Coating Inspector

Q1. What does pH value show?

Ans: Acidity or alkaline nature of a solution
Q2. FBE powder coating?
Ans: Thermoset
Q3. Solvent and paints shall not be applied over substrate of temp greater than?
Ans: 80°C
Q4. Brush off blast cleaning?
Ans: SSPC SP7
Q5. Swedish standard for near white metal blast cleaning?
Ans: Sa 2.5
Q6. How RH can be measured?
Ans: Sling Psychrometer
Q7. What can be measured using sling psychrometer?
Ans: Relative Humidity
Q8. DP can be measured by?
Ans: Whirling psychrometer
Q9. What is the pressure for blotter test?
Ans: 50 PSI
Q10. What is classification of coating?
Ans: Organic and Inorganic coating
Q11. When recoat interval to be monitored?
Ans: Every coat
Q12. PE can be done by cross extrusion or sideways extrusion?
Ans: TRUE
Q13. Gauge used for 25mic film coating
Ans: Digital gauge, Pocket spot instrument gauge, Banana Gauge
Q14. Requirement for light in confined space?
Ans: 12V explosion proof (500 lux)
Q15. Sigma paint can be painted over Jotun?
Ans: True
Q16. Lining is not suitable for
Ans: UV protection
Q17. Aramco standard for safety requirements?
Ans: SAES-H-102
Q18. Safety catch of the spray gun shall always be engaged when unattended?
Ans: Airless spray, Conventional spray, Spray booth
Q19. What is the advantage of centrifugal blast machine?
Ans: Dust containment
Q20. What will be done prior to blasting of crude tank bottom plate?
Ans: Solvent cleaning to remove oil & grease
Q21. What will be the WFT when DFT is 75mic with VS% of 50?
Ans: 150 micron
Q22. How much quantity is required to paint 100 Sq M with DFT of 300Mic?
Ans: 30.3 Liters
Q23. What affects the coat when dry spray, oxide formation?
Ans: Coating Adhesion
Q24. What is the abrasive medium for SSPC SP12?
Ans: Water
Q25. What does spray nozzle tip 421 denote?
Ans: 40° and 0.021 Inches
Q26. What does the pump ratio mean?
Ans: Inlet of pump and outlet of pump
Q27. Painter wants to use 5L but not available, painter has only 20 L of Part A & B. What can he
do?
Ans: Full cans to be used
Q28. Holiday voltage for epoxy immersion service?
Ans: 2400 +/- 50
Q29. Hand applied paint system for splash zone?
Ans: APCS 22B
Q30. WFT = DFT x 100 /VS
Ans: TRUE
Q31. SSPC SP7
Ans: Brush-off blasting
Q32. Four elements to control corrosion
Ans: Anode, Cathode, Electrolyte, Metallic Pathway
Q33. DFT gauge can be calibrated by
Ans: Manufacturer, Laboratory, Coating inspector
Q34. Out of which four elements mainly control corrosion
Ans: Anode
Q35. Thermal spray done immediately can shout off
Ans: FALSE
Q36. Covered with both mill scale & rust
Ans: Condition B
Q37. Fusion bond epoxy coating holiday is done by
Ans: High voltage holiday detector
Q38. If DFT is 400 to 500 microns, voltage used is 1500 volts
Ans: FALSE
Q39. Minimum surface preparation is required by
Ans: Commercial blast
Q40. How many volts of light required in immersion services?
Ans: 12 volts of explosion proof
Q41. Rust grade A is
Ans: Adherent mill scale with little rust
Q42. How many layers of paint needed for 100-meter square & DFT is 300 micron?
Ans: 30.3 Liters
Q43. If we check DFT for 10 meter square and DFT Value is found low (less than specified)
Ans: FALSE
Q44. Centrifugal blasting consists of
Ans: Grit & shot
Q45. Steel covered with rust & partial pitting observed
Ans: Condition C
Q46. DFT = Wet x VS / 100 (Calculation)
Ans: WFT * VS / 100
Q47. While using airless spray both air & paint come in separate channels & finally mixed?
Ans: FALSE
Q48. After completion of paint application too much dust particles settled before dried, what
defect can be found?
Ans: Over spray
Q49. While doing blasting, blaster gets injured, immediately shout off
Ans: Dead man valve
Q50. SSPC SP12 defined as
Ans: Water
Q51. NACE RP 0188 is
Ans: Holiday test
Q52. SSPC VIS 1 is
Ans: Surface preparation standard of rust grade
Q53. Surface profile has been measured by:
Ans: Surface comparator
Q54. SSPC SP6 is
Ans: Commercial blasting
Q55. Hand applied splash zone is
Ans: APCS 19A
Q56. For curing, some coatings require
Ans: Moisture
Q57. Surface cleaning assessment for power tool cleaning:
Ans: SSPC VIS 2
Q58. Flash point definition
Ans: The minimum temperature at which a liquid produces enough vapor to ignite in the presence of an
ignition source.
Q59. SSPC PA2 definition
Ans: Standard for measuring dry film thickness of coatings applied to ferrous and non-ferrous metals.
Q60. Galvanic corrosion occurs on
Ans: Metal
Q61. 45:1 ratio of airless spray pump
Ans: Inlet to outlet pump ratio
Q62. Feathering definition
Ans: The process of tapering the edges of a coating or paint layer to create a smooth transition for
repainting or blending
Q63. Some buried coatings shall not be 100% holiday checked prior to burial
Ans: Yes
Q64. SSPC VIS I-89 definition
Ans: Visual standard for assessing cleanliness levels for surfaces prepared by abrasive blasting.
Q65. Min. Pressure at nozzle required for Abrasive blast cleaning
Ans: 90 PSI
Q66. For cone-shaped tanks coating, Coating shall be done
Ans: Roof to bottom
Q67. FBE coating powder in liquid form stage is mentioned as
Ans: Gel stage
Q68. Dew point (definition)
Ans: The temperature at which air becomes saturated with moisture and condensation begins to form.
Q69. Induction time (definition)
Ans: The time required for a mixed coating to become suitable for application after combining its
components.
Q70. Min moisture content required for new concrete structure prior to coating
Ans: 0.04
Q71. Max allowed speed of probe in Holiday test:
Ans: 30 mm/s
Q72. Type of field adhesion test used for FBE coating
Ans: Cross cut
Q73. Surface profile measurement instrument
Ans: Dial micrometer
Q74. Part of blasting equipment that helps when a worker faints during abrasive blasting
Ans: Dead man’s handle
Q75. Holiday test shall not be done if temperature of substrate is more than
Ans: 68°C
Q76. Potassium Ferrocyanide test is used for detecting
Ans: Soluble Iron salts
Q77. Max allowed chloride content for abrasives
Ans: 50 ppm
Q78. Stripe coating for Inorganic zinc coating shall be done at:
Ans: After first coat application
Q79. Attachment form submitted for coating inspector to review daily activities according to
SAES-H-100-01
Ans: Attachment A and B
Q80. SSPC SP1
Ans: Solvent cleaning
Q81. PE coating on piping can be done by Cross extrusion / sideways extrusion
Ans: TRUE
Q82. Profile measurement range for X-Coarse testex tape
Ans: 35–115 microns
Q83. Gauge used for dry film thickness on thin film coating
Ans: Digital gauge, Banana gauge, Pocket spot Instrument gauge
Q84. MSDS shall be used by
Ans: Coating, Solvent, Cleaners
Q85. Weld cap/internal protrusion shall not be more than
Ans: 1.5 mm
Q86. Sigma paint can be over-coated with Jotun
Ans: FALSE
Q87. Silica gel is not a good desiccant
Ans: FALSE
Q88. Silica sand can be used for abrasive blasting
Ans: FALSE
Q89. Coating shall be done within ----hrs of blasting completion
Ans: 4 Hours
Q90. Who will recommend the solvent type for coating
Ans: Manufacturer datasheet
Q91. VS% of Paint system is available in
Ans: SAES-H-001
Q92. Hand tool cleaning will make the surface
Ans: Smooth and shiny
Q93. Surface cleaning requirement for Road crossing area pipeline coating except APCS-113C
Ans: Sa2
Q94. Blisters formed on coating by
Ans: Water/solvent entrapment underneath the coating film
Q95. Coating on sharp edges/corners will be
Ans: Removed/peeled off
Q96. Surface appearance Characteristic of cleaning/Degree of cleanliness
Ans: SA2 & SA2½ can be measured by SSPC-Vis1
Q97. What is surface profile and how to measure surface profile?
Ans: Maximum Peak-To-Valley depth, surface profile can be measured by:
(a) Visual comparator
(b) Surface profile Micrometer
(c) Testex tape with Micrometer
Q98. Method of coating application used for immersed service
Ans: Airless spray coating
Q99. Sealer coat application is possible immediately following thermal spray coating
Ans: True

