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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.
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), (Yellowand 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.
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
Thread Type:ET (Equal Thread), BSP (British Standard Pipe), NPT (National Pipe Thread).
COLOR CODE:
AC Supply: Phase Black
Neutral White
Ground Green or Green with yellow tracer
TYPE OF THERMOCOUPLE:
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 thickness0.64mm
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 use to identify I.S. wiring.
If used for connections of equipment to ground rods or ground grid to be minimum25 mm2 (# 4AWG).
Intrinsically safe system shall be used in zone 0 hazardous area.
MV cable to be cover in trench by Thermal send.
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.
SIZING OF CABLE:
0.75 mm2 18 AWG
1.0 mm2 17 AWG
1.5mm2 16 AWG
2.5mm2 14 AWG
4.0mm2 12 AWG
6.0mm2 10 AWG
10mm2 08 AWG
16mm2 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 16mm2 in diameter or19mm2 in diameters.
Earth Tester is used for measuring of earthling system.
Underground wire for grounding to wire connections shall be cadweld or thermoweld. 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 minimum25 mm2 (# 4AWG)
Metallic cable trays shall be bonded at both end points and a minimum of every 25meter to the local ground grid.
If buried/ used for grids or interconnections of ground rods to be minimum70mm2 (2/0AWG)
Be copper or copper jacketed steel or galvanized steelor 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 to Tray:
Level 1 to Level 2 gap should be 150mm
Level 2 to Level 3 gap should be 500mm
Level 1 to Level 3 gap should be 650mm
Tray to Conduits:
Level 1 to Level 2 gap should be 100mm
Level 2 to Level 3 gap should be 350mm
Level 1 to Level 3 gap should be 450mm
Conduit to Conduit:
Level 1 to Level 2 gap should be 75mm
Level 2 to Level 3 gap should be 225mm
Level 1 to Level 3 gap should be 300mm
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 2.4meter.
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
ConduitSeal
Conduit Unions and Couplings
Factory Elbows
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 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 450mm (18 inches) from the enclosure.
PB: Pull Box
RGS: Rigid Galvanized Steel.
The minimum depth of burial requirements for underground installations shall be as per:
System Voltage Direct Buried Cable Direct BuriedPVC Duct Bank &Direct Buried 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
ENCLOSURES:
Indoors and Outdoors Plant Area:
Indoors: With in 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 isattached 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 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.
Samir(QA/QC Engineer) | QA/QC Notes 10
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.
Area classification
Symbol for equipment built to American
Standards
Type(s) of protection designation
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’ Send or Powder filled 1
Ex ‘s’ Special Protection 0
GAS GROUP:
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) Zone0 (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:
INGRESS RATINGS:
Q: Explain the meaning of “INGRESS PROTECTION”
A: The appliances ability to keep out solids and liquids, IE 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..?
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.
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).
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.
GroupG: 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.
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.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.
Samir(QA/QC Engineer) | QA/QC Notes 16
SCADA: Supervisory Control and Data Acquisition.
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.
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.
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.
43. What should be the attitude of a QC Inspector while carrying out an Inspection activity?
Ans: Following are the characteristics of a perfect inspector:
a. Should never compromise with the quality at the time of performing inspection.
b. Should be sincere towards performing the responsibilities.
c. Should be punctual.
d. Should be exemplary in approach while carrying out inspection.
e. Should have the capabilities to convince the authorities about the irregularities with knowledgeable representation.
44. What are the requirements for carrying out installation inspection of any instruments and receiving inspection of the said
equipment?
Ans: Following are the requirements at the time of execution of an inspection.
a. Instrument data sheet.
b. Test Instrument Certificate.
c. Vendor instruction manual.
d. Test Instrument instruction manual.
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 equipments required for the execution of the project.
52. What do you know about NEC, NEMA VE1, NEMA VE2, NEMA RN?
Ans: NEC – National Electrical Code earlier used to be published under the statutory body of NFPA since 1897, from 2005
edition it is categorized as an internationally accepted method inspection procedure guidelines covering all most all the
field related to Electrical, Instrumentation and Communication Engineering.
