QA/QCInstrumentationInspectorQuestioner

1. WhatisScheduleQ?
Answer:ScheduleQisanattachmentinthecontract,whichistheprovisionofQualityAssurance
andControl,InspectionandTestPlan.
2. WhatisQA/QC?
Answer:QA/QCmeansQualityAssurance/QualityControlthepurposeofQA/QCistoestablish
thesequenceofrequirementforthequalityofmaterial,qualityofworks,itsinspection,and
records.
3. WhatarethebasicresponsibilitiesofQA/QCinspector?
Answer:Toensureexecutionofworksandcomplyfullyasperstandardandapprovedspecs.
4. WhatarethebasicrequireddocumentsforQC/QCinspector?
Answer:ThebasicrequireddocumentsforQA/QCinspectorarethefollowing:
ITP:(InspectionTestPlan)
WP:(WorkProcedure)Standardproceduretoexecutetheworks/task.
P&ID:(Piping&InstrumentDiagram/Drawing)asareferencetoensurethattheworkisasper
standarddrawing.
MTC:(MaterialTestCertificate)toensurethatmaterialscompliesthePES(ProjectEngineering
Standards)specs.
CalibrationReport:ToensureparametersarecorrectandcheckedasperIDS.
PP:(PlotPlan)toensurethattheinsetsareinstalledasperP&IDandPPasperconvenience.
Hookup:Toensurethattheremoteconnectionofpneumaticisdonecorrectly.
Wiringdiagrams:Toensurethatthewiringisdonecorrectly
5. WhatareQA/QCsITPsandQCP?Giveabriefdescription.
Answer:ITPmeansinspectionandTestPlan,adocumentthatcontainsthedetailsofworkscope
andtherequiredtypesofinspections,(surveillance,inspection,witnessorholdpoints)toensure
thatqualityofworkisbeingdoneinpropersequencesasrequired.
QCP(QualityControlProcedure),thisprocedureaddressestheactivitiesandrequirementsin
details.
6. WhatisNCR?WhyaQA/QCinspectorneedsit?
Answer:NCRmeansNonComplianceReport,QA/QCinspectorhavereservationandtherightsto
issueawarningifthecontractordoesntcomplyorviolatewiththerequiredstandardand
specification.
7. WhatisgeneralWorkProcedure(WP)?
Answer:Thegeneralsequenceofactivitieswillbeasfollows:
Receivingthedrawinganddocuments
Reproductionofdrawings
Issuingdrawingtosite
Newissuingnewrevision
Shreddingofdrawings
Redliningdrawings
Transmittalofredlinestoclient(asbuilt)
RestrictedaccesstoDCO
Workpermitpriortostartwork
Records

 8. Wh hatisredlininng?Whatisittscolorcodee?
Answer:Incasseofanychan ngesneededtothestandaardapproveddrawingwhiiletheprojecttis
beingconstrucctedortested dtherelevanttdrawingwil lberedlined d,thecolorccodingareREED(if
annyadditionreequiredintheedrawing)GR REEN(ifanyddeletionisreqquiredinthed drawing)Bluee(ifany
coommentsisadded).

9. Wh hatisthediffferencebetw weeninspection,witnessaandholdpoin nt?
Answer:
Inspection nworkcanbe eexecutedwiithoutclientssQA/QCand somepartso ofworkcanbbe
inspectedifrequired.
Witnessw workcanbeexxecutedwithoutclientsQ QA/QCanditcanbeinspeccteduponthee
completionofwork.
Holdpointtworkcanno otbeexecutedwithoutclieentsinspectiion.
10. Whhatisdifferencebetween nhazardousaandnonhazaardousareas??
Answer:Ahazardouslocatiionisdefined dasanareaw
wherepotentiialforfireorexplosionexistdue
toothepresencceofflammab blegases,liqu
uidsorvaporss.Anonhazaardousareaissalocationw where
thhereisnoriskkofanykindo
ofexplosionss.
11. WhhatisISO?
Answer:ISOm meansInternaationalStandaardOrganizattion,someexxamplesofitsstandardsarreISO:
90001ISO:9002 2ISO:9003etc.
12. Whhatisthestandardheightttoinstallthe einstrumentts?
Answer:Thesttandardheighttoinstallth heinstrumenntsis1.4meteers,butitcan nvarylessormoreas
perlocationsconvenience..
Additionalnottes:Fieldinsttruments(Tra ansmitters,inndicators,I/PS,etc.)shallb
beinstalledin
nan
acccessiblelocaationwithcennterline1.4m(nominal)abbovegradeorrplatform.
13. Whhatarethesttandardnozzzlesorientatio onsforproceesscontrolsyystem?