Instrumental Inspector
Q1. Zones (IEC, NEC, NEMA)
Ans: IEC uses Zones 0–2, NEC uses Classes/Divisions, and NEMA specifies enclosure protection
ratings.
Q2. Valve Open/Close Status
Ans: Shown by position indicators or limit switches.
Q3. Foundation Fieldbus
Ans: Digital protocol for communication in industrial automation.
Q4. Instrument Location (Oil & Gas)
Ans: Near equipment like tanks, pipelines, and separators.
Q5. DCS, ESD, SCADA
Ans: DCS is for process control, ESD for safety shutdown, and SCADA for remote monitoring.
Q6. Drawing for Tubing Inspection
Ans: Pneumatic Tubing Layout or P&ID.
Q7. Drawing for Final Installation Inspection
Ans: Instrument Hook-Up or Loop Diagram.
Q8. Typical Installation Drawing
Ans: Shows details of mounting, wiring, and tubing.
Q9. Instrument Error in Calibration
Ans: Difference between actual value and measurement.
Q10. Types of Temperature Sensors
Ans: Thermocouples, RTDs, thermistors, and infrared sensors.
Q11. RTD vs. Thermocouple
Ans: RTDs are accurate and stable; thermocouples cover a wider temperature range.
Q12. HART Protocol
Ans: Enables analog and digital communication on the same wiring.
Q13. Hazardous Area
Ans: Area with potential for explosive atmospheres.
Q14. IP (Ingress Protection)
Ans: Specifies protection against solids and liquids for enclosures.
Q15. IEC 529 Specification
Ans: Defines IP ratings like IP65 for enclosures.
Q16. NEMA Standards
Ans: Define protection levels of electrical enclosures.
Q17. NEMA-250
Ans: Specifies standards for enclosures in hazardous and non-hazardous areas.
Q18. Hazardous Area Junction Box
Ans: Use explosion-proof (Ex d) or intrinsically safe boxes.
Q19. LOOP Package
Ans: Documentation for instrument loop details and testing.
Q20. Marshalling Cabinet
Ans: Connects field devices to control system panels.
Q21. Field Instrument Height
Ans: Typically 1.2–1.5 meters above ground.
Q22. Size of Impulse Tube
Ans: Commonly 1/4 or 3/8 inch.
Q23. Maximum Length of Impulse Tube
Ans: Up to 15 meters to avoid lag.
Q24. Bench Calibration
Ans: Apply test signals, compare outputs, and adjust.
Q25. Hot vs. Cold Loop
Ans: Hot is operational; cold is de-energized for testing.
Q26. Marshalling Cabinet Shields
Ans: Connect shields to grounding bus bars.
Q27. Analog Input Cable Shields
Ans: More shields prevent signal interference compared to digital cables.
Q28. Meggering Resistance for Control Cable
Ans: Should be above 1 MΩ.
Q29. PQP full form.
Ans: Project Quality Plan detailing inspections and testing.

