thickness of terminal block shall be 5mm or higher with
Spring type terminal block are not acceptable, Terminal block shall be fire retardant halogen
free, High strength material such as polyamide on equivalent in accordance with UL94.
COLOR CODE:
AC Supply: Phase Black
NeutralWhite
Ground Green or Green with yellow tracer
TYPE OF THERMOCOUPLE :
Design and installation of power and wiring system for instrument shall be in accordance
with NFPA 70 and NEC.
Fireproofing of cable in fire hazardous area shall be in accordance with SAES-B-006.
| QA/QC Notes 3
Shielded cables shall be used as required to reduce Electrostatic noise. The shield shall be
grounded at one point only.
Cable Shield: Prevent Electromagnetic Electrostatic Interference from being endued into the
inner wire conductor.
Field Bus Cable shall Comply with IEC 61158-2 (Type A)
Primary cable installation 350mm we can keep it open with instrument side otherwise have
to provide conduit or tray.
Cable Insulation thickness .38 mm PLTC/ITC
TC Cable thickness = 0.64mm
Light blue color coding shall be used to identify intrinsically safe wiring the preferred
practice is to specify intrinsically safe interconnecting cable with blue outer jacket.
Alternative blue sleeves slipped over the jacket.
At all the points of termination may used to identify I.S. wiring.
If used for connections of equipment to ground rods or ground grid be min 25 mm 2
(#4AWG)
Intrinsically safe system shall only be used in zone 0 hazardous area.
Guide Lines to identify T/C and T/C Extension wires.
For Extension wires having insulation color to American National Standard Institute ANSI C96.1
the negative wire is always RED colored as per American standard.
CABLE GLAND:
For Hazardous & Non Hazardous locations shall be in accordance with BS 6121 or BS 50262
Sizing of Cable:
1mm2 18 AWG 1 mm2
1.5 mm2 16 AWG 1.5 mm2
| QA/QC Notes 4
2.5 mm2 14 AWG 25 mm2
4 mm2 12 AWG 35 mm2
6 mm2 10 AWG 50 mm2
10 mm2 8 AWG 70 mm2
16 mm2 5 AWG 120 mm2
GROUNDING SYSTEM:
Ground rods 2.4M minimum length.
Cathode protection material is used galvanized steel.
Individual Ground rod maximum resistance should be less than 25Ω Ohm.
For copper or copper jacketed steel rods is a min of 16mm in diameter and galvanized
iron 19mm in diameters.
From main grid ground grounding conductor connected trough termite weld and
compression connector after apply boatman paint and tap
Earth Tester is used for measuring of earthling system.
Underground wire to wire connections shall be Caldwell or thermoweld. Compression
connector shall not be used.
Shields and armour of power cables shall be grounded at both ends.
If used for connections of equipment to ground rods or ground grid be min 25 mm 2
(#4AWG)
Metallic cable trays shall be bonded at both end points and a min of every 25m to the
local ground grid.
If buried and used for grids and or interconnections of ground rods be min 70mm 2
(2/0AWG)
Be copper or copper jacketed steel or galvanized steel copper jacketed steel shall meet
the requirements of UL 476 (Underwriters Laboratories).
Power Applications: Metal cable trays must be grounded and eclectically continuous
systems per NEC article 318.
Types of Testing Instruments
Ratio ohmmeter
Double-balance bridge
Single-balance transformer
Induced-polarization receiver and transmitter
Method of Testing
Non-Power Applications: Cable tray systems containing conductors outside the scope of
NEC Article 250 (such as communications, data, signal cables, etc.)
TRAY INSTALLATION :
| QA/QC Notes 5
Cable Tray Installation: The publication is intended as practical guide for the proper
installation of cable system. Cable tray systems design and Installation shall comply with NEC
Article – 392 & 318, NEMA VE 1, NEME VE 2 and NEMA FG 1 and follow safe practices as
described in NFPA 70E.
