Engineering Standard

SAES-J-902 22 July 2013

Electrical Systems for Instrumentation
Document Responsibility: Instrumentation Standards Committee

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope............................................................. 2
2 Conflicts and Deviations................................. 2
3 References..................................................... 2
4 Definitions....................................................... 4
5 General........................................................... 4
6 Conduit and Cable Sealing............................. 5
7 Enclosures...................................................... 6
8 Conduit, Conduit Fittings and Supports.......... 7
9 Cable Trays.................................................... 8
10 Connections at Field Instruments
and Junction Boxes................................ 9
11 Power Supply............................................... 11
12 Signal/Control Wiring.................................... 14
13 Routing......................................................... 17
14 Signal Segregation, Separation
and Noise Reduction............................ 21
15 Termination.................................................. 25
16 Identification................................................. 27
17 Grounding..................................................... 29

Previous Issue: 3 July 2012 Next Planned Update: 3 July 2016

Revised paragraphs are indicated in the right margin Page 1 of 33
Primary contact: Al-Abeediah, Saeed Mohammad on +966-3-8801338

Copyright©Saudi Aramco 2013. All rights reserved.

Document Responsibility: Instrumentation Standards Committee SAES-J-902
Issue Date: 22 July 2013
Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

1 Scope

This Standard establishes the design criteria for the installation of power and wiring
systems for electrical instrumentation.

2 Conflicts and Deviations

2.1 Any conflicts between this Standard and other applicable Saudi Aramco
Engineering Standards (SAESs), Materials System Specifications (SAMSSs)
Standard Drawings (SASDs), or industry standards, codes, and forms shall be
resolved in writing by the Company or Buyer Representative through the
Manager, Process & Control Systems Department of Saudi Aramco, Dhahran.

2.2 Direct all requests to deviate from this standard in writing to the Company or
Buyer Representative, who shall follow internal company procedure SAEP-302
and forward such requests to the Manager, Process & Control Systems
Department of Saudi Aramco, Dhahran.

3 References

The selection of material and equipment, and the design, construction, maintenance, and
repair of equipment and facilities covered by this standard shall comply with the latest
edition of the references listed below, unless otherwise noted.

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedure

SAEP-302 Instructions for Obtaining a Waiver of a Mandatory
Saudi Aramco Engineering Requirement

Saudi Aramco Engineering Standards

SAES-B-006 Fireproofing for Plants
SAES-J-903 Intrinsically Safe Systems
SAES-J-904 FOUNDATION™ fieldbus (FF) Systems
SAES-P-100 Basic Power System Design Criteria
SAES-P-103 Batteries and UPS Systems
SAES-P-104 Wiring Methods and Materials
SAES-P-111 Grounding
SAES-T-151 Communication D.C. Power System

Page 2 of 33
Document Responsibility: Instrumentation Standards Committee SAES-J-902
Issue Date: 22 July 2013
Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

SAES-Z-020 Design and Installation of Fiber Optic Cable

Systems for Process Control Networks

Saudi Aramco Materials System Specifications

17-SAMSS-516 Uninterruptible Power Supply System
23-SAMSS-010 Distributed Control Systems
34-SAMSS-820 Instrument Control Cabinets – Indoor
34-SAMSS-913 Instrument and Thermocouple Cable

Saudi Aramco Library Drawings

DC-950043-001 Electrical Connections for Field Mounted Instruments
DC-950150-001 Recommended Grounding Scheme for Process
Automation System

3.2 Industry Codes and Standards

American National Standards Institute

ANSI MC96.1 Temperature Measurement Thermocouples
ANSI/ISA TR12.21.01 Use of Fiber Optic Systems in Class I Hazardous
(Classified) Locations

Institute of Electrical and Electronics Engineers

IEEE 518 IEEE Guide for the Installation of Electrical
Equipment to Minimize Electrical Noise Inputs to
Controllers from External Sources
IEEE 1100 Recommended Practice for Powering & Grounding
Sensitive Electronic Equipment, the Emerald Book

International Electrotechnical Commission

IEC 60529 Degrees of Protection Provided by Enclosures

National Electrical Manufacturers Association

NEMA ICS 6 Enclosures for Industrial Controls and Systems
NEMA 250 Enclosures for Electrical Equipment
(1000 Volts Maximum)
NEMA VE 1 - 2002 Metal Cable Tray Systems
NEMA VE 2 -2006 Cable Tray Installation Guidelines

Page 3 of 33
Document Responsibility: Instrumentation Standards Committee SAES-J-902
Issue Date: 22 July 2013
Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

National Fire Protection Association

NFPA 70 - 2005 National Electrical Code (NEC)
NFPA 72 - 2002 National Fire Alarm Code

Underwriters Laboratories, Inc.