Mechanical & Welding Inspector

Q1. Impact Test (API 650)
Ans: Impact testing is limited by material thickness, temperature, and whether the steel meets the re-
quired toughness properties.
Q2. Internal Pressure Test for Tank (API 650)
Ans: Per API 650, tanks are tested at a hydrostatic pressure equal to the maximum design liquid level
plus static head pressure.
Q3. Types of Fluid
Ans: Includes Category D (non-hazardous), Normal Fluid Service, Category M (toxic), and High-Pressure
Service.
Q4. RT Percentages of Normal and M Fluid
Ans: Normal fluid service requires a random RT of 5–10%, while Category M fluid may require 100% RT
depending on risk assessment.
Q5. What Do You Know About Piping Class
Ans: Piping class specifies material, pressure-temperature ratings, and fitting types for specific services.
Q6. PWHT (Post Weld Heat Treatment)
Ans: Soaking time depends on material thickness, typically 1 hour per 25 mm; cooling time is controlled to
avoid material distortion.
Q7. Do You Work for Pipeline; What Is the ASME Code and Standard?
Ans: The applicable code is ASME B31.8, which governs the design, construction, testing, and operation
of gas pipelines.
Q8. Hydrotest Criteria for Pipeline
Ans: Hydrotesting is done at 1.25 times the design pressure for a specified duration (usually 8 hours) with
no pressure drop.
Q9. What Do You Know About Sour Service
Ans: Sour service involves exposure to hydrogen sulfide (H₂S), requiring materials and coatings resistant
to sulfide stress cracking per NACE standards.
Q10. How to make material selection for piping or valves
Ans: Material is selected based on service conditions, pressure-temperature ratings, corrosion resistance,
and applicable standards.
Q11. NCR (Non-Conformance Report)
Ans: A formal document reporting non-compliance with project specifications or standards.
Q12. If corrective action is not possible to apply, can you go to the next step in NCR?
Ans: Yes, proceed with disposition options like acceptance-as-is or rework based on project authority
approval.
Q13. In your project, how to know that the right material has arrived for inspection
Ans: Verify materials against purchase orders, material test certificates (MTC), and project specifications.
Q14. In an NCR what portion is QA related and what portion is QC related?
Ans: QA focuses on root cause analysis and preventive measures, while QC addresses detection and
correction of the defect.
Q15. As Per ASME B31.8 what is NDT selection criteria?
Ans: NDT selection is based on pipe material, joint type, operating pressure, and service conditions.
Q16. What are four types of pipe as per ASME B31.8?
Ans: Seamless, welded, cast, and composite.
Q17. Tell me about ASME B31.4
Ans: It governs the design, construction, operation, and maintenance of liquid pipeline systems.
Q18. What do you know about the Hydrotest Package?
Ans: It includes test procedures, acceptance criteria, calibration records, and testing documentation.
Q19. What is sour service?
Ans: A service involving exposure to hydrogen sulfide (H₂S), requiring materials resistant to sulfide stress
cracking.
Q20. How do you know if this pipe is suitable for sour service or not?
Ans: By reviewing MTC for compliance with NACE MR0175 and verifying HIC and SSC test results.
Q21. Which code we follow for the material selection of sour service?
Ans: NACE MR0175/ISO 15156.
Q22. What is HIC?
Ans: Hydrogen Induced Cracking caused by the absorption of hydrogen in susceptible materials.
Q23. As Site QA, how will you handle site activity from start to end?
Ans: Monitor compliance with project specifications, verify materials, oversee inspections, and document
findings through to closure.
Q24. Explain API 5L Gr X65 PSL2 S
Ans: API 5L specifies pipeline steel grades, X65 denotes strength, PSL2 defines stricter quality, and "S"
indicates sour service suitability.
Q25. From MTC how will you know that this pipe is for sour service or general purpose?
Ans: Check for compliance with NACE MR0175, HIC test results, and specified hardness limits.
Q26. What is the mechanical testing required for pipe used in sour service?
Ans: Tensile, impact, hardness, and HIC/SSC tests.
Q27. What is the working procedure for Mechanized GMAW process?
Ans: Set up equipment, align the joint, select the correct parameters, and automate the welding process
for uniformity.
Q28. Code of Hydro Testing
Ans: ASME B31.3 or B31.8 specifies hydro testing requirements based on system type.
Q29. Parameters in WPS for PWHT
Ans: Holding temperature, soaking time, heating, and cooling rates.
Q30. Main Contents of NCR and Evaluation
Ans: Description of non-conformance, root cause analysis, corrective action plan, and disposition
evaluated based on compliance to standards.
Q31. Procedure of Root Cause Analysis with Example
Ans: Identify the issue, analyze contributing factors, determine the root cause, and implement corrective
actions.
Q32. Code of Power Piping
Ans: ASME B31.1.
Q33. Code for Pressure Testing Requirements
Ans: ASME B31.3, B31.8, or API 650 depending on the application.
Q34. Sequence of Fabrication
Ans: Starts with material preparation, cutting, fitting, welding, NDT, assembly, and ends with final
inspection and testing.
Q35. Wall Testing Experience
Ans: Yes, performed pressure and integrity testing per ASME or API standards.
Q36. What is RAD in W-12?
Ans: Represents Radiographic Acceptance Details for W-12 weld joints.
Q37. What is internal clamp and external clamp?
Ans: Internal clamps align pipes from inside; external clamps do so from the outside.