Conduit Spacing:
NSL 1 2 3
1 0 75 300
| QA/QC Notes 6
Tray to Tray:
Level 1 to Level 2 gap should be 150mm
Level 2 to Level 3 gaps should be 200mm
Level 1 to Level 3 gaps should be 650mm
Tray to Conduits:
Level 1 to Level 2 gap should be 100mm
Level 2 to Level 3 gap should be 150mm
Level 1 to level 3 gaps should be 450mm
Conduit to Conduit:
Level 1 to Level 2 gap should be 75mm
Level 2 to Level 3 gap should be 150mm
Level 1 to level 3 gaps should be 300mm
All metal cable trays, enclosures used for intrinsically safe wiring shall be grounded to
the plant grounding system with a min of # 4AWG copper wire with green insulation.
Cable Tray material shall be galvanized, carbon steel in indoor air condition area.]
Bare copper cable does not used in or on aluminum cable tray.
Channel cable tray width shall be 3, 4, or 6 inches with a minimum loading depth of 1-
1/4 inch.
Cable tray joint fitting name is splice plate
Cable tray Expansion splice plate installed every 18M
Expansion plate moving distance 25mm
Ladder tray used for power cable and for home run cable also using ladder tray
For field run cable channel cable tray using
SS tray are using were fire propping area
Non metallic cable tray permitted in corrosive area. Non metallic cable trays shall be
made of flame retardant material.
Duct Banks: consist of either hot dip galvanized rigid steel or PVC conduit, incase in
concrete.
75 mm of concrete from the outside surface of the duck bank to any conduit or
reinforcing steel.
Fabricated spacers shall be used at intervals not exceeding 2.4m.
The spacers shall provide a min conduit separation of 50 mm for 2 inch and above
conduit.
For equipment, devices, or appropriates certified as intrinsically safe, only those that
are certified are category EEX or AEX “ia” shall be used.
| QA/QC Notes 7
TIPS FOR CONDUIT INSTALLATION :
Conduit fittings and accessories include conduits and pull boxes:
Conduit cover and gaskets
Conduit Seal
Conduit Unions and Couplings
Check pull box every 4 bends
Check conduit fittings suitable for hazardous location [if installed in hazardous location]
Check conduit to conduit distance as per SAES-J-902
Check conduit installation as per IFC drawing and typical drawing
Check support as per NEC
Factory Elbows
Check Seal fittings if required
Check the thread joint
Check the clamp, thread size it is approved or not or as per typical drawing
Drain
Breathers
Plugs
Conduit Connectors reducers
Expansion fittings
Straps and Clamps
Bushing
Cable and duct seal, etc.
Seals are provided in conduit & cable system to minimize the passage of gases and
vapors and prevent the passage of flame from one portion the electrical installation the
conduit.
Bushings: where a conduit enters a box, fittings or other enclosure a bushing shall be
provided to protect the wire from abrasion.
Bends:
Number in one run: There shall not be more than the equivalent of four quarter bends (360
degree total) between pull point to point.
Mandrel Testing: Testing of underground duct bank and bend radius of conduit is 90 deg.
When union cannot be avoided in underground conduit installation, unions shall be protected
with heat shrinkable sleeves.
Conduit and cable sealing shall be installed in accordance with NEC-5050.10.
Conduit seals shall be installed within 450mm (18 inches) from the enclosure.
PB: Pull Box
RGS: Rigid Galvanized Steel.
| QA/QC Notes 8
Split Conduits: Split conduit Installation shall be used to repair existing conduits which
contains existing cable these conduits shall be installed in accordance with the manufacturer’s
recommendations or NEMA TCB2 User manual for the installation of order ground plastic
conduits.
We can use maximum bend in one conduit (Point to Point) 360 degree, but we have to
avoid 90 degree bend or sharp bends.
If there is sharp bend so we can perform Mineral Test.
Direct buried conduits (Underground) shall be threaded, rigid steel per accordance ANSI
C80.1 and addition it shall be hot dip galvanized and PVC coated as per NEMA RN1
(min thickness of PVC 40 mils) or PVC conduit type DB-120 (Minimum elasticity 500-
000 PSI) as per NEMA TC6 & TC8 type.
Concrete incase conduit shall be threaded, rigid steel as per ANSI C80.1 and in addition
it shall be hot dip galvanized.