UL 94 Standard for Safety Test for Flammability of Plastic
Materials for Parts in Devices and Appliances

4 Definitions

The following list of definitions shall apply to this Standard:

Class 1 Circuit: A circuit complying with National Electrical Code (NEC) Article 725,
Part II.

Class 2 Circuit: A circuit that complies with National Electrical Code (NEC)
Article 725, Part III.

Class 3 Circuit: A circuit that complies with National Electrical Code (NEC)
Article 725, Part III.

Data Link: Any information channel used for connecting data processing equipment to
any input, output, display device, or other data processing equipment.

Drain Wire: In a cable, the non-insulated wire in intimate contact with a shield to
provide for termination of the shield to a ground point.

Home-Run Cable: A cable, typically multi-pair/triad, extending between the field

junction boxes and marshaling cabinets in control or PIB buildings.

Severe Corrosive Environments: For the purposes of this standard only, severe
corrosive environments include:
a. Outdoor offshore locations, and
b. Outdoor onshore locations within one kilometer from the shoreline of the Arabian
Gulf; all of the Ras Tanura Refinery and Terminal; and within three kilometers
from the shoreline of the Red Sea. If any part of a specific plant falls within these
limits, the entire plant area shall be treated as severe corrosive environment.

5 General

5.1 Design and installation of power and wiring systems for instrumentation shall be
in accordance with NFPA 70 - 2005 National Electrical Code (NEC), unless
otherwise supplemented by this standard.

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Document Responsibility: Instrumentation Standards Committee SAES-J-902
Issue Date: 22 July 2013
Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

5.2 Foundation Fieldbus wiring systems shall be installed in compliance with

SAES-J-904 FOUNDATION™ fieldbus (FF) Systems.

5.3 Electrical and electronic equipment in hazardous areas shall meet

listing/certification requirements specified in SAES-P-100 and the NEC.

5.4 Intrinsically Safe Systems

5.4.1 Intrinsically safe systems shall only be used in Zone 0 hazardous areas
or when the vendor's standard product offering is supplied as
intrinsically safe.

5.4.2 Intrinsically safe systems shall be installed in compliance with

SAES-J-903, Intrinsically Safe Systems.

5.5 Fireproofing of cables in fire hazardous areas shall be in accordance with

SAES-B-006.

5.6 Fire Alarm systems shall be installed in accordance with NEC Article 760 and
NFPA 72 - 2002.

5.7 Cable Ties

5.7.1 All cable ties used in the field shall be 'nylon coated 316 stainless steel.'

5.7.2 All cable ties used inside of enclosures and buildings (i.e., field junction
boxes, marshaling cabinets, control rooms, and PIBS) shall be weather
resistant nylon cable ties with a stainless steel barb. The cable tie shall
have a maximum continuous use temperature rating of 85ºC or higher.
Commentary Note:

Cable tray with covers shall not to be considered as 'inside of an

enclosure'; therefore, nylon coated 316 stainless steel ties shall be used.

6 Conduit and Cable Sealing

6.1 Conduit and cable sealing shall be installed in accordance with NEC Article
505.16, except as specified in sections 6.2 and 6.3.

6.2 Armored Cable Sealing

Certified flameproof (Type ‘d’) cable glands using a compound barrier seal shall
be used on all instruments and enclosures located in hazardous areas requiring
sealing per the NEC. Where sealing is not required by the NEC, Certified
Flameproof (Type “d”) cable glands shall be used on all instruments and
enclosures including those located in non-hazardous areas.

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Document Responsibility: Instrumentation Standards Committee SAES-J-902
Issue Date: 22 July 2013
Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

6.3 Conduit Sealing for Individually Shielded Twisted Pair/Triad Cable

When individually shielded twisted pair cable passes through a conduit seal, it
shall be treated as a single conductor and shall be sealed with the outer jacket
intact. In addition, the cable end within the enclosure shall be sealed by an
approved means.

7 Enclosures

7.1 Enclosures for instruments in outdoor plant areas shall be NEMA Type 4 in
accordance with NEMA ICS 6 and NEMA 250 or IEC 60529 Type IP 65.
Enclosures in severe corrosive environments shall be NEMA Type 4X or
IEC 60529 Type IP 66.

7.2 The field junction box, in a Class I, Zone 2 location and in non-hazardous areas,
shall be a single door NEMA Type 4X or IEC 60529 Type IP 66 box. The box
construction shall meet the following requirements:

7.2.1 Type 316 stainless steel body, door, and hardware.

7.2.2 Continuously welded seams, finished smooth.

7.2.3 Stainless steel hinge.

7.2.4 316 Stainless steel captive clamps.