Q38. Brief line class example?
Ans: Example – 150# for low-pressure service, 300# for medium-pressure service.
Q39. What is pickling and passivation?
Ans: Pickling removes scales/rust; passivation improves corrosion resistance.
Q40. Tie-in joint definition?
Ans: A joint used to connect two pipeline sections after construction.
Q41. Types of bead?
Ans: Stringer bead, hot pass, fill pass, and cap bead.
Q42. PWHT brief?
Ans: Post Weld Heat Treatment relieves stress and enhances material properties.
Q43. What is dolly mix welding?
Ans: A technique using mixed filler rods for special alloy repairs.
Q44. What is PMI?
Ans: Positive Material Identification ensures material composition matches specifications.
Q45. Scrapper use which type of valve is used?
Ans: Scraper valves like ball valves or full-bore gate valves are commonly used.
Q46. What are hydrostatic requirements?
Ans: Test at 1.25 times design pressure for a specified duration with no leaks.
Q47. How you calculate backpurging?
Ans: Calculate flow rate and volume of inert gas required based on pipe size and length.
Q48. Lowering process?
Ans: Ensure alignment, coating integrity, safe lowering, and proper bedding.
Q49. As a mechanical inspector how you control storage handling?
Ans: Monitor material condition, ensure proper stacking, and avoid exposure to moisture.
Q50. Joint Design variable as per ASME section IX for Qualifications of PQR?
Ans: Includes groove angle, root opening, backing, and filler metal type.
Q51. What do you know about the low hydrogen electrode?
Ans: A low hydrogen electrode minimizes hydrogen content, reducing risk of cracking.
Q52. What are the requirements for low hydrogen electrodes?
Ans: Must meet AWS classification and be suitable for the base material and environment.
Q53. What are the requirements of storage of the low hydrogen electrodes?
Ans: Store in a dry oven at 250-300°F to avoid moisture absorption.
Q54. What's the recommendation and restrictions of low hydrogen electrodes?
Ans: Use as recommended for clean surfaces; restrict for contaminated or wet conditions.
Q55. State the essential variables for Welders qualifications?
Ans: Essential variables include material type, welding process, and position.
Q56. State the applied Standards of the Construction code (B31.3)?
Ans: B31.3 applies to process piping, specifying design, materials, and fabrication standards.
Q57. Did you use API 1104 before?
Ans: Yes, used as acceptance criteria for welding and NDT in ASME B31.8 construction.
Q58. Did you work with in-service welding?
Ans: No, but defined in-service welding as Hot Tapping per API 1104.
Q59. Which code is Applied for hot tapping?
Ans: API 1104 is the code applied for hot tapping procedures.
Q60. State the Codes for testing Gate valves, Ball Valves, and PSV valves?
Ans: Gate valves – API 598; Ball valves – API 6D; PSV valves – API 527.
Q61. What are the tie-in weld types?
Ans: Common types include fillet, butt, and socket welds.
Q62. What is the Layup process?
Ans: Layup preserves idle equipment by cleaning, drying, and using protective coatings.
Q63. How to evaluate a new welder's performance (explain the conditions of Progressive
sampling)?
Ans: Monitor welding quality using random sampling; increase checks if defects are found.
Q64. Essential & Non-Essential Variables of WPS/PQR
Ans: Essential variables affect mechanical properties (e.g., material type, welding process), while non-
essential variables (e.g., joint design) do not.
Q65. Essential & Non-Essential Variables of WQT
Ans: Essential variables include position, material, and process; non-essential variables involve non-
critical details like joint preparation.
Q66. Handling and Storage of CS and SS Pipes
Ans: Store separately to avoid contamination, protect from moisture, and use supports to prevent
bending.
Q67. Handling and Storage of Different Kinds of Valves
Ans: Keep valves in a clean, dry environment; ensure proper end caps and avoid direct ground contact.
Q68. Handling and Storage of Pressure Safety Valves
Ans: Store in an upright position with calibrated tags intact; protect from dust and physical damage.
Q69. Handling and Storage of RTR and GTR Pipes
Ans: Avoid direct sunlight, store on flat surfaces, and prevent stacking to avoid deformation.
Q70. Content of NCR
Ans: Includes description of non-conformance, root cause analysis, corrective action plan, and approval.
Q71. Closure or Closing Process of NCR
Ans: Verify corrective actions, document evidence, and obtain approval for closure from authorized
personnel.
Q72. Essential Variable of WPS
Ans: Includes material type, welding process, filler metal, and position as they affect weld properties.
Q73. Selection Criteria of Pressure Gauge for Hydrotest
Ans: Should have a range 1.5–4 times the test pressure and comply with ASME standards.
Q74. How Do You Communicate with Your Client?
Ans: Through regular meetings, emails, and reports to ensure clear and professional communication.
Q75. Have You Ever Worked with Aramco?
Ans: Yes/No; explain your role or express readiness to adapt to Aramco standards if not.
Q76. Handling and Managing Multiple Contractors
Ans: Prioritize tasks, establish clear communication channels, and monitor progress through regular
updates.
Q77. Storage and Handling Process of Welding Consumables
Ans: Store in a dry area, maintain temperature as per manufacturer’s instructions, and issue on a FIFO
basis.
Q78. Roles and Responsibilities with Current Organization
Ans: Ensure quality assurance, supervise inspections, and maintain compliance with project standards.