NEMA VE1 – National electrical manufacture association VE1
NEMA VE2– Deals with cable tray installation specification
53. What are the articles refereed during carrying out the following activities?
(1) Grounding. (2) Installation of cable Tray. (3) Fire alarm System Installation. (4) Installation Instrument Cable Tray etc,
Ans: (1) Grounding Article 250 (Chapter IX for instrumentation), (2) Installation of cable tray Article 392, (3) Fire Alarm System
Art 760 (4) Installation of instrument cable tray art 727.
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).
66. What is the Expansion joint? What should be the standard gap maintained in expansion joint?
Ans: It I the breathing space provided to accommodate the expansion of horizontal cable tray to suit with different climatic
condition by maintaining a standard length wise distribution.
According to NEMA VE2 it is after every 20 meter with a spacing (expansion joint) of 25mm to be maintained. It
sometimes differs, but should not be more for the horizontal length of the cable try.
71. What is the minimum thickness of concrete from outside surface of the duct bank to any conduit or reinforcing steel?
Ans:75mm
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:Withought 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.
76. What should be done, when union cannot be avoided in underground conduit installation?
Ans: Unions shall be protected with heat-shrinkable sleeves.
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?
Ans: ½ Inch.
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.
84. What is the minimum distance from main door to marshaling panel?
Ans: Minimum shall be 3 meter from main door to marshaling panel.
88. What shall be minimum acceptable insulation resistance of instrument cable during MeggerTest?
Ans: 100 Mega ohms
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:
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:
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
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.
Samir(QA/QC Engineer) | QA/QC Notes 24
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.
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.
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.
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.
2. Why the oil samples test shall be taken from the transformer?
Ans: To check the conductivity, analyses and characteristics of the oil.
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.
10. How do you check whether the winding of a motor is good or bad?
Ans: WR (Winding Resistance), IR (Insulation Resistance).
12. What are the two method of winding connection in 3-Phase motors?
Ans: Star Winding & Delta Winding.
14. What is the paint name which is the used in grounding cable?
Ans:Vetomens Paints.
16. If the IR value of the motor winding is very low what would you do to improve it?
Ans: Motor need over hauling.
17. What is the name of the test equipment used to measure the following?
Ans:
Current: Ammeter
Voltage: Voltmeter
Resistance: Ohm
Insulation Resistance: Megger
18. What is the different between primary and secondary cell?
Ans: Primary Cell is Anode (+)
Secondary cell cathode (-)
19. If the current is 15A what will be the size of the cable?
Ans: 6 mm2 or 10 mm2
20. What is the max speed obtained by 3 phase induction motor with normal state supply?
Ans:
28. What is range of low voltage and medium voltage and high voltage?
Ans: Low Voltage: 110 ~ 380 VAC
Medium Voltage: 489 ~13.8 KV
High Voltage: 14.6 ~115 KV
29. What is the different between star and delta connection with types of motor?
Ans:
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
Question?
What is EMF?
Ans.:
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
Samir(QA/QC Engineer) | QA/QC Notes 29
HT – (High Tension) – 320VAC ~460VAC
MCC – (Main Control Connection) or (Motor Control Center)
PCC – Power Control Connection
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.
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)
1. Please explain the required equipments, Tools and Consumables for Cable Pulling?
Ans:Wench (Motor) or Tagger (Motor), Lubricant Compound, Rop
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:
12. What is the different between guide clamp and holding clamp?
Ans:
3. What is the standard wire fill requirement for conduit sealing fittings?
a) 30%
b) 25%
c) 40%
d) 35%
Ans.: b) Per NEC-501.C-6
4. What is the maximum percentage of cross section a conduit raceway can be filled containing three (3) or more conductors?
a) 100%
b) 50%
c) 40%
d) Not Required.
