Interview Questions

1. Introduction

2. Your role as a QC Inspector

3. What is the meaning of hold and witness point. Hold and Witness for contractor qC and PID.

4. What is captive transformer

5. What is switchboards and switchrack. What is the rating of switchrack.

6. Types of conduits

7. Types of cable glands

8. What is the grounding rod, size and material of the ground rod.

9. Level of inspection. Describe one by one.

10. What is the meaning of MTA. Briefly describe it.

11. What is INCr. Content of INCr. Reference for description like schedule Q , standard etc if
schedule Q then which attachment. What is ACD. Can we extend ACD.

12. Special process in electrical.

13. How we preserve material. What is the standard or procedure for preservation.

14. If the preservation of material is not mentioned in SAEP-385 then how will you store and
preserve the material.

15. What type of testing we do in cable before and after installation.

16. Sheath test voltage and timing duration.

17. In which standard sheath testing is mentioned.

18. What is pass, fail criteria for sheath test.

19. If we have 12/20 KV then how much test voltage we apply in Hi-pot.

20. Substation ground conductor size. Substation and other area ground conductors will be bare
or insulated.

21. What is the substation work space.

22. In which standard workspace is mentioned for substation.

23. Substation front and back side minimum clearance.

24. Height of cable tray from ground floor and above cable tray to ceiling.

25. For Street light which type of solar panel is used.

26. What is standard for solar panels.

27. What is Lighting protection. In which standard lighting protection.

28. How much spare quality we place in duct bank. If we have 100 ducts then how much shall
we install spare ducts.

29. What is CP. Which standard we use for CP.

Scenario 1: Grounding System Design for a New Facility

Question 1:
What is the grounding rod, size, and material of the ground rod as per Aramco standards?

Answer:
In line with SAEP-104 and SAEP-105, the grounding rod should be made of copper-bonded
steel for its corrosion resistance and high conductivity properties. The recommended size of the
rod is typically 5/8 inch to 1 inch in diameter and a length of 8 to 10 feet.

 The material should ensure durability and effective conductivity, with copper-bonded
steel being standard for its high corrosion resistance, especially in challenging
environments like those in Aramco facilities.
 SAEP-104 recommends achieving a grounding resistance of 5 ohms or less to ensure
safe operation in case of electrical faults.

Scenario Example:
You are designing a new facility in a coastal area where high humidity and salinity could affect
the grounding system. To ensure reliability, you select copper-bonded steel rods, and install
multiple rods connected in a ring configuration to minimize the grounding resistance below the
5-ohm requirement of SAEP-104.

Scenario 2: Transformer Selection and Protection

Question 2:
What is a captive transformer, and how would you size it according to Aramco standards?
Answer:
A captive transformer is a transformer dedicated to supplying power to a specific load or
critical area of a facility, isolated from the main electrical grid. Captive transformers are typically
used for mission-critical operations or areas requiring uninterrupted power supply.

 SAEP-104 specifies that a captive transformer should be sized to handle the peak load
demand plus an additional 10-20% margin to accommodate future growth or temporary
overload conditions.
 The transformer’s protection should include overcurrent protection, differential
protection, and fault protection as outlined in SAEP-105.

Scenario Example:
For a new offshore oil rig, you need a captive transformer to supply power to essential systems
like HVAC, lighting, and critical machinery. You calculate the peak load to be 500 kVA, and
based on SAEP-104, you select a 550 kVA transformer to account for potential future load
increases. The transformer is isolated from the main plant grid, and protection schemes such as
overcurrent protection and differential protection are applied to ensure safety.

Scenario 3: Electrical Switchgear and Switchboard Design

Question 3:
What are switchboards and switchracks, and what is the rating of a switchrack as per Aramco
standards?

Answer:
A switchboard is a large, insulated panel that houses electrical components like circuit breakers,
fuses, and switches to control, distribute, and protect electrical circuits. A switchrack is a similar
device used for distributing electrical power but is typically simpler and smaller in size.

 Switchboards typically handle the main distribution of power in a facility, and their
ratings are based on the maximum current they can safely handle.
 The rating of a switchrack is generally up to 600V for low-voltage applications. In
SAEP-104, the design and specifications of these systems must comply with the safety
and functional requirements for operation, with proper coordination between protection
devices.
 SAEP-185 also governs the installation and maintenance of electrical equipment,
ensuring that these components are suitable for safe and reliable operation in Aramco
facilities.

Scenario Example:
In a chemical processing plant, you need to design an electrical distribution system. After
evaluating the load requirements, you choose a low-voltage switchboard rated for 4000A to
manage the main electrical distribution, ensuring compliance with SAEP-104. Additionally, a
switchrack is selected with a 400A rating for use in a secondary panel to manage non-critical
load distribution.