Piping Inspector
Q1. ASME Code for Design of Process Piping Systems in Refineries & Chemical Industries
• ASME B31.3.
Q2. American Institute Standards Referred by Piping Engineers
• API, AISI, ASTM, ANSI, AWS, AWWA, ASME
Q3. Different ASME B31 Codes for Pressure Piping
• B31.1: Power Piping
• B31.2: Fuel Gas Piping
• B31.3: Process Piping
• B31.4: Liquid Pipelines
• B31.5: Refrigeration Piping
 • B31.8: Gas Pipelines
• B31.9: Building Services Piping
• B31.11: Slurry Transportation
Q4. Which American institute standard does piping engineer refer?
• ASME (American Society of Mechanical Engineers)
Q5. What are the different sections of ASME code? Where are these sections referred?
• Section I: Power Boilers
• Section II: Materials
• Section V: NDE (Non-Destructive Examination)
• Section VIII: Pressure Vessels
• Section IX: Welding & Brazing
• Each section is referred based on design, construction, fabrication, and inspection standards.
Q6. What is the ASTM code for the following?
• Carbon Steel: ASTM A106
• Alloy Steel: ASTM A335
• Stainless Steel: ASTM A312
• Nickel Steel: ASTM B161/B163
Q7. What is the basic difference between Pipe specification A106 Gr.A / Gr.B/ Gr.C?
• Based on tensile strength:
• Gr.A: Lowest
• Gr.B: Medium
• Gr.C: Highest
• Also varies in chemical composition and allowable stress.
Q8. How can flanges be classified based on Pressure-Temperature ratings?
• Based on class: 150, 300, 600, 900, 1500, 2500 as per ASME B16.5
• Each class corresponds to pressure rating at a reference temperature.
Q9. How can flanges be classified based on facing?
• Raised Face (RF)
• Flat Face (FF)
• Ring Type Joint (RTJ)
• Tongue & Groove (T&G)
• Male & Female (M&F)
Q10. What is centering ring in connection to spiral wound gasket?
• Carbon steel external ring that aligns the gasket in the flange bore.
Q11. What will be the AARH finish on flange face for using spiral wound gasket?
• 125–250 AARH (Arithmetic Average Roughness Height)
Q12. On which type of flanges the use of spiral wound gasket is restricted?
• Not recommended on 150# flanges except for weld neck and lap joint flanges (per ASME B16.5).
Q13. Up to what temperature limits should low-strength carbon steel bolts not be used for flanged
joints?
• Not above 200°C or below -28°C.
Q14. Up to what temperature can carbon steel materials be used?
• Up to 425°C.
Q15. Which material is used for temperature above 426°C?
• Alloy steel.
Q16. Which type of material is used for corrosive fluid?
• Stainless steel.
Q17. Which piping materials are used for drinking water, instrument air, etc.?
• Galvanized steel.
Q18. What is the difference between Pipe and Tube?
• Pipe: Identified by NB and Schedule (thickness)
• Tube: Identified by OD and thickness (BWG)
Q19. From which size onwards NB of pipe is equal to OD of pipe?
• From 14" NB and above.
Q20. What should be the radius of long radius elbow?
• 1.5D (D = nominal diameter)
Q21. What should be the radius of short radius elbow?
• 1D (D = nominal diameter)
Q22. What is the basis of using short radius & long radius elbows?
• Long radius: Used where pressure drop is critical or flow needs to be smooth
• Short radius: Used in compact spaces or for high-pressure drop conditions
Q23. Where are the ERW spiral & longitudinal pipes used?
• Usage depends on availability; functionally similar in certain conditions
Q24. Where are ERW & Seamless pipes used?
• Above 18": ERW
• Below 18": Seamless (preferred for high pressure and temperature)
Q25. What is the main use of ASTM A53 & A106 Gr.B pipes?
• ASTM A53: Utility services
• A106 Gr.B: High-pressure and high-temperature services
Q26. From which side of pipe will you take a branch connection?
• Gas, steam, cryo: Topside
• Liquid: Bottom side
Q27. Why do we provide High Point Vent (HPV) and Low Point Drain (LPD) in piping?
 • HPV: Remove air during hydrotesting
• LPD: Drain water post-hydrotesting