Conduit Installed exposed (not embedded in walls) above grounding in outdoor
industrial facilities shall be threaded rigid steel per ANSI C80.1 and in addition it shall be
sot dip galvanized.
Conduit above ground in severe corrosive environments shall be as threaded, rigid
steel as per ANSI C80.1, in addition shall be factory PVC Coated (min thickness of 40
PVC mils) as per NEMA RN-1.
Electrical Metallic tubing (EMT) is acceptable only in non-hazardous indoor locations.
EMT shall comply with the requirement of ANSI C80.3
Intermediate metal conduit (IMC) is prohibited.
The Min conduit size shall be ¾ inch, except for instrumentation wiring inside building.
Conduit and threaded conduit fitting shall have tapered (NPT) threads in accordance
with ANSI/ASME B1.20.1
| QA/QC Notes 9
Impulse Tubing Installation Tips:
1.Slop of Impulse tubing: Minimum of 1mm, for every 12mm towards tapping point. for gas
service
2.Test Pressure of Impulse Line: 1.5 Times of the working pressure with 3 minute.
3.Instrument Tubing size = ½” x 0.89mm (Wall thickness) = 0.035 Inches.
4.Tubing supports should be spaced not more than four feet apart.
Pressure and D/P instruments in liquid or condensable vapor service shall be self-venting (i.e., mounted
below the process connections) with all impulse lines sloping downward approximately 1:12 -minimum
toward the instrument
5.Pressure and D/P instruments in gas service shall be self-draining (i.e., mounted above the process
connections) with all lines sloping downward approximately 1:12 minimum toward the process connection.
6. Field instruments shall be mounted as close as possible to the process connection to minimize the
length of instrument impulse lines. Where practically possible, the length of the impulse line should not
exceed 6 m (20 ft.)
Enclosures:
Indoors and Outdoors Plant Area
Indoors: With in the Perimeter of the Process Unit (NEMA 250 / NEMA ICS6)
Outdoor: Out side the Perimeter of Process Area (IP54)
Severe Corrosive Environment (Industrial Area) NEMA Type 4X or IP66.
Non Industrial Area IP34.
Name Plate Shall is attached to the cabinets using stainless screws.
Indoor Cabinets shall be made of metal.
The Cabinet shall be a NEMA Type 1 as per NEMA 250 and NEMA ICS6.
NEMA ICS6: Enclosures for Industrial Controls and System.
The Max Door Width shall be 900mm (36 Inch)
The Marshalling cabinets from the front surface to the surface of rear terminal block,
shall not be more than 46 cm (18 Inch)
A min of prime, undercoat & finishing coat of enamel or polish is required.
Interior cabined color shall be white or of light color such as light gray off.
Name plate for cabinets and panels letter height and spacing shall follow ISA RP 60.6
Name Plate shall be made from laminate Plastic, white – Black - White (Information
engraved into the black core) with white surface.
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.
| QA/QC Notes 10
Ans: Quality Control “Those activities and techniques used to achieve and maintain the
quality of product, process or service”.
5. What is non-conformity?
Ans: Non-conformity “Non-fulfillment of requirement”.
15. What is difference between inspection (Surveillance), witness and Hold point?
Ans: Inspection: Work can be execute without client’s inspection and it can be
inspected some part of them if it is required.
Witness: Work can be executed, without client inspection and then it can be inspected
upon the completion of work.
Hold Point: Work can’t be executed without client inspection.
| QA/QC Notes 12
20. What are areas Classification? Give a brief?
Ans: As per NEC and NACA, following are the hazard classification?
Class I: Location in which flammable gases or vapors may be present in the
atmosphere in quantities sufficient to produce explosive or ignitable mixture.
Class I gases/Vapors are divided into four following groups:
Group A: Presence of Acetylene.
Group B: Presence of Hydrogen, Butadiene, Ethylene oxide etc.
Group C: Presence of Ethylene, Glycol-propane, Carbon Mono-oxide etc.
Group D: Presence of gasoline, acetone. Butane, Propane, alcohol, Natural gas
(Methane), etc
Class II: Location in which the presence of combustible dust are in the air in sufficient
quantity to ignite or explode.
