Electrical QC Inspector Course & Interview Questions Part-1
1. Types of Cable?
XLPE PVC – Cross Link Polyethylene Polyvinyl Chloride
THHN/THWN – Thermoplastic High Heat Resistance Nylon coated Cable
AWG – American Wire Gauge
Mineral-insulated copper-clad cable
Non-Metallic Sheathed Cable
Metallic Sheathed Cable (or Armored Cable)
FEP/SS. JKT. Cables
2. Kinds of Transformer Windings?
3. Saudi Aramco Low Voltage wire color coding for AC Supply?
P – Black
N – White
G – Green or Green with white with yellow tracer
4. Saudi Aramco Low Voltage wire color coding for DC Supply?
P – Red
N – Black
5. Saudi Aramco Low Voltage wire color coding for Three Phase system?
L1 – Red
L2 – Yellow
L3 – Blue
N – Black
G – Green or Green with white with yellow tracer
6. Four Kinds of Saudi Aramco Project Phase and Activity code?
7. What are some contents of Surveillance Report
Report Control No.
Comments or Recommendation
8. What are the some contents of Non Conformity Report (NCR)?
Report Control No
NCR Description and reference of violation
Executioner Personnel Signature
Final resolution personnel signature
9. What are the Specific contents of project Method of Statement (MS) or Project Procedure?
Definitions and Abbreviations
Health, Safety and Environment Policy
Authorities and Responsibilities
Methods and general guidelines
Tools, Equipment and Materials
10. Inspection Level as per SAUDI ARAMCO
Level 0 = Inspection Level 0 includes documentation requirements only, no vendor inspection required.
Level 1 = Visual Inspection witnessing by inspector
Level 2 = Certificates/Records to be checked by inspector
Level 3 = Certificates/Data to be provided by vendor/Supplier/Manufacturer
11. Kinds of Switchgear?
SF6 – Sulphur hexafluoride switchgear
GIS – Gas Insulated Switchgear
Mettal clad Switchgear
LV Metal enclosed switchgear
12. What are the Task to be considered of conducting Medium Voltage circuit breaker testing?
Visual and mechanical inspection
Breaker triple and velocity test
Pick-up voltage test on tripped and closed coil
Tripped circuit breaker by operating protective relays
Insulation resistance test
13. What are the required testing to be conducted for Power Transformer?
Transformer Turns and Ratio Test (TTR)
Winding Resistance Test (WRT)
Megger Test/Insulation Resistance and Polarization index test
Short Circuit test of full load test
Open Circuit Test
400 Hz. Induced Over voltage test
Transformer oil test process
Di-Electric strength test
Water content (PPM) Test
Inter facial Tension
Acid Neutralization Number Test
Rapid Pressure Relay
14. What are those steps to be considered on checking any inspection activities for SF6 Switchgear and Transformers?
Visual Inspection – Inspect physical damage, Compare name plate data with approved drawing and specifications, Check the device voltage rating, Check pressure gauge and their ambient temperature as per the chart. Inspect the porcelain bushing for cracks or any damages. Check structural steel for damages and losses of parts
Mechanical Inspection Test – Verify cover, bolts and inter connecting hardware are properly installed and checked if the grounding installed as per drawing
Electrical Inspection – Perform 5KV. DC. Insulation Resistance test in each Pole, Phase to Phase and Phase to Ground for 1 Minute. Performed AC or DC. Hi-potential test
15. What are those steps to be considered on checking during product testing activities?
Check the validity of calibration certificate for the testing devices being used
Working permit has been issued prior to conduct the test
Proper product arrangement and preparation
Check if right tools are being used
Make sure enough manpower are available
Proper communication shall be established
16. What are the documents to be prepared for raising an RFI for Material Receiving?
Documents that can provide Materials Specifications supplied as per the requirements
Documents that Identify the material inspection level
The product Data sheet if it is conform to the requirements
Seek for released note of the product if it is inspectable materials Level 1 – 3, and Material Technical appraisal if non-inspectable Level 0.