Civil Inspector
Q1. What is the standard for water leak test and how to do?
Ans: Standard is ASTM D5121. Fill tank, maintain pressure, check for leakage within specified duration.
Q2. Number of concrete cylinders for testing purposes?
Ans: Usually 6 cylinders per 50m³ concrete or per batch, as per standard practice.
Q3. How do you inspect civil works?
Ans: Check dimensions, alignment, material quality, safety compliance, and compare against approved
drawings on site.
Q4. What is a slump test and how much should it be for fresh concrete?
Ans: Slump test measures workability. Typically, 75–100mm for normal concrete on site.
Q5. Excavation procedure?
Ans: Excavate per approved drawings, maintain slope angles, identify soil type, remove water if needed,
and install proper safety shoring.
Q6. Slab procedure?
Ans: Set formwork, place reinforcement, pour concrete in layers, vibrate for compaction, and finish
surface.
Q7. If the rebar is rusted what actions are required?
Ans: Clean rust using wire brush or sandblasting and apply anti-corrosion coating before concreting.
Q8. Interval of the concrete and revolution?
Ans: Follow project specifications; re-vibration must occur before setting begins to avoid cold joints.
Q9. Asphalt testing?
Ans: Includes Marshall stability, penetration, ductility, softening point, and aggregate gradation tests.
Q10. Concrete curing period?
Ans: Minimum 7 days for moist curing; 28 days required to achieve full design strength.
Q11. What is the purpose of geotechnical study?
Ans: To determine soil bearing capacity, identify strata profile, groundwater level, and provide safe
foundation design data.
Q12. What is admixture in concrete and types?
Ans: Admixtures modify concrete properties. Types: water reducers, accelerators, retarders, and
superplasticizers.
Q13. How to protect deep excavation?
Ans: Use shoring, bracing, sheet piling, or soil nailing to support trench walls and prevent collapse or
water ingress.
Q14. What's the purpose of bending rebars?
Ans: To shape rebars according to structural drawings for strength, fit, and anchorage in concrete.
Q15. Bituminous curing period?
Ans: Minimum of 7 days moist curing; longer durations enhance durability and performance.
Q16. What's the purpose of rebar coating?
Ans: Prevents corrosion, enhances bond with concrete, and increases structural life, especially in
aggressive environments.
Q17. What's the purpose of concrete chamfer?
Ans: Chamfers prevent edge chipping, enhance aesthetic appearance, and reduce spalling risk.
Q18. Document requirements for concrete inspection?
Ans: Approved drawings, mix design reports, material test certificates, method statements, and inspection
checklists.
Q19. What are basis of design for foundations?
Ans: Based on geotechnical investigation, structural load, settlement limits, and soil bearing capacity.
Q20. Soil testing procedures and tools?
Ans: SPT, plate load test, moisture content, sieve analysis, proctor compaction, and CBR tests.
Q21. Allowable concrete temperature?
Ans: Should be within 10°C to 32°C during placement as per industry standards.
Q22. How to perform inspection for pre-cast members?
Ans: Inspect for dimensions, alignment, surface finish, connection points, lifting anchors pre- and post-
installation.
Q23. Compaction procedure?
Ans: Place soil in layers, adjust moisture content, and compact using rollers or compactors to achieve
95% Proctor density.
Q24. How to perform soil grading?
Ans: Remove debris, level surface, adjust moisture, and compact in layers as per technical specification.
Q25. What's piling?
Ans: Piling is a deep foundation method using driven or bored piles to transfer load to deeper, competent
soil.
Q26. What's mass concrete and requirements?
Ans: Mass concrete involves large volumes prone to thermal cracking. Requires low-heat cement and
temperature monitoring.
Q27. Inspections to be performed prior to pouring concrete?
Ans: Check formwork, reinforcement, embedded items, cleanliness, alignment, and ensure approval of
concrete mix.
Q28. What's the reason for concrete defects such as honeycomb and how to repair?
Ans: Caused by poor compaction or segregation. Repair by chipping affected area and applying non-
shrink grout or repair mortar.
Q29. Maximum time of concrete duration from batch plant to site?
Ans: Max 90 minutes or 300 drum revolutions; maintain proper temperature and slump until placement.
Q30. How to get approved concrete and asphalt mix design?
Ans: Perform trial mixes in laboratory, conduct required tests, and submit results for consultant approval.
Q31. What's a construction joint?
Ans: Interface between two successive concrete pours; helps in phasing of work and accommodates
shrinkage or movement.
Q32. Water-cement ratio?
Ans: Critical for strength and durability; typically ranges from 0.40 to 0.60 based on structural
requirement.
Q33. Scaffolding installation code?
Ans: Follow IS 3696 or OSHA standards. Ensure bracing, anchoring, planking, guardrails, and regular
inspection.
Q34. What is CBR?
Ans: California Bearing Ratio test evaluates subgrade strength and suitability for pavement layers.