Class II conductive/non conductive dust is divided into three below.
Group E: Presence of metal dusts (aluminum, magnesium and chemical dust etc)
Group F: Presence of black carbon, charcoal, coal or coke dust etc.
Group G: presence of non-conductive dust (foam, starch, combustible plastics etc.)
Class III: Location in which easily ignitable fibers or flying are present but are not likely
to be in suspension in air in quantities sufficient to produce ignitable mixture.
Division – 1: The hazards are present continuously or periodically under normal
operation condition.
Division – 2: The Hazards are only presents during accidental or abnormal condition.
26. What is Microprocessor control system? Give a brief of PLC, DCS and SCADA?
Ans: Computer based control process system is called microprocessor control system.
The brief of PLC, DCS and SCADA are as following:
PLC: Programmable Logic Control System.
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.
30. What are inspection points for Junction Box and Marshalling cabinets?
Ans: Material Inspection, type, size as per approved specification, installation hook up
for frame, bracket or stands, fixed properly means shaking free, Name Plate, and tag
no.
31. What are standards methods or ferrules addressing to and from a Junction Box?
Ans: For to side only terminal’s address required which shall be close to terminal either
side and complete information shall be of from side after or before as per left and right
side.
| QA/QC Notes 14
36. What is RFI? When an RFI will be raised?
Ans: Request for inspection (RFI), RFI shall be raised only when the status of the
preliminary inspection is satisfactory, and the works (items) are Hold or Witness Point.
37. What is Cable tray and how is it identified separately for Electrical and Instrumentation?
Ans: Cable tray is the device used to provide support and protection to the laid cable in
side the building or outside pipe rack.
40. What is the loop and how is the loop folder made?
Ans: Loop is the electro-mechanical presentation of the circuit concerning to flow of
liquid or gas, alarm system, control valve operation and other specific for which field
installation instrument involvement is considered.
There are certain condition and requirements to be fulfilled to complete the loop check.
The list of attachments including drawing, check list and punch list and other listed
documents are arrange in folder (loop wise) for having an easy access to carry out the
loop check and final hand over of the project. That folder with all possible documents is
known as loop folder.
41. What is the specialty rather characteristics of loop check? How do you come to know
that loop check is completed
Ans: a. Loop check is a clear blue print of a successful system functioning (activity
wise),
b. This emphasises the serviceability of each instrument installed either in field or inside
the building,
c. This exposes also the limitation of some systems functioning as per the attached
filled punch list,
d. One of the ready documents for final hand over of a project on completion,
e. It is always two team’s operation-one will be on field and the other will be in the
control room, After every successful completion of loop check it is marked with Red
Colored Label bearing the date of the loop check and the witnessing parties initial.
| QA/QC Notes 15
45. What should be the attitude of a QC Inspector while carrying out an Inspection activity?
Ans: Following are the characteristics of a perfect inspector:
a. Should never compromise with the quality at the time of performing inspection.
b. Should be sincere towards performing the responsibilities.
c. Should be punctual.
d. Should be exemplary in approach while carrying out inspection.
e. Should have the capabilities to convince the authorities about the irregularities
with knowledgeable representation.
46. What are the requirements for carrying out installation inspection of any instruments
and receiving inspection of the said equipment?
Ans: Following are the requirements at the time of execution of an inspection.
a. Instrument data sheet.
b. Test Instrument Certificate.
c. Vendor instruction manual.
d. Test Instrument instruction manual.
49. 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.
50. What are the linked documentations carried out related to QC activity for oil & gas
construction project?
Ans: a. Application for inspection from construction department after completion of
every activity.
b. Production of drawing based on the planning.
c. Method application priority wise.
d. Procurement of item and equipments required for the execution of the project.
55. What are the articles refereed during carrying out the following activities?
(1) Grounding. (2) Installation of cable Tray. (3) Fire alarm System Installation. (4)
Installation Instrument Cable Tray etc,
Ans: (1) Grounding Article 250 (Chapter IX for instrumentation), (2) Installation of cable
tray Article 392, (3) Fire Alarm System Art 760, Installation of instrument cable tray art
727.