Scenario 4: Cable Management and Installation

Question 4:
What are the types of conduits used in electrical installations, and which ones would you select
in an industrial environment?

Answer:
Common types of conduits include:

1. Rigid Metal Conduit (RMC): Made of galvanized steel, this provides excellent
protection for electrical cables and is often used in outdoor or hazardous environments.
2. Electrical Metallic Tubing (EMT): Lightweight and easy to install, EMT is commonly
used in commercial applications but is not recommended in areas where high mechanical
protection is needed.
3. Flexible Metal Conduit (FMC): Typically used in areas that require flexibility, such as
for connecting equipment or for places that might require movement.
4. PVC Conduit: Ideal for underground applications or areas with corrosive materials, but
not suitable for areas exposed to high heat or mechanical impact.

In an industrial environment per SAEP-104 and SAEP-105, RMC and PVC conduits are
generally preferred, particularly in areas with high risk of mechanical damage or environmental
exposure. EMT can be used for indoor areas with less exposure to physical damage.

Scenario Example:
For a new petrochemical facility, you design the electrical cable routing for the entire site. You
use RMC for outdoor and high-risk areas to ensure mechanical protection, and PVC conduit is
chosen for underground cable routes to minimize the risk of corrosion, in accordance with
SAEP-104.

Scenario 5: Cable Termination and Protection

Question 5:
What are the types of cable glands, and which ones are suitable for use in hazardous areas?

Answer:
Cable glands are used to securely terminate cables, providing mechanical support and electrical
continuity. Common types include:
 1. Standard Cable Glands: Used for general applications to prevent the cable from being
damaged or pulled out of place.
2. Explosion-Proof (Ex d) Cable Glands: These are essential for use in hazardous
locations, as they prevent the ignition of flammable atmospheres.
3. Armored Cable Glands: Used for armored cables to provide grounding and prevent
damage to the cable's metal sheath.
4. Weatherproof Cable Glands: Used in outdoor environments to provide a weather-tight
seal.

In hazardous areas as per SAEP-104 and SAES-P-111, Ex d (explosion-proof) cable glands are
essential to prevent the ingress of flammable gases, dust, or vapors. They are selected based on
the Zone classification of the area and ensure the protection of both personnel and equipment.

Scenario Example:
For a refinery facility classified as Zone 1 (explosive atmosphere), you select Ex d certified
cable glands for all electrical connections to ensure the safety of the equipment and personnel.
You follow SAES-P-111 guidelines to ensure proper sealing and installation for the explosion-
proof rating.

Scenario 6: Electrical Maintenance and Safety

Question 6:
How would you ensure electrical safety during maintenance operations on high-voltage
substation equipment?

Answer:
Electrical safety during maintenance operations is critical, especially in high-voltage
environments like substations. The following steps ensure worker safety:

1. Lockout/Tagout (LOTO): Per SAEP-385, all sources of electrical energy should be

locked and tagged out to prevent accidental energization during maintenance.
2. Personal Protective Equipment (PPE): As per SAEP-104 and NEC 110.16,
appropriate arc flash-rated PPE (e.g., clothing, gloves, face shields) must be worn by all
maintenance personnel working on electrical systems.
3. Grounding: Temporary grounding is essential to ensure all equipment is at earth
potential, preventing shock hazards. The grounding system should meet the SAEP-104
grounding standards.
4. Fault Current Calculations: Before maintenance, conduct a fault current analysis and
determine the available fault currents, ensuring that all protective devices are properly
rated to clear faults safely.

Scenario Example:
During the annual maintenance of a 33kV substation, you ensure that all electrical panels are
locked out, and PPE is issued to all technicians. Temporary grounding is established for the
high-voltage equipment, and a thorough hazard assessment is performed in accordance with
SAEP-104 and NEC standards.

Final Thoughts:

These scenario-based examples and answers give you a comprehensive understanding of how
to approach electrical system design, safety, and equipment specifications within an Aramco-
compliant environment. The responses incorporate standards such as SAEP-104, SAEP-105,
SAEP-185, SAES-P-111, and related NEC and IEC standards. These are essential for
addressing real-world challenges while ensuring compliance with Aramco’s rigorous safety and
operational requirements.

+++++++

INCr stands for Initial Non-Conformance Report. It is a formal document issued when a
material, process, or procedure deviates from the approved specifications or requirements during
a project or inspection. The purpose of the INCr is to formally record and report any non-
conformance issues that arise and to track corrective actions to resolve the non-conformance.