Seek for Material Test Certificate/ Material Conformity report
MTO of the product
17. What will you do if during Material Receiving inspection found out a damage or material deficiencies?
Identify/verify the damage materials and segregate to quarantine product, on the area between accepted products.
Initiate Non-Conformance Report (NCR) for the Mishandling of the materials and caused of defect.
18. What are those Six Attachment in Schedule Q, Quality Requirements?
Attachment I – Contractor and Subcontractor Quality personnel Qualification requirements
Attachment II – Company Standards & Procedures containing quality requirements
Attachment III – Quality requirements for contractor supplied materials
Attachment IV – Quality requirements for construction phase
Attachment V – Summary of Quality System Deliverables
Attachment VI – Project Specific Quality Requirements
19. While performing a High Potential Test what are the procedures being done?
Prepared the product being test make sure it is cleaned and secure for corona flush over
Seek for a working permit
Provide necessary warning signage
Check for proper manpower
Check if they have proper communication
Seek for the JCC of the testing personnel
Check the device calibration certificate validity
Inject the desired voltage of the product being tested for the so called Step Voltage given
Records the leakage current measured for the 1st step voltage given
Records the leakage current measured for the 2nd step voltage given
Records the leakage current measured for the 3rd step voltage given
Records the leakage current measured for the 4th step voltage given
Records the leakage current measured for the desired injected voltage given
Steady the desired injected current given within 15 minutes
Take a records of leakage current in every 1 minute
After conducting the test discharge the current by using hot stick and secured by grounding
20. What are the inspection responsibilities of an inspector?
W1 – 100% Witness Inspection/Test
W2 – Sample Witness Inspection/Test
H1 – 100% Hold Point for QC. Inspection or test
H2 – Sample Hold Point for QC. Inspection or test
R1 – 100% Review of Documents
R2 – Sample Review of Documents
RH1 – 100% Review and Approval of Documents
RH2 – Sample Review and Approval of Documents
S – Surveillance
21. Differentiate between QA. and QC, What is QA and QC?
QA – Monitoring the correct implementation of QC
QC – Is a set of specific procedure and examination performed in a particular item in order to achieve a certain level of quality
22. What is Electricity?
Is the science dealing with electric charges and currents with the stationary or moving electrons and protons
23. What is Electron?
Is a negatively charged subatomic particles
24. What is Protons?
A suitable particle with positive charge equal to the negative charge of an electron
25. What is Load Bank?
A Load Bank is a device which develops an electrical load, applies the load to an electrical power source and converts or dissipates, the resultant power output of the source.
26. What are some types of Load Bank?
Resistive load bank
Inductive load bank
Capacitive load bank
27. What is resistive load bank?
A resistive load bank, the most common type, proves equivalent loading of both generator and prime mover.
28. What is capacitive load bank?
A capacitive load bank is similar to a reactive load bank in rating and purpose, except leading power factor loads are created.
29. What are the load bank applications?
Engine Generators, Battery Systems, UPS Systems, Inverters, Ground Power Units, Auxiliary Power Units, Aircraft Power Generators, Wind Generators, and Hydro Generators are used to
test, prove and maintain AC or DC generators and power supplies
30. What are the load bank purposes?
Test – Precision testing instrument which applies a discrete, selectable electrical load to a power generator and measures the response of the generator to the applied load. Measurements of response stability and endurance can be made and corresponding calibrations and adjustment can be effected while a precise load is maintained on the power source
Exercise – Exercise load banks assure the long term reliability and readiness of standby generators by providing a means for routine maintenance exercise of the generator under load. Exercise load banks eliminate the detrimental effects of unloaded operation of diesel engine contractual performance specifications
Demonstration – A sophisticated engineering tool for demonstrating product performance and capability to buyers and users and for fulfilling contractual performance specifications.