57. What would be the thickness of the top layer of a Duct Bank and color?
Ans: 5mm and Red Dye.
59. What are types of conduits used in electrical and instrumentation wiring circuits?
Ans: Rigid Metallic Conduit (RMC), Intermediate Metallic Conduit (IMC), Rigid
Nonmetallic Conduit (RNC).
60. What are the differences between a JB (Junction Box) and Terminal Box?
Ans: The purpose of JB (Junction Box) is used as a linkage between one or more inlet
and one or more outlet. Whether terminal box has inlet on or more but out let may be
one for earthen or it may not be. JB can be used in between the routing for providing
support and extra opening but TB is used as Termination means at the end of the
routing.
| QA/QC Notes 17
65. What is the role of QC during shut down?
Ans: QC has the major role to be played at the time of shut down. It is the responsibility
of QC to officially hand over any completed project to the client with all the
documentations to be provided with the real completed project. This including the
records of completion (activity wise) areas with limitations as shown in punch list, the
processing and final inspection test report of the actual functioning of the project by
making it operational.
67. How are the hazardous and non hazardous areas classified?
Ans: Hazardous and non hazardous areas are classified according to the classifications
and zones.
68. What is the Expansion joint? What should be the standard gap maintained in expansion
joint?
Ans: It I the breathing space provided to accommodate the expansion of horizontal
cable tray to suit with different climatic condition by maintaining a standard length wise
distribution.
According to NEMA VE 2 it is after every 20 M with a spacing (expansion joint) of 25mm
to be maintained. It sometimes differs, but should not be more for the horizontal length
of the cable try.
Duct Bank:
73. What is the minimum thickness of concrete from outside surface of the duct bank to any
conduit or reinforcing steel?
Ans: 75mm
74. What is mean by Guwat and Guwa, where it is applicable for use?
Ans: You can use in conduit installation for lighting purpose.
Guwat: With terminal block.
Guwa: Withought Terminal block.
| QA/QC Notes 18
75. How the Metallic and PVC conduit entering from below of any equipment like
switchgear control cabinets and similar enclosures sitting?
Ans: The metallic conduit shall be cut and threaded 50mm above finished grade level
and a threaded insulated grounding bushing shall installed, also PVC conduit shall be
cut flush with finished grade level and shall have its inner edge filed to a smooth radius.
76. What type of sealing is used for all ducts inside all manholes and hands holes where
permitted inside hydrocarbon handling plants?
Ans: All ducts shall be sealed with 3M scotch cast brand 4416 cable duct sealing kits or
other methods approved by the electrical standards committee chairman.
78. What should be done, when union cannot be avoided in underground conduit
installation?
Ans: Unions shall be protected with heat-shrinkable sleeves.
81. What is the minimum conduit size excepted for instrumentation wiring inside building?
Ans: ¾ Inch.
82. What is the minimum conduit size excepted for prefabricated skids and in-industrial
area?
Ans: ½ Inch.
84. What are the conduit fittings for outdoor rigid steel conduit and liquid tight flexible metal
(LFMC)?
Ans: Shall be cast or forged steel, cast iron or malleable iron either hot-dip galvanized
(preferably) electroplated.
90. 4What shall be minimum acceptable insulation resistance of instrument cable during
megger test?
Ans: 100 Mega ohms
| QA/QC Notes 19
91. Name some testing equipments used for instrument calibration?
Ans: Deadweight tester, Digital multimetter, Megger, Digital pressure calibrator,
Temperature calibrator, Temperature bath, Field communicator, Vibration meter.
92. What shall be the maximum acceptable attention value of fiber during OTDR test?
Ans: 0.5Db/Km or less for wave length of1310 nm and 0.3Db /Km or less .for wave
length of 1550nm.
TRANSFORMERS:
95. Why the oil samples test shall be taken from the transformer?
Ans: To check the conductivity, analyses and characteristics of the oil.
99. What is the symmetrical interrupting current rating fuse on the HV –side of
transformers?
Ans: The symmetrical interrupting current rating of a fuse shall not be less than max
symmetrical sub transient fault current.