Ans.: c) Per NEC Chapter 9
5. What is the maximum distance between supports for rigid metal conduit (RMC) on horizontal straight run?
a) Shall be supported @ intervals not exceeding 4 meter (12 ft.)
b) Shall be supported @ intervals not exceeding 5 meters (15 ft.)
c) Shall be supported @ intervals not exceeding 3 meters (10 ft.)
d) None of above.
Ans.: c) Per NEC-344.30
7. Per NEC, What is the minimum number of conduit threads should be engages @ hazardous locations?
a) At list minimum of 5 threads.
b) 4 threads
c) 3 threads
d) None of above
Ans.: a) Per NEC-501.4
8. Per NEC, What is the maximum number of over current devices allowed in branch circuit panel board?
a) 45 over current devices
b) 50
c) 55
d) 42
Ans.: d) Per NEC-408.15
9. Per NEC, What is the minimum working clearance requirement in front of low voltage electrical equipment?
a) 900 mm (3 ft.)
b) 800 mm (2.5 ft.)
c) 700 mm (2.25 ft.)
d) 600 mm (2 ft.)
Ans.: a) Per NEC-110.26 (Table 26 (A) (1)
10. Per NEC, which of the following listed below are or maybe present in the air in quantities sufficient to produce explosive or
ignitable mixture?
a) Flammable gases or vapor.
b) Combustible gas.
c) Easily ignitable fibers or flying by which are not likely to suspension in the air.
d) All of the above.
Ans.: b) Per NEC-100
12. Per NEC, what is the percent ampacity of Branch circuit conductors supplying single motor-compressor?
a) 50
b) 60
c) 100
d) 125
Ans.: d) Per NEC-440-32
13) Per NEC, All 125 volts, single phase, 15, 20 amps receptacles installed in location specified in bathrooms & Kitchens shall be?
a) Single receptacle
b) Duplex receptacle
c) Ground fault circuit interrupter (GFCI)
d) None of the above
Ans.: c) Per NEC-210.8 A (1)
17) What is the method is permitted to be utilized for splicing direct buried cable.
a) Splice Box
b) Not Permitted
c) Materials suitable for the application
d) A &C
Ans.: d) Per NEC-30.50
19) What is the minimum length of free conductors shall be left at each Outlet, Junction & Switch point for splices or connection of
fixtures or devices?
a) 6 inches
b) 4 inches
c) 2 inches
d) None of the above
Ans.: a) Per NEC-300.14 & Ans.: b) Per NEC-310.16 (table)
20) How many hours the maximum current is expected to continue on a continuous load?
a) 3 Hrs or More
b) 2 Hrs or More
c) 3 Hrs or More
d) 5 Hrs or More
Ans.: c) Per NEC-100
22) In hazardous classified locations, seals are needed in the following instances?
a) Where conduit leaves a division 1 of division 2 area to a less or non-hazardous location.
b) Where conduit enters an explosion proof type enclosure with arcing devices or high temperature equipment.
c) Where conduit enters an enclosure with terminal splices or tap (If the conduit is 2 inches or more in diameter)
d) All the above.
Ans.: d) Per NEC 501
23) Where the voltage exceeds 600 volts, Nominal, Permanent & conspicuous warning signs shall be provide reading as follows?
a) Careful – Low voltage – keep out
b) Danger – high voltage – keeps out
c) Danger – high voltage – out
d) Danger – high speed – keep out
Ans.: b) Per NEC-110-34
24) A service drop conductors & service entrances conductors shall be arranges so that water ….. service raceway or equipment?
a) Will slide
b) Will not enter
c) Will enter
d) Will transfer
Ans.: b) Per NEC-230.54(g)
25) In case of appliance receptacle/outlets installed in dwelling unit for specific appliances, such as Kitchen Equipment. It shall be
installed within ……….. of the intended location of the appliance?
a) 1.8 m
b) 2.3 m
c) 3.5 m
d) 4.5 m
Ans.: a) Per NEC-210.50 ( c )
26) What is the reference table from NEC that requires the maximum number of conductors permitted in standard boxes?
a) NEC 110
b) NEC 240
c) NEC 250.66 (Table-1)
d) NEC 314.16 (A)
Ans.: NEC 314.16
32) Per NEC, how grounding conductors & bonding Jumpers connected to the equipment?
a) Exothermic welding
b) Listed pressure connector
c) Listed clamps or other listed means
d) All of the above.