Content of INCr:

The INCr typically contains the following information:

 Description of Non-Conformance: A clear explanation of the non-conformance,

including details about the specific material, process, or procedure involved.
 Reference to Specifications: The specific Aramco standards, technical specifications,
or codes that the material or procedure failed to comply with.
 Root Cause Analysis: An analysis identifying the cause of the non-conformance,
whether it is due to materials, workmanship, design, or environmental factors.
 Corrective Action Plan: A plan detailing the steps required to rectify the issue and bring
the material or process back into compliance.
 Impact Assessment: Evaluation of how the non-conformance affects the overall project,
safety, quality, or timeline.

Example of INCr (Initial Non-Conformance Report) for Electrical Work

Scenario:

While performing a routine inspection of an electrical installation for a new industrial plant, the
Electrical QC Inspector discovers that the cable insulation on some of the installed power
cables does not meet the required Aramco electrical specifications (e.g., SAES-P-111 for
electrical installations). The cables have been installed incorrectly, and the insulation type does
not match the approved material specified in the contract.

Steps in Handling the INCr Process:

1. Description of Non-Conformance:
o Non-Conformance: The insulation material of the installed power cables is not
compliant with the approved electrical specifications in the contract and does
not meet the required standards for fire resistance.
o Details: The contractor used a non-approved type of PVC-insulated cable
instead of the XLPE (Cross-Linked Polyethylene) cables as per Aramco’s
SAES-P-111 standard for cable specifications.
2. Reference to Specifications:
o The Aramco Engineering Standard (SAES-P-111) outlines the required types
of cables for electrical installations, which specify the insulation type and fire
resistance standards.
o The Aramco Standard requires that all power cables have XLPE insulation for
specific fire safety properties and durability, which were not met by the installed
cables.
3. Root Cause Analysis:
o Cause: The contractor's procurement team mistakenly sourced cables with PVC
insulation, assuming it met the standard requirements. There was a breakdown in
communication and coordination during the procurement phase, and proper
verification of the material’s compliance with SAES-P-111 was missed.
o Contributing Factors: Lack of detailed checks during the materials inspection
process and inadequate quality control during the supply chain management.
4. Corrective Action Plan:
o Step 1: The non-compliant cables will need to be removed and replaced with the
correct XLPE-insulated cables.
o Step 2: A full re-inspection of all electrical materials will be conducted to
ensure no further deviations from Aramco specifications.
o Step 3: The procurement team will undergo additional training to ensure proper
verification of materials during sourcing and handling.
o Step 4: Additional quality assurance measures will be implemented during
procurement and inspection phases to prevent recurrence of such non-
conformances.
5. Impact Assessment:
o Quality Impact: The incorrect insulation could result in lower fire resistance
and long-term durability of the electrical installation, affecting the overall safety
of the plant.
o Safety Impact: The use of non-compliant cables could pose significant fire
safety risks in the event of electrical faults, especially in high-voltage
applications.
 o Timeline Impact: The replacement of the cables will cause a delay in the
project schedule as it involves removing and replacing a significant portion of
the electrical wiring.
o Cost Impact: The corrective actions will incur additional costs for materials and
labor associated with replacing the non-compliant cables and conducting further
inspections.

INCr Report Example:

Initial Non-Conformance Report (INCr)

Project Name: New Industrial Plant
Project Number: 1234-5678
Date: 16th March 2025
INCr Number: INCR-2025-001

Non-Conformance Description:
The insulation material on the installed power cables does not comply with the approved
Aramco standards as per SAES-P-111. The cables were installed with PVC insulation, which
is not in compliance with the specification requiring XLPE insulation for improved fire
resistance.

Reference Specifications:

 SAES-P-111: Section 5.3 – Cable Insulation Material Requirements (XLPE)

 Aramco Electrical Standards – Fire Resistance Requirements

Root Cause:
The incorrect cables were procured due to an error in the material selection process, where PVC-
insulated cables were mistakenly assumed to meet the specification requirements.

Corrective Action Plan:

 Remove and replace all non-compliant cables with XLPE-insulated cables.

 Conduct a comprehensive inspection of all materials to ensure full compliance with
Aramco standards.
 Provide training for the procurement and inspection teams to prevent future errors.
 Implement additional quality assurance procedures to verify materials and suppliers
during procurement.

Impact:

 Quality: Reduced fire safety due to improper insulation material.

  Safety: Increased risk of fire hazards in the event of electrical faults.
 Schedule: Project delay due to replacement of cables.
 Cost: Additional costs for cable replacement and inspections.

Signed by:

 Electrical QC Inspector: [Name]

 Contractor Representative: [Name]
 Aramco Representative: [Name]

Summary:

An INCr is used to formally document and address any non-conformances, like the incorrect
insulation in this electrical example. The report includes a detailed explanation of the issue, its
root cause, the corrective actions to resolve it, and the potential impacts on safety, quality, cost,
and schedule. The goal is to ensure that corrective actions are taken swiftly and effectively to
maintain the integrity and compliance of the project.