102. How do you calculate new factor from new range using old factor and old range?
Ans:
| QA/QC Notes 20
103. Definition of Instrument Range and Span?
What is CV of a valve?
| QA/QC Notes 21
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.
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:
Common Things:
Type of Lugs: (1) Shanap Type (2) Pin Type (3) Ring Type (4) U Type
Gland Size: ½” ¾” 1”1½” 2”
Thread Type: ET (Equal Thread), BSP (British Standard Pitch), NPT (National Pipe Pitch).
ELECTRICAL:
LT – (Low Tension) – 50VAC ~ 230VAC
HT – (High Tension) – 320VAC ~460VAC
MCC – (Main Control Connection (Motor Control Center)
PCC – Power Control Connection
Vibration Meter (Monarch instrument Model Examiner 1000) Using to get the Vibration (mm/s)
NB: The Duration of the no load run is 4 Hrs, Every 30mm needed to get a reading.
Using for winding resistance tests of voltage transformer, current transformer, etc..?
DC Dielectric Test Set (Biddle Model 220123).
Used to test the insulation resistance of cables, bus bars, breakers, VT’s, ct’s, etc…?
Digital Multimeter Model: 77iii
Programma (Freja 300)
Relay test unit for: (transformer management relay, feeder management relay, motor management
relay, also used to test the ATS of switchgear, ammeters and voltmeters
Torque wrench (model 64-046).
Power Clamp Meter (Model: Unites 93510).
True RMS AC/DC clamp meter (Tektronix Model: DCM910)
Relay Test Unit (Programma Model Sverker 750)
| QA/QC Notes 23
INTERNATIONAL STANDARD AND CODES
| QA/QC Notes 24
B40.1
API RP551 Process measurement instrumentation
API RP554 Process instrumentation and control
IEC 79-0 Electrical apparatus for explosive atmosphere.general
requirement
IEC 60529 Classification of degree of protection provided by enclosures(IP)
NFPA 72 National fire alarm code
ANSI/ISA Control valve response measurement from steps input
TR75.25.0
2
UL 94 thickness of terminal block, High strength material
ANSI/ISA Recommendations for the Preparation, Content, and
RP12.2.02 Organization of Intrinsic Safety Control Drawings
ISA RP12.6 Wiring Practices for Hazardous (Classified) Locations
Instrumentation Part 1: Intrinsic Safety
2. What is the maximum permissible seat leakage rate of class IV control valve as per FCI 70.2?
Ans --0 .01% of rated capacity
8. For square edge orifice plate the upstream edge of the orifice must be square and sharp without
defect any sort .so that the beam of light is reflected by the upstream edge when viewed without
magnification TRUE OR FALSE
ANS—TRUE
| QA/QC Notes 25
10. What is the maximum segment length of foundation fieldbus
Ans—1900 meters
11. What is distance of the tray maintaining from ceiling
Ans-450mm
12. What is the width of marshalling panel?
Ans -900mm
13. What type of battery used in UPS SYSTEM?
Ans-1.lead acid 2.nickal cadmium
14. What is the maximum resistance value accepted when meggoring a cable?
Ans—50 Moms
15. For above grad equipments can be clamp using in grounding installation
Ans- No [clamp not allowed]
16.In a grounded thermocouple the shield can be connected to thermocouple head[ true or false]
Ans –false
17. What is the maximum length of conduit shall be left at each outlet, junction & switch point for
splices connection of fixture?
Ans-6 inch[150mm]
18. What are the suitable means /method of connecting grounding conductors & bonding to electrical
equipment and electrode?
Ans –compression type
19. What is the maximum value in OHM permitted for grounding equipment in industrial area
connected on a single electrode?
Ans –25 ohm
20. In analog signal system supply voltage shall be normally
24 v dc
21. As per NEC, how many degrees bend permitted in conduit installation?
4quarter bend 360 deg only permitted
22. As per NEC what is the maximum number of over current devices allowed in branch circuit
panel.