Ans.: d) Per NEC-250.8
34) Which of the following cables listed below are suitable for class 1, division 1 & Locations?
a) Armored type
b) Metal clad (MC type)
c) PLTC – Power limited tray cables
d) None of above.
Ans.: a) & b) per (NEC 320.12 & NEC 330.10)
35) A 3-Phase system has phase to phase 480V AC, What is the phase to ground to Neutral voltage?
a) 480/SQ Root of 3 = volts
b) 480/CU.Root of 3 = volts
c) 480/3 = volts
d) None of above
Ans.: a)
36) Raceways shall only be used as a means of support for other raceway on the Following condition?
a) Where the raceway or means of support is identified for the purpose.
b) Where the raceway contains power supply conductor for electrically controlled equipment.
c) Where the raceway is used to support boxes or conduit bodies in accordance with 314.23
d) All of above.
Samir(QA/QC Engineer) | QA/QC Notes 36
Ans.: d) Per NEC-300.11 (B)
37) Metal clad (type MC cables) is a factory assembly of one & more insulated circuit conductors with or without optical fiber
enclosed in an armor of interlocking metal or corrugated metallic sheath shall not be used?
a) In direct burial unless the metallic sheath shall be suitable for the condition.
b) In cable tray or any raceway.
c) In hazardous (classified) locations as permitted in Articles 501, 502, 503, 504 & 505.
d) None of the above.
Ans.: a) Per NEC-330.12
39) What is the temperature rating for lighting fixtures where combustible materials shall be present for such installation?
a) 90 °C
b) 80 °C
c) 85 °C
d) None of the above.
Ans.: a) Per NEC-410.5
40) Luminaires (Fixtures) shall be installed …………… so that combustible Material is not subjected to temperature excess of 90 °C
(194 °F)?
a) Equipped with shades or guards
b) Shall be rated 208 volts
c) Shall be high – pressure sodium.
d) All of the above.
Ans.: a) Per NEC-410.5
41) What is the minimum clearance height of luminaire (Fixture) lamp holder over a Highly combustible materials?
a) 3.5 mts
b) 2.5 mts
c) 1.5 mts
d) None of the above.
Ans.: c) Per NEC-410.6
42) What type of Luminaire (Fixture) installed at indoor location requires thermal Protection?
a) Ballast of Fluorescent luminaire (Fixture)
b) Incandescent Luminaire.
c) Both a. & b.
d) None of the above.
Ans.: c) Per NEC-410.73
43) What would be the type of Lamp holder to be installed in a Wet or damp location?
a) Wet or Damp location
b) GFCI type
c) Weatherproof Type.
d) All the above.
Ans.: c) per NEC-410.49
44) Per NEC series, the following letters d, e & m provides different type of protection that’s stands for?
46) What are the suitable means / method of connecting grounding conductors & bonding to electrical equipment and ground
electrode?
a) Listed clamps.
b) Thermite welds.
c) Compression type connection.
d) All of the above.
Ans.: d) per NEC-250-70
48) When it is necessary to bury more than one pipe or rod in order to lower the Resistance to ground, it should be placed …… ft
apart.
a) 70 ft.
b) 75 ft.
c) 06 ft.
d) 50 ft.
Ans.: c) 6 ft.
49) What is the maximum value in Ohms permitted for grounding equipment? In industrial area connected on a single electrode.
a) 25 Ω
b) 30 Ω
c) 10 Ω
d) 05 Ω
Ans.: a) per NEC-250.6
50) What kind of motor can be installed in Class 1, Division 1 & Class 1 Division 2 Location?
a) Shall be UL listed.
b) Shall be explosion proof type.
c) Shall be identified for Class 1 Division 1 & Class 2 Division1.
d) All of above.