Exception:

316 Stainless steel captive screws may be used in lieu of captive

clamps provided that the screws do not penetrate the door gasket.
Keylocks and padlocks are not acceptable.

7.2.5 Data/Print pocket on inside of door.

7.2.6 External mounting brackets.

7.2.7 Collar studs for mounting inside panel.

7.2.8 Ground stud for terminating A/C safety ground wire.

7.2.9 Removable door.

7.2.10 316 Stainless steel back panels.

7.3 All field junction boxes shall be mounted vertically, i.e., the door shall open
from left-to-right or from right-to-left.

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Document Responsibility: Instrumentation Standards Committee SAES-J-902
Issue Date: 22 July 2013
Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

7.4 Instrument enclosures and junction boxes having an internal volume exceeding
2,000 cm³ shall be provided with Type 300 Series stainless steel breather and
drain fittings, or a combination breather and drain fitting.

7.5 All instrument enclosures and junction boxes shall be third party certified.
Self certification is not acceptable.

8 Conduit, Conduit Fittings and Supports

8.1 Conduit, conduit installation, fittings, and supports shall comply with
SAES-P-104 Wiring Methods and Materials, Section 8, Conduit, Conduit
Fittings and Supports.
Exception:

Where conduit sealing is required, Paragraphs 6.1 and 6.3 of this standard shall
be followed.

8.2 In outdoor installations, conduit bodies and fittings shall have threaded cover
openings.
Exception:

For non-circular conduit fittings (such as L-shaped bodies (LB), wire pulling
fittings, etc.), screwed or bolted covers are acceptable. Snaptight covers or
covers with internal holding levers are not acceptable.

8.3 A conduit outlet box (e.g., GUAT) shall be installed within eighteen (18) inches
of the field device. The cable to the instrument shall be looped one or more
times within this fitting; the sizing of the conduit outlet box shall take into
account the bending radius of the cable.
Commentary Note:

The new transmitters and digital valve controllers have very small connection
heads compared to previous models. Therefore, a conduit outlet box is being
mandated within 18” of the device to allow for a spare loop of cable. This can
potentially prevent maintenance from having to re-pull cable if the cable end has
been damaged.

8.4 Flexible conduit shall be used at the instrument end of the conduit to provide
isolation from vibration, protection against thermal expansion of the rigid
conduit systems and for ease of maintenance.

8.4.1 For Class I, Zone 1 locations, flexible fittings listed for the area shall
be used.

8.4.2 For Class I, Zone 2 locations and unclassified areas, the flexible
conduit shall be Liquidtight Flexible Metal Conduit (LFMC).

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Document Responsibility: Instrumentation Standards Committee SAES-J-902
Issue Date: 22 July 2013
Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

The LFMC shall have a sunlight resistant cover which resists oil and
chemical breakdown and shall be rated for temperatures ≥ 90ºC.

8.5 Metallic conduit shall be grounded as required in SAES-P-111.

9 Cable Trays

9.1 Cable tray specification shall be per NEMA VE 1 - 2002. The tray installation
shall be per this standard, NEMA VE 2 -2006 and SAES-P-104.

9.2 Homerun cable trays shall be of the ladder type, i.e., two longitudinal side rails
connected by individual transverse members (rungs). The distance between
consecutive rungs shall not exceed 229 mm (9 inches). Ladder cable tray material
shall be copper-free aluminum (aluminum with a maximum of 0.4% copper).
These requirements are also applicable to cable trays supporting multipair/triad
instrumentation cables inside control buildings and/or substations.

9.3 The cable tray system shall be installed with the manufacturers standard fittings,
clamps, hangers, brackets, splice plates, reducer plates, blind ends, connectors,
and grounding straps.

9.4 All fasteners (i.e., nuts, bolts, washers, etc.) used to connect and assemble the
cable tray system shall be 304 SS. In severe corrosive environments, 316 SS
fasteners shall be used.

9.5 Cable Trays shall be grounded as required in SAES-P-111.

9.6 In new grass root projects, cable trays extending between the process area and
the control room or process interface building, or trays installed beneath raised
computer floors, in control rooms or PIB shall be sized for a minimum of 20%
spare space for future expansions. This spare capacity is in addition to the
installed 20% spare cabling.