42 [per NEC 408.15]
25. What is the minimum grounding conductor used for equipment grounding?
25 mm2
1.As per approved material and specification ,2.As per location plan , 3.As per P&ID, 4.Mounting
height,5.Impuls tubing installation as per hook up drawing ,6.Tag installation, 7.Orientation of transmitter
30.As a minimum, all pressure devices shall be specified with over-range protection to ______ times
the maximum system operating pressure.
| QA/QC Notes 26
a) 1-1/2
b) 2
c) 3
d) 5
e) 8
a) Vent/Drain valves.
b) Control valve
c) Glove valve
d) Shut down valve
e) Release valve
32. All the field termination cabinets (junction boxes) shall be _____
a) NEMA Type 3
b) NEMA Type 7
c) NEMA Type 4X
d) NEMA Type 9
e) NEMA Type 8
33. Pressure and D/P instruments in liquid or condensable vapor service shall be self-venting (i.e.,
mounted below the process connections) with all impulse lines sloping downward approximately ___
minimum toward the instrument in SAES-J-003
a) 1:12
b) 1:100
c) 1:20
d) 1:40
e) 1:50
34. Pressure and D/P instruments in gas service shall be self-draining (i.e., mounted above the process
connections) with all lines sloping downward approximately ___ minimum toward the process
connection.
a) 1:20
b) 1:100
c) 1:12
d) 1:40
e) 1:50
35. The loop document / Package shall at least comprise of the follow:
a) Instrumentation Calibration Records
b) Instrument Data Sheets
c) Instrument Loop Diagrams
d) Piping and Instrument Diagram
e) All of the above
39. Design and Selection of Process Control & Instrumentation System should include:
a) Suitability
b) Reliability
c) Quality
d) Accuracy & Repeatability
e) All of the above
40... Instrument & Control system (Outdoor, unsheltered) shall be rated for operation for Outdoor
temperature of:
a) 10 deg. C to 35 deg. C.
b) 0 deg. C to 30 deg. C.
c) 0 deg. C to 55 deg. C.
d) 10 deg. C to 55 deg. C.
e) 0 deg. C to 65 deg. C.
a) 32
b) 0
c) -40
d) 40
e) 100
42. Rangeability of 10:1 is major requirement in flow measurement. Which of the following method
will be most appropriate?
a) Orifice
b) Positive Displacement
c) Turbine Meter
d) Variable Area
e) None of the above
43. Displacement type instruments may be used for level range up to and including:
a) 1800 mm
b) 1830 mm
c) 1500 mm
d) 2200 mm
| QA/QC Notes 28
e) 3000 mm
44. for temperature measurement requiring maximum accuracy, following shall be used:
a) T/C
b) RTD – 2 wire
c) RTD – 3 wire
d) RTD – 4 wire
e) Filled System Instrument
a) Elevated range
b) Suppressed range
c) Elevated zero range
d) Ultimate range
e) None of the above
a) Concentric
b) Segmental
c) Eccentric
d) Quadrant Edge
e) All of the above
a) Orifice
b) Magnetic flow meter
c) Rotameter
d) Positive displacement meter
e) None of the above
48. in new grass root projects, cable trays extending between the process area and the control room
or process interface building, or trays installed beneath raised computer floors, in control rooms or
PIB shall be sized for a minimum of ___
49. Cable tray fill shall comply with NEC Article ___
a) 392
b) 250
c) 500
d) 501
e) 503
50. Instrument Cables from Field Junction Boxes are generally connected to ___ at Control Room
a) Marshaling Cabinets
b) DCS Cabinets
| QA/QC Notes 29
c) ESD Cabinets
d) SCADA Cabinets
e) I/O Cabinets
a) 316 SS
b) 304 SS
c) Plastic
d) Steel
e) Nylon
52. The minimum size of supply takeoffs for instrument air shall be ____.
a) ½ inch
b) 1 inch
c) 2 inch
d) ¾ inch
e) 1-1/4 inch
53. In instrument air sub header ______ spare takeoff fittings and block valves shall be
Installed on the branch header.
a) 20 %
b) 40 %
c) 25 %
d) 30 %
e) 10 %
54. Fire Alarm systems shall be installed in accordance with NEC Article ____
a) 250
b) 760
c) 384
d) 500
e) 504
55. A conduit outlet box (e.g., GUAT) shall be installed within _____ inches of the field device
a) 12
b) 6
c) 18
d) 30
e) 10
56. All fasteners (i.e., nuts, bolts, washers, etc.) used to connect and assemble the cable tray system
shall be ____
a) 304 SS
b) 316 SS
c) Both a & b
d) Galvanized Steel
e) None of the above
a) 12 AWG.
| QA/QC Notes 30
b) 18 AWG.
c) 16 AWG.
d) 10 AWG.
e) 8 AWG.