Notes:

Forliquid,steamandh heattransfermediaservicces,pressurettapsshallbelocatedonth he
horizontallsideofthep
pipingor45ddegreesdownnfromhorizo ontal.Thepreessuretapsen nsing
lines(impu
ulseline)shalllbeslopeddo
owntothetrransmitter(m
minimumof1perfoot).
Forgasanndvaporservvices,pressureetapsshallbeelocatedonttheverticalfrromtopofthepiping,
horizontallor45degreeesfromverticcal.Thepresssuretapsensiinglines(imppulseline)sha
allbe
slopeduptothetransm mitter(minimumof1perffoot).

Note2:

Instrumentsingasandvaporsserviccearelocateddabovetheirrprocessconttrolconnectio onpoint.
Instrumentsinliquidorrcondensing serviceareloocatedbelow wtheirprocessscontrolconnnection
point.

14. WhhatisLoopteest?
Answer:toenssurethatthesystemwirin ngfromfieldttocontrolcon
nsoleisfuncttioningasreq
quired.

15. Whhatisthediffferencebetw
weenOpenLo oopandCloseeLoop?
Answer:
OpenLoop pAloopsysstemwhichoperatesdirecctwithoutanyyfeedbackan nditgenerateesthe
outputinrresponsetotheinputsignal.
CloseLoop pAloopsysstemwhichusesameasurrementoftheeoutputsignaalthroughfeeedback
andacomparisonwiththedesiredo outputtogennerateanerroorsignalthatisappliedtothe
actuator.

hatisfeedfo
16. Wh orwardandfe
eedbackwardcontrolsysstem?
Answer:

17. WhhatisLogicG
Gate?
Answer:Adigiitalcircuitwitthoneormoreinputvoltaagebutonlyo
oneoutputvooltage.
18. WhhatisFoundaationFieldbussystem?
Answer:Afullyydigitalcontrolsystemiscalledfoundaationfieldbusssystem.
19. WhhatismeantbyFAT,SAT,RAT?
Answer:FATFactoryAccep ptanceTest//SATSiteAccceptanceTestt/RATRunA
AcceptanceTeest



 20. WhatisMicroprocessorcontrolsystem?GiveabriefdescriptionofPLC,DCSandSCADA.
Answer:AcomputerbasecontrolprocesssystemiscalledMicroprocessorcontrolsystem.
PLC:ProgrammableLogicControlsystems,PLCsareusedinpracticewiththeaimofachievinga
higherdegreeofavailabilityorfaulttolerance.Thetypesare:FaultTolerant:1outof2system
objective,reducetheprobabilityoflossesofproductionbyswitchingtoastandbysystemand
FailSafe:2outof2systemobjective,protectlife,theenvironmentandinvestmentbysafely
disconnectingtoasecureoffposition.
DCS:DistributeControlSystem,referstoacontrolsystem,processoranykindofdynamic
system,inwhichthecontrollerelementsarenotcentralinlocation(likethebrain)butare
distributedthroughoutthesystemwitheachcomponentsubsystemcontrolledbyoneormore
controllers.
SCADA:standsforSupervisoryControlAndDataAcquisition.Asthenameindicates,itisnota
fullcontrolsystem,butratherfocusesonthesupervisorylevel.Assuch,itisapurelysoftware
packagethatispositionedontopofhardwaretowhichitisinterfaced,ingeneralvia
ProgrammableLogicControllers(PLCs),orothercommercialhardwaremodules.

21. Whataretheinspectionpointsforcabletrayinstallations?
Answer:Materialcheckasperapprovedspecification,materialtypesandsize,trayshookup,
properdistancestructure,traytotrayi.e.power/control/signal/lowandhighvoltage,supportand
fixedstronglynotshaking.
22. Whataretheinspectionpointsforcablelaying?
Answer:Materialcheckasperapprovedmaterialspecification,typesandsize,meggering,cable
routingdrawing,completionofcableroute(tray,conduitortrenchetc.),andcablenumbering
(tags),cablebending,useofpropertoolsandequipmentforcablepulling,degreeofprotection.
23. Whataretheinspectionpointsforfieldinstrumentswithimpulsetubing?
Answer:Materialcheckasperapprovedmaterialspecification,typesandsize,installationasper
hookup,checklineroutetoavoidanyobstruction,checktubebending,andchecktubesupport,
compressionfittingofferrules,andthenpressuretest(hydrostatictest)shallbedone.
24. WhataretheinspectionpointsforJunctionBoxandMarshalingcabinets?
Answer:Materialinspection,typesandsizeasperapprovedspecification,installationhookupfor
frame,bracketorstands,fixedproperly,nameplateandtagnumbers.
25. WhatisthestandardofinstallingaDP(DifferentialPressure)transmitteringasserviceandwhy?
Answer:InstallationofDPtransmitteringasserviceshallbeabovetheprocesstoavoidthe
malfunctioningandliquiddrain(condensate)intotheprocesslineeasily.
26. Howdoyoudeterminethecorrectinstallationoffloworifice?
Answer:Theorificedate(tag)shallbepunchedintheupstreamoftheorifice;thedata(tag)side
shallbeintheupstreamofflowdirection.
27. Explainwhytheshieldofthesignalcableisnotearthedonbothsides?
Answer:Toavoidcurrentnoise(resonance).
28. WhatisFinalRFI?Whenitshallberaisedup?
Answer:WhentheQA/QCdepartmentofthecontractorissatisfiedthattheworkdetailedinthe
constructionRFIiscompleted,thentherequestshallbesubmittedforinspectiontotheclients
QA/QCdepartment.