Ans.: d) per NEC 340, 520.2
51) What is the required percent overload of a continuous-duty motor with 1.15 or greater service factor & marked @ 40 Deg. C
temperature rise?
a) 20
52) What table in NEC requires minimum bending space of 5 inches (38 mm) within motor controller enclosure for a conductor size
1/0 AWG?
a) 250 – 12A
b) 430 – 10B
c) 100 – D20A
d) Chapter – 9
Ans.: b) per NEC-430.10 (B) table.
53) What is the ampere rating for motor circuits disconnect switch rated 600 volts nominal or less?
a) 125 % of the full load current rating of the motor.
b) 120 % of the full load current rating of the motor.
c) 115 % of the full load current rating of the motor.
d) 110 % of the full load current rating of the motor.
Ans.: c) per NEC-430.110
54) Motor in Class 1 Division 1 location shall be identified in which of the following?
a) Of totally enclosed type supplied with positive pressure ventilation from a source clean air with discharge to a safe area.
b) Of a type designed to be submerged with a liquid that is flammable only when vaporized & mixed with air.
c) Shall be of listed type suitable for the ventilation.
d) All of the above.
Ans.: d) NEC-501.8
55) What type of enclosure is to be used for motors installed @ Class 1, Division 1 location?
a) Non explosion proof type.
b) Immersed oil type.
c) Explosion proof type.
d) Not applicable.
Ans.: c) NEC-501.3
56) What is the required ambient temperature in Deg C for motor to be installed @ Class 1, Division 2 Location?
a) 35 Deg. C
b) 40 Deg. C
c) 45 Deg. C
d) None of the above
Ans.: b) NEC-501-8(B)
57) Rigid non-metallic conduit shall be installed as a complete system & shall be securely fastened within?
a) 3 ft (914 mm)
b) 6 ft (828 mm)
c) 9 ft (2742 mm)
d) None of the above
Ans.: c) as per NEC-352.30
58) Surge arrester is a protective device that limits the surge voltages by discharging or bypassing surge current, it shall be used
when any of the following condition exists?
a) At a point on a circuit where it is connected to each ungrounded conductor.
b) Means to provide protection of circuits that may be disconnected from the generating bus.
c) Both a & b.
d) None of the above.
59) Medium voltage type MV cable shall be permitted to use in power system rated up to 35000 volts on the following condition?
a) For direct buried application.
b) In cable raceway
c) In wet & dry locations
d) All of the above
Ans.: d) as per NEC-328.10
61) Flexible liquid tight metal condition can be installed in Class 1, Division 2 location provided?
a) Length shall not exceed 12”
b) Shall be of UL listed suitable for the application.
c) Shall have additional grounding conductor.
d) Both b & c.
Ans.: d) as per NEC-501.4 (B) (2).
62) Each instrument wires shall be permanently tagged and identified at both end with a method?
a) Permanently marked in block numeric or typed on tubular heat shrinkable.
b) By slip on sleeves.
c) Wrap-around, tigidsnap-on or adhesive type markers.
d) Both a & b.
Ans.: d) as per SAES-J-902/7.6.1
63) Instrument grounding bus (IGB) shall be connected in safety grounding system?
a) Shall provide greater integrity of the rest of the safety ground when a case ground instrument remove from the system.
b) Shall be connected to safety ground system grid with 25mm2 copper wire connected in a close loop configuration.
c) To minimize electrical interference in signal transmission circuits.
d) All of the above.\
Ans.: d) as per SAES-J-902/9.1
64) All techniques used to comply with area classification requirements shall comply with?
a) NEC Chapter 5
b) The authority having jurisdiction
c) NEC chapter 2
d) NEC chapter 3
Ans.: a)
66) All electrical equipment including instrumentation shall be designed and installed in accordance with?
a) NEC
b) OSHA 1910 Subpart S
67) Any box, including junction boxes, containing voltages higher than …… shall have a caution sign?
a) 5 V ( AC or DC)
b) 50 V ( AC or DC)
c) 200 V ( AC or DC)
d) 1000 V ( AC or DC)
Ans.: b)
68) A circuit in which any spark or thermal effect is capable of causing ignition of a mixture of flammable or combustible material in
air under prescribed test condition is consider?
a) Intrinsically safe circuit.
b) Emergency shutdown circuit.
c) Both a & b
d) None of the above.