HVAC Inspector
Q1. You receive a shipment of ductwork. What's your step-by-step check?
Ans: Compare delivery note vs. PO, inspect for dents or rust (reject if damaged), and verify gauge
thickness using a micrometer.
Q2. A batch of refrigerant pipes has no end caps. What do you do?
Ans: Reject the batch—open ends may allow ingress of dirt or moisture, compromising system integrity.
Q3. What's the first thing you check when receiving brazing rods?
Ans: Verify certification (e.g., AWS A5.8) and check for proper sealed packaging and moisture-free
condition.
Q4. How should insulation materials be stored on-site?
Ans: Store indoors, elevated on pallets, and protected with tarpaulins from moisture, dust, and physical
damage.
Q5. How should packaged AC units be stored before installation?
Ans: Place on wooden pallets in a shaded, dry, and well-ventilated area, covered with tarps to prevent
environmental damage.
Q6. What's the acceptance criteria for a duct leakage test?
Ans: Leakage must be ≤5% at 1-inch water gauge pressure, as per SMACNA standards.
Q7. During a pressure test, a chilled water pipe leaks at a weld. What's your action?
Ans: Tag the defect, log the issue, mandate re-welding at the joint, and perform retesting post-repair.
Q8. How do you verify airflow in a duct is correct?
Ans: Use an anemometer at air terminals and compare measured CFM with the design requirement
(acceptable range ±10%).
Q9. A worker is brazing refrigerant pipes without nitrogen purge. What do you say?
Ans: “Stop the activity—nitrogen purge is mandatory to avoid internal oxidation and maintain system
cleanliness.”
Q10. An access door is blocked by electrical conduits. How do you fix it?
Ans: Coordinate and instruct relocation of conduits—access panels must remain fully accessible for
maintenance operations.
Q11. A worker brazed pipes without nitrogen. What's your action?
Ans: Cut out the defective joint, conduct proper nitrogen purge, and re-braze in accordance with project
standards.
Q12. A fire damper fails its drop test. What's next?
Ans: Inspect fusible link for correct rating, verify damper blade alignment, and replace defective
components as needed.
Q13. The contractor didn't do a nitrogen purge test report. Your move?
Ans: Suspend inspection and withhold approval—submission of test reports is a prerequisite for
refrigerant charging.
Q14. What is QA/QC?
Ans: QA (Quality Assurance) is proactive and ensures preventive controls; QC (Quality Control) involves
inspection to validate conformity of deliverables.
Q15. What is an NCR (Non-Conformance Report)? Give one HVAC example.
Ans: An NCR documents deviation from standards—example: brazing completed without nitrogen purge
in HVAC piping.
Q16. What is a Special Procedure in QA/QC?
Ans: A documented method for performing critical or high-risk activities that require special controls and
prior approval.
Q17. What are the key elements of an NCR?
Ans: Include non-conformance description, referenced standard/code, correction, corrective action, root
cause analysis, and action closure date (ACD).
Q18. What is RCA (Root Cause Analysis)?
Ans: A systematic process to identify the fundamental cause of a non-conformance and implement
actions to prevent recurrence.
Q19. Difference between Correction and Corrective Action?
Ans: Correction addresses the immediate issue (e.g., fixing a leak), while corrective action implements
systemic prevention (e.g., worker training or procedure revision).
Q20. Significant source of energy waste in duct systems?
Ans: Duct leakage—leads to pressure drop and HVAC inefficiency.
Q21. Minimum thermal (R) value as set forth in Uniform Mechanical Code Tables
Ans: The minimum allowed duct insulation value is R-6 for ducts outside conditioned space, per standard
UMC and referenced energy-code provisions
Q22. Duct hangers and support size and thickness as per Uniform Mechanical Code
Ans: Metal straps must be a minimum of 1 in (25 mm) in width and of equivalent or heavier gauge than
the duct being supported, per UMC Sec 603.10 .
Q23. Duct wall thickness for positive pressure ducting systems as per Uniform Mechanical Code
Ans: UMC mandates using wall thickness per SMACNA pressure-class tables; higher pressure ratings
require thicker gauge. For example, a Class 0/1 supply duct must meet SMACNA minimum wall-gauge
requirements, applicable to positive-pressure systems .
Q24. Duct wall thickness for negative pressure ducting systems as per Uniform Mechanical Code
Ans: Similar to positive pressure, UMC relies on SMACNA table minimum gauges by pressure class;
negative-pressure ductwork must also meet those wall-thickness requirements specified for the
applicable SMACNA pressure class to prevent collapse under vacuum.
Q25. Fire/Smoke/Fire-Smoke Damper installation standards NFPA
Ans: Installation must comply with NFPA 90A and NFPA 80, ensuring dampers close properly under
fire/smoke conditions.
Q26. Damper sleeve extension for dampers without an actuator or access door
Ans: Minimum 300 mm extension is required for accessibility and maintenance.
Q27. Turning vanes required in rectangular elbows as per SMACNA
Ans: Turning vanes are mandatory in high-velocity systems to reduce pressure loss and turbulence.
Q28. What is an NCR (Non-Conformance Report)? Give one HVAC example.
Ans: A formal document to record deviations; e.g., brazing refrigerant pipes without nitrogen purge.
Q29. What is a Special Procedure in QA/QC?
Ans: A pre-approved method for non-routine or high-precision tasks, often used when standard
procedures are insufficient.
Q30. What are the key elements of an NCR?
Ans: Nonconformity description, reference standard, correction, corrective action, root cause, and ACD
(Action Completion Date).
Q31. What is RCA (Root Cause Analysis)?
Ans: A systematic process to identify the underlying reason for a defect and eliminate recurrence.
Q32. Difference between Correction and Corrective Action?
Ans: Correction is an immediate remedy; corrective action is a permanent fix to prevent recurrence.
Q33. Minimum gauge thickness for short radius turning vanes
Ans: 22 gauge is the minimum required as per SMACNA.
Q34. Flexible duct testing and certification standard
Ans: Governed by UL 181, which specifies construction, labeling, and fire resistance.
Q35. When are thrust blocks required for thermoplastic and RTR piping?
Ans: At every change in direction—bends, tees, or reducers.
Q36. What are the two exemptions to thrust block installation?
Ans: Gravity flow systems and pipes ≤75mm with restrained joints.
Q37. Which standard governs thrust block design for RTR piping?
Ans: AWWA M45 provides guidelines for design and installation.
Q38. What is required when a pipe enters/leaves a thrust block?
Ans: Use neoprene wrapping to prevent direct contact and ensure flexibility.
Q39. What's the clearance between water and firewater lines?
Ans: A minimum of 12 inches (305 mm) is required.
Q40. What is the minimum spacing between sprinklers?
Ans: 6 ft (1.8 m) minimum per NFPA 13 standards.
Q41. What is the minimum distance of a sprinkler from walls?
Ans: 4 inches (102 mm) minimum clearance.
Q42. How far should sidewall sprinklers be from light fixtures?
Ans: 3 ft (0.9 m) minimum to prevent obstruction and heat shielding.
Q43. What's the minimum water closet clearance from side walls?
Ans: 15 inches (381 mm) measured from the centerline of the fixture.
Q44. How much space is needed between adjacent urinals?
Ans: 24 inches (610 mm) minimum for user comfort and privacy.
Q45. Can stormwater be mixed with sewage pipes?
Ans: No, strict separation is required by code.
Q46. Which material is PROHIBITED for supporting drainage piping in a trench under the IPC?
Ans: Concrete blocks are not allowed due to instability and lack of proper support.
Q47. What additional support is required for a horizontal 4-inch PVC drainage pipe at a 90-degree
turn when suspended from a ceiling?
Ans: Sway bracing must be installed to counteract movement and stress.
Q48. Which of the following is NOT an approved method for sealing a pipe penetrating an exterior
wall?
Ans: Foam sealant is not approved; use firestop sealants or caulk listed for wall penetrations.
Q49. What is the minimum slope required for condensate piping?
Ans: ¼% slope or 1/8 inch per foot is required to ensure drainage.
Q50. Where must the lavatory be in an employee toilet room relative to the water closet?
Ans: It must be in the same room, ensuring hygiene compliance.
Q51. How far must a urinal partition extend from the wall?
Ans: 18 inches is the standard minimum for privacy compliance.
Q52. What is the maximum allowable water pressure in a water distribution system?
Ans: 80 psi maximum; pressure-reducing valves are required above this.
Q53. What type of joints are required for PE-RT plastic tubing and fittings?
Ans: Heat-fusion joints are mandated for leak-proof connections.
Q54. Which component must be installed with a pressure-reducing valve?
Ans: A strainer is required upstream to protect the PRV from debris.
Q55. What material is approved for transition fittings between copper and galvanized steel piping?
Ans: Copper alloy is approved to prevent galvanic corrosion.
Q56. What is the maximum flow rate for non-metered public lavatories at 60 psi?
Ans: 0.5 gallons per minute (gpm) maximum per UPC/IPC.
Q57. How must corrosive liquids be treated before entering the sanitary drainage system?
Ans: They must be diluted or neutralized before discharge.
Q58. What is the maximum retention time for untreated gray water in a collection reservoir?
Ans: 24 hours, to prevent biological degradation and odor.
Q59. What type of valve is required upstream of a nonpotable water storage tank?
Ans: A shutoff valve is required to isolate the system when necessary.
 Electrical Inspector Q&A
Q1. What is the minimum depth for underground electrical conduit?
Ans: 600 mm for low voltage, 1000 mm for high voltage