29. Whataretherequireddocumentsforaninspection?
Answer:Thefollowingaretherequireddocumentsforaninspection:
RFI(RequestForInspection)
P&ID(PipingandInstrumentationDiagram)forlineverification
PPforlocation
Wiringdiagramforwiringdetails
Datasheetforcalibrationandpressuretest
Hookupetc.forremotetubing/airline
QR(QualityRecord),formaintainingrecords
WP(WorkProcedure)tocheckeachandeverystepsasperspecifications
QCO,(QualityControlObservation)forissuingincaseofminorviolation
NCR,(NonConformityReport)forissuingincaseofmajorviolation
30. WhataretherequireddocumentsforaRemoteLoopfolder?
Answer:ThefollowingaretherequireddocumentsforaRemoteLoopfolder:
Looppackagechecklist
ILD(InstrumentLoopDiagram)
Instrumentloopacceptancerecord(TR/TestRecord)
P&ID(PipingandInstrumentationDiagram)
ISS/IDS(InstrumentSpecificationSheet/InstrumentDataSheet)
Alarmlist
CalibrationRecord(TR)
CableMeggerreport(primarypriortopulling)
CableMeggerreport(secondaryafterpulling)
PressureTestRecord(TR)
MCCheckRecord(Remoteloop)(Greencolor)
MCPunchlist
Looppunchlist
31. WhataretherequireddocumentsforaLocalLoopfolder?
Answer:ThefollowingaretherequireddocumentsforaRemoteLoopfolder:
Looppackagechecklist
ILD(InstrumentLoopDiagram)(ifnotmechanicalloop)
CableMeggerreport(primarypriortopulling)(ifnotmechanicalloop)
CableMeggerreport(secondaryafterpulling)(ifnotmechanicalloop)
Alarmlist
P&ID(PipingandInstrumentationDiagram)
ISS/IDS(InstrumentSpecificationSheet/InstrumentDataSheet)
CalibrationRecord(TR)
PressureTestRecord(TR)ifrequired
MCCheckRecord(Remoteloop)(Greencolor)
MCPunchlist
Visualcheckpunchlist/Loopcheckpunchlist


32. Whatarethevariouslevelsofinspection?
Answer:Thelevelsofinspectionarefollowing:
LevelofInspectionforMaterials:
a) Level0Documentsrequirementsonly,noinspection
b) Level1Inspectionpriortoshipping
c) Level2minimumrequirements,preinspectionmeetings,oneormoreunspecifiedin
progresssurveillancevisits.
d) Level3Sameaslevel2,exceptthatinprogresssurveillanceinspectionshallbeinregular
basis.
e) Level4ResidentInspectorcontinuouslymonitortheworkprogress.
LevelofInspectionforConstructionphase:
a) HoldPoints[H]:Theinspectionactivitywillnotproceedwithoutthepresenceofinspector.
b) WitnessPoints[W]:TheinspectionactivitiescanbeproceedingafterissuingRFI.
c) Review[R]:Verificationofdocumentation(NMR)onitscorrectnessasperspecificationand
drawings.
d) Surveillance[S]:Theinspectorhastherighttoconductrandominspectionofwork.
e) Inspect[I]/Perform[P]/Test[T]:constructioncanproceedtonextphasewithoutclient
QA/QC.

33. WhatisITP?WhatisHoldandWitnesspoints?
Answer:ITPmeansinspectionandTestPlan,adocumentthatcontainsthedetailsofworkscope
andtherequiredtypesofinspections,HoldPoint[H]isthelevelofinspectionthattheclient
QA/QCmustberequiredthroughRFIandcannotproceeduntilinspectionisdonebytheclient.
WitnessPoint[W]isthelevelofinspectionwhichtheinspectionactivitycanproceedwithoutthe
clientsQA/QCorifclientisnotavailableasperRFIschedule.

34. WhatisRFI?WhenanRFIwillberaised?
Answer:TheRequestforInspectionshallberaisedonlywhenthestatusofthepreliminary/internal
inspectionissatisfactory,andthework(items)areHoldorWitnesspoints.