9.7 Cable tray fill shall comply with NEC Article 392.

9.8 Cable tray supporting armored cables extending between field instruments
and junction boxes shall be ventilated bottom, channel cable tray. The channel
cable tray shall be designed, manufactured, and marked in accordance with
NEMA VE 1 - 2002. The working load of the cable tray shall consist of the
weight of the cables, plus a concentrated static load of 45 kg at the center of the
span. The static load can be converted to an equivalent uniform load using the
formula in NEMA VE 1 - 2002. The overall working weight shall not exceed
the rated load capacity of the cable tray as defined in NEMA VE 1 - 2002.
In addition to the requirements in sections 9.1 and 9.5, the channel cable tray
system shall meet the following:

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Document Responsibility: Instrumentation Standards Committee SAES-J-902
Issue Date: 22 July 2013
Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

9.8.1 The channel cable tray material shall be copper-free aluminum

(aluminum with a maximum of 0.4% copper).

9.8.2 Channel cable tray width shall be 3, 4, or 6 inches with a minimum

loading depth of 1-¼ inch.

9.8.3 The channel cable tray system shall be installed with the manufacturers
standard fittings, clamps, hangers, brackets, splice plates, reducer
plates, blind ends, connectors, and grounding straps.

9.8.4 The channel cable tray system shall be installed with flanged covers.

9.8.5 The ventilated strait sections shall have slots (approximately 3/16” x
½”) to facilitate the use of cable ties to secure the cable(s). The slots
shall repeat every 12-18 inches.

9.8.6 The ventilated strait sections shall have splice holes, repeating every
12-18 inches to simplify field modifications.

9.8.7 All fasteners (i.e., nuts, bolts, washers, etc.) used to connect and
assemble the channel cable tray system shall be 304 SS. In severe
corrosive environments, 316 SS fasteners shall be used.

9.8.8 The channel cable tray system shall be free from burrs or other sharp
projections that could cause damage to the cable jacket during
installation.

10 Connections at Field Instruments and Junction Boxes

10.1 Connections at Field Instruments

10.1.1 All connections at the field instrument shall be made on screw type
terminal blocks. Wire nuts and spring type terminals shall not be used.
Instruments with integral terminal blocks shall be connected directly to
the field cable.

10.1.2 If the instrument is fitted with factory sealed fly leads then they shall
be connected to a screw type terminal block installed in a GUA conduit
fitting. A typical installation arrangement is shown in Library Drawing
DC-950043-001, Electrical Connections for Field Mounted
Instruments. For armored cable installation, the armored cables shall
be terminated using cable glands per Section 6.2. The support and
routing of the armored cable to the junction box shall be per paragraph
13.1.1.2. Both ends of any armored cable shall be terminated using
glands as specified above.

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Document Responsibility: Instrumentation Standards Committee SAES-J-902
Issue Date: 22 July 2013
Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

10.1.3 The outer jacket of shielded twisted single pair/triad cables shall be left
intact up to the point of termination. Drain wires and mylar shields on
shielded cables shall be cut and insulated with heat shrink sleeve at the
field instrument unless otherwise specified by the instrument
manufacturer. For armored cables, the “outer jacket” is the jacket
covering the pair or triad; not the jacket covering the armor.

10.2 Connections at Field Junction Boxes

10.2.1 All instrument wiring shall be routed to field junction boxes.

Conduit and cable entries to field junction boxes shall be through the
bottom. Top entry is allowable provided a drain seal is installed on the
conduit within 18” of the enclosure. Side entry (within six inches of
the bottom) shall be permitted only when space limitations dictate.
The number of conduit entries shall be kept to a minimum. All unused
entry ports shall be fitted with approved plugs.

10.2.2 Conduit entries shall be through gasketed hubs, except in explosion-proof

installations where the connection shall be through threaded connections.
Armored cable entry to the junction boxes shall be per paragraph 6.2.
Top entry of armored cable into the junction box is not acceptable.

10.2.3 In severe corrosive environments, cable glands shall be protected

against corrosion, either by a heat shrink sleeve, anti-corrosion tape or
PVC shroud. Gasket materials shall be oil resistant.

10.2.4 All connections and entries shall comply with the electrical area
classification.

10.2.5 Low point conduit drains shall be provided as needed.

10.2.6 Twisted, multi-pair/triad cables shall be cut to the appropriate length to

minimize looping and flexing of the cable within the junction box.

10.2.7 For twisted shielded single pair/triad cables the outer jacket shall be
left intact up to the point-of-termination (approximately three to four
inches from terminal blocks). The shield drain wire shall be insulated
from jacket end to terminal. Approximately, one inch of heat shrink
tubing shall be applied over the jacket end. For armored cables, the
“outer jacket” is the jacket covering the pair or triad; not the jacket
covering the armor.