Q2. What does IP 65 mean?

Ans: Dust tight and protected against water jets

Q3. What is the color code for a three-phase system?

Ans: R: Red, Y: Yellow, B: Blue, Neutral: Black/Blue, Earth: Green/Yellow

Q4. What does IR test measure?

Ans: Insulation Resistance between conductors and earth

Q5. Minimum IR value for LV cable at 500V?

Ans: 1 MΩ

Q6. How is earth resistance measured?

Ans: Using Earth Resistance Tester (Fall-of-Potential method)

Q7. What is the acceptable earth resistance value?

Ans: Less than 1 ohm (for substations), <5 ohm (general)

Q8. Standard used for cable color coding?

Ans: IEC 60446

Q9. What is the purpose of loop impedance testing?

Ans: To ensure fault current will trip the breaker within required time

Q10. What is the Megger used for?

Ans: Measuring insulation resistance

Q11. What is RCD and its function?

Ans: Residual Current Device; detects leakage current and trips power

Q12. What does Lux meter measure?

Ans: Light intensity (in lux)

Q13. What is the minimum lux level for indoor lighting (general work)?
Ans: 300–500 lux

Q14. What is a Single Line Diagram (SLD)?

Ans: A simplified representation of electrical system

Q15. Minimum separation between power and data cables?

Ans: 300 mm (parallel), 50 mm (crossing)
Q16. What is the purpose of earthing?
Ans: To protect people and equipment from fault current

Q17. What type of test is done after cable pulling?

Ans: Continuity test, insulation resistance test

Q18. What is a dielectric strength test?

Ans: High voltage test to ensure cable insulation integrity

Q19. What does KA rating on circuit breakers mean?

Ans: Short circuit withstand capacity in kiloamperes

Q20. What is the function of a CT (Current Transformer)?

Ans: To reduce high currents to measurable levels for meters/protection

Q21. Purpose of PT (Potential Transformer)?

Ans: Step down voltage for metering/protection

Q22. What is cable meggering?

Ans: Checking insulation of cables using megger

Q23. What is the minimum bending radius for LV cable?

Ans: 12 × cable diameter

Q24. What is a busbar?

Ans: A metallic strip for power distribution

Q25. Standard for electrical safety in industrial plants?

Ans: NFPA 70E

Q26. What is minimum clearance from floor to live part in LV panel?

Ans: 2.0 meters

Q27. What is cable glanding?

Ans: Securing and sealing cable entry into panels

Q28. What is torque wrench used for in electrical?

Ans: To apply correct torque on terminals and connections

Q29. What is dielectric constant?

Ans: Ratio of permittivity of material to that of vacuum

Q30. Cable insulation class for 0.6/1 kV cable?

Ans: Class 2
Q31. Flame-retardant cable standard?
Ans: IEC 60332

Q32. What is the function of surge arrestor?

Ans: To protect equipment from voltage spikes

Q33. What is the touch voltage limit?

Ans: 50V AC (as per IEC)

Q34. How to identify phase sequence?

Ans: Using Phase Sequence Meter

Q35. What test is conducted after transformer installation?

Ans: IR test, ratio test, polarity test, functional test

Q36. What is a trip curve in MCB?

Ans: Time-current characteristic for tripping

Q37. Earth conductor minimum size for lightning system?

Ans: 70 mm² copper or 95 mm² aluminum (as per IEC 62305)

Q38. What is the color code for earthing wire?

Ans: Green or Green-Yellow

Q39. How is loop continuity tested?

Ans: By checking resistance end-to-end of loop

Q40. What is considered a live part?

Ans: Any conductive part energized under normal conditions