58. The minimum sizes for process sensing tubing (impulse line) shall be ____
a) 1/2 inch
b) 1/8 inch
c) 1/4 inch
d) 1 inch
e) 1-1/4 inch
59. The slope of all main and branch headers for instrument air shall be _____2.5 inches per 100 feet
b) 2.5 inches per 100 feet[64mm for every 30 meter]
59 what is the minimum distance between power cable 1000v and control cable under 1000v?
Ans -300mm
60. what is maximum allowable length of impulse tubing?
Ans. 6 mtrs
61. Threaded entries into explosion proof equipment shall be made up with at least __ threads fully
engaged.
Ans -5 threads
62. In Saudi Aramco standard corrosive area pvc conduit installation accepted in above ground?
Ans- false
Ans- 610mm
SAIPEM
Interview questions
What is the maximum acceptable length & diameter of the copper jacketed grounded rod as per
SAES-P-111?
Ans. 2.4 M long *16 mm dia
62. In conduit installation system how many threads are fully engaged?
Ans –5 threads
64.what type of fasners used to connect to assemble to the cable tray in sever corrosive area
Ans -316 SS
| QA/QC Notes 31
66. What is the maximum permissible seat leakage rate of class IV control valve as per FCI 70.2?
Ans --0 .01% of rated capacity
68. how many foundation field bus device connected to each spur?
Ans –1[one]
71.what is the maximum distance between each support in rigid metal conduit installation ?
Ans –3 meter
75. All the field termination cabinets (junction boxes) shall be _____
NEMA Type 4X
76. In the conduit duct bank installation system what is the maximum allowable distance between each
spacer ?
Ans - 2.4 meter
Positive –black
Negative –white
Common-red
| QA/QC Notes 32
83.Instrument control wires and cable system shell be designed and installed in accordance with?
ANSI/NFPA—70
84. as per SA standard what size of cable is to be used for two hole compression terminal connection
Ans-4/0[5AWG or 16 mm2]
87. In SAS what type of temperature sensors element used for measuring temperature ?
Ans –RTD & THERMOCUPLE
88.What is the seal liquid used for filling impulse line on crude & viscous liquid ?
Ans—glycol
89.What is the minimum distance for direct buried cable ?
Ans- 610mm
460mm
92. The power cable tray in Saudi Aramco shall be
Ladder tray
93. Metallic cable trays shall be bonded at both end points and a minimum of every
25M
94. Low voltage power system at saudi armco shall be solidly grounded TRUE OR FALS
REUE
95. WHAT IS THE MINIMUM LENGTH OF GROUNDING RODS
2.4 meters
97. Insulation resistance of MCB pole to pole, line to load, and pole to ground shall not be less than
50 mega-ohms._ when test voltage 1000 volts DC is applied
98. Minimum grounding conductor size used for equipment connection to ground rods or ground grid
25mm² (#4 AWG)
99. For a single grounding rod resistance to ground should be less than
25 ohms
| QA/QC Notes 33
100. The grounding resistance of made electrodes (grounding rods/or ground grid) used for system
grounding shall not exceed __1 ohm__ for solidly grounded systems above 600V
Check the cable as per RFI,check type of cable pair or traid cable and single pair cable always
16AWG not 18AWG [some vendor cable only come as 18 AWG],check site material receiving report, check
pacing list, check inspection release certificate ,check drum number as in receive ,check factory
acceptance test certificate for each drum ,check routine and dimensional test certificate ,check certificate
of compliance ,check purchase order ,check 9com number ,and transmittal
| QA/QC Notes 34