Ans.: a) as per NEC-504.2
69) Terminal strip for ESD wiring shall be completely separated from all other wiring including power, control & instrumentation and
shall have at least?
a) 150 % additional equipment.
b) 200 % additional equipment.
c) 100 % additional equipment.
d) 20 % additional equipment.
Ans.: d) as per SAES-J-902/7.5.3
70) Instrument, control wire and cable system shall be designed and installed in accordance?
a) With ANSI/NFPA 70 National Electrical Code
b) With UNIFORM Code requirements.
c) With T standards
d) With S standards
Ans.: a) as per SAES-J902/7.1
71) Instrumentation signal & control cable in the field may be routed aboveground within process facility by a method?
a) In overhead cable trays.
b) In conduit system where all low spot that moisture can accumulate shall be provided by drains.
c) In fire hazardous areas where installation shall be as per SAES-B-006.
d) All of above.
Ans.: d) as per SAES-J-902/7.2.1
72) What is the Basic Saudi Aramco Industrial Facility Power Generation?
a) 6.9 kV 3, 4 wires
b) 13.8 kV 3, 4 wires
c) 4.16 kV 3, 4 wires
d) None of the above
Ans.: b) as per SAES-P-100/Para-6.1.3
73) Per S. Aramco Standard, what types of cables are to be used for security lighting or perimeter & area lighting?
a) Un armor cables
b) Armor cables
c) Metal clade cables
74) Per S. Aramco Series, spring pressure twist-on type connectors & pressure sets screw with insulating caps are permitted?
a) In non-industrial application
b) For lighting & receptacle circuit in non-hazardous locations.
c) Both a & b
d) None of the above
Ans.: c) Per SAES-P-104. Para-6.3
75) Per S. Aramco Standard, what type of wire/ cable connector is to be used for control wiring?
a) Insulated ring tongue.
b) Locking for tongue
c) Flanged fork tongue & pin type compression
d) All of the above.
Ans.: d) per SAES-P-104, Para-6.6
76) Per Saudi Aramco Standard, A type 300 stainless steel breather & brain fittings are required for enclosure, junction boxes,
having an internal volume of?
a) Less than 1,000 cubic centimeters
b) Less than 1500 cubic centimeters
c) Exceeding 2000 cubic centimeters
d) Exceeding 5000 cubic centimeters
Ans.: c) as per SAES-P-104 Para 7.7
77) Per Saudi Aramco Standard series, what is the minimum size of conduit permitted to be installed inside building of non-industrial
area?
a) 2 in
b) 3 in
c) ½ in
d) ¾ in
Ans.: d) as per SAES-P-107, Para-8.6
78) Per Saudi Aramco Standard, Electrical Metallic tubing (EMT) is acceptable to be installed in what location?
a) In hazardous outdoor locations
b) In non-hazardous outdoor locations
c) In hazardous in door locations
d) In non-hazardous in door locations
Ans.: d) as per SAES-P-104 Para-8.4
79) According SAES series, what type of enclosure cab be installed on severe corrosive environment?
a) Type NEMA 3R, 3 & 4
b) Type NEMA 4X, 3 & 4
c) Type NEMA 1
d) None of above
Ans.: d) as per SAES-P-104, 7.3
80) As per standard series, what is the minimum clearance for crossing or parallel between DB cable or conduit?
a) 150 mm
b) 200 mm
c) 250 mm
d) 300 mm
Ans.: d) as per SAES-P-104, Para-6.1
82) As per Standard series, what ist he minimum maintained luminance level required inside battery room?
a) 500 Lux
b) 750 Lux
c) 300 Lux
d) 200 Lux
Ans.:c) as per SAES-P-123 articles
83) Per Saudi Aramco Standard what is the characteristics of grounding rods?
a) Be copper or copper jacketed steel or aluminum.
b) IF aluminum, only be used in areas protected by cathodic protection
c) Have a minimum length of 2 meters.
d) For copper or cooper jacketed steel rods be min of 16 mm
Ans.: d) as per SAES-P-111/5.2
84) What would be the color of insulated grounding conductor as per Saudi Aramco Standard?
a) Yellow Jacket or Yellow Jacket with Green Strips
b) Green Jacket or Green Jacket with White Stripes.
c) Green Jacket or Green jacket with Yellow Stripes.
d) None of the above.
Ans.: c) as per SAES-P-111/5.1
85) Per Saudi Aramco Standard, what is the minimum creepage distance measured between line & ground, based on the line-to-line
voltage, e.g. for 13.8 kV outdoor termination?
a) 525 mm
b) 542 mm
c) 552 mm
d) None of the above.
Ans.: c) Per SAES-P-104, Para, 6.12
86) What is the minimum grounding conductor used for equipment grounding?
a) 25 mm2 (#4 AWG)
b) 16 mm2 (#6 AWG)
c) 35 mm2 (#2 AWG)
d) None of the above
Ans.: a) as per SAES-P-111/5.1
89) What is the minimum clearance depth for direct buried low voltage cable?
a) 460 mm
b) 500 mm
c) 600 mm
d) 920 mm
Ans.: c) as per SAES-P-104, Para-10.1 (Tabel-2)
90) What is the maximum number of field splices permitted in circuit for new installation of cables rated above 1000V (excluding
submarine cables)?
a) Is the number made necessary by the use of standard size reels with full length cables?
b) Is the number made necessary by the use of standard size reels with full length cables, plus on extra spices?
c) Is the number made necessary by the use of standard size reels with full length cables, plus on extra spices?
d) None of the above.
Ans.: b) as per SAES-P-111/8.3
92) As per Aramco Standard, what is the minimum size of wire for grounding grid?
a) 240 mm2
b) 70 mm2
c) 120 mm2
d) 35 mm2
Ans.: b) as per SAES-P-111/5
93) In what Standard reference shall be used for electrical area classification?
a) SAES-B-006
b) SAES-B-014
c) SAES-B-068
d) SAES-B-086
Ans.: c)
97) What SAES series requires minimum depth clearance for 600 volts to 35 kV direct buried cable power supply?
a) 700 mm
b) 800 mm
c) 920 mm
d) 1070 mm
Ans.: c) as per SAES-P-104/10.1 (Table-2)
98) What type of conduit can be used in concrete encased duct bank installation?
a) Hot-Dip galvanized rigid steel conduit.
b) PVC conduit
c) RGS-PSV coated conduit
d) All of the above.
Ans.: d) as per SAES-P-104/10.4
99) What is the minimum size of equipment grounding connected to a ground grid or rods?
a) 70 mm2
b) 35 mm2
c) 25 mm2
d) 16 mm2
Ans.: c) as per SAES-P-111/5.1
101) What is the distance & height requirements on installing duplex, wire, 20A, Receptacle outlet inside substation?
a) Every 8 mts. Or wall space & 15mts.above the floor.
b) Every 6mts. Or wall space & 1 mts.above the floor.
c) Every 5 mts. Or wall space & 2 mts. above the floor.
d) All of the above.
Ans.: b) as per SAES-P-119/6.7
102) Medium voltage cables rated 5 kV to 35 kV shall have the out jacket consist of?
a) Polyvinyl chloride (PVC) suitable for 90 deg C maximum rated conductor temperature.
b) Shall be sunlight & oil resistant.
c) Both a & b
d) None of above.
Ans.: c) as per 15-SAMSS-502