10.2.8 For individually shielded twisted multi-pair/triad cables each pair/triad

shall be heat shrink sleeve insulated from the cable-jacket-end up to the
point-of-termination to keep the foil shielding intact and free from

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Document Responsibility: Instrumentation Standards Committee SAES-J-902
Issue Date: 22 July 2013
Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

accidental grounds. The shield drain wire shall be insulated from foil
end to terminal. Approximately, two inches of heat shrink tubing shall
be applied over the jacket end.

10.2.9 Terminal blocks used in junction boxes shall be per Paragraph 15.2.

10.2.10 The terminals shall be mounted on vertical DIN rails (i.e., horizontal
DIN rails are not allowed).
Commentary Note:

This section is specifying vertical DIN rails in 'field junction boxes'.

This section is not intended to apply to ancillary termination boxes,
e.g., smart ZV control stations, GUA fittings, etc.

10.2.11 The DIN rail shall only be mounted on the inside panel (back-pan) of
the junction box.

10.2.12 Twenty percent (20%) unused DIN rail length shall be provided in
field junction boxes.

11 Power Supply

11.1 Supply Voltages

11.1.1 Where instrument-circuit power distribution panels are used, each

panel shall be dedicated to a single voltage level. These panels shall
not provide power to non-instrumentation circuits. Distribution panels
shall be furnished with a minimum of 20% spare circuit breakers.

Redundant power supplies feeding process automation systems,

emergency shutdown systems, metering systems, auxiliary systems or
field instrumentation shall be fed from separate distribution panels.

11.1.2 Power wiring for field instruments, two-wire analog transmission loops,
field switch contacts, etc., shall be individually fused and provided with
a means of disconnecting the power without disturbing terminated
wiring (e.g., knife-switch-type terminal blocks). Visual indication of a
blown fuse condition shall be provided.
Exceptions:

1) Wiring connected to I/O modules or to interfaces containing individual

current-limiting circuit protection does not require fuses.

2) Low level signal wiring connected directly to I/O does not require fuses.
Low level signals are defined as Millivolt, Microamp, Pulse and
Frequency Signals under 1 Volt.

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Document Responsibility: Instrumentation Standards Committee SAES-J-902
Issue Date: 22 July 2013
Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

Commentary Note:

Fuse application, location, and amperage ratings must be properly

sized and coordinated, taking into account the maximum expected load
at the maximum operating temperature of the indoor cabinet (50°C).

11.1.3 Equipment shall be suitable for the supply voltages shown in Table 1.

Table 1 – Supply Voltages

Supply Voltage
System/Device Nominal NEC Class
Tolerance
24 VDC 21 - 28 VDC 1 or 2
Annunciator
125 VDC 113 - 137 VDC 1 or 3
Power
120 VAC, 60 ±2 Hz 110 - 126 VAC 1 or 3
Shutdown and 24 VDC 21 - 28 VDC 1 or 2
isolation system 125 VDC 113 - 137 VDC 1 or 3
power 120 VAC, 60 ±2 Hz 110 -126 VAC 1 or 3
24 VDC 21 - 28 VDC 1 or 2
Field switch
125 VDC 113 - 137 VDC 1 or 3
contacts
120 VAC, 60 ±2 Hz 110 - 126 VAC 1 or 3
Analog signal 24 VDC
21 - 28 VDC 1 or 2
(loop power) (4-20 mA)
Instrumentation 24 VDC 21 - 28 VDC 1 or 2
power 120 VAC, 60 ±2 Hz 110 - 126 VAC 1 or 3

11.1.4 Where multiple online DC power supplies are connected to a single

power bus, diode auctioneering shall be used to ensure bump less
transfer in the event of a single power supply failure. Where multiple
DC power supplies are an integral part of a manufacturer's standard
product, the manufacturer's standard method of load sharing shall apply.

11.1.5 For supplies to DC instrument loads, voltage stabilization shall be

provided to maintain the output voltage within tolerable limits of the
loads served.

11.2 Backup Supply Systems

11.2.1 UPS Systems

11.2.1.1 All process instrumentation, gas chromatographs, analyzers,

emission monitoring devices, PLCs, burner management
systems, MOV control circuits and master stations,
distributed control systems, terminal management systems,
vibration monitoring systems, tank gauging systems,
metering systems, stand-alone controllers, computational
devices, annunciators, fire and gas detection/safety systems,

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Document Responsibility: Instrumentation Standards Committee SAES-J-902
Issue Date: 22 July 2013
Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

SCADA systems, and emergency shutdown (ESD) systems

shall be powered by UPS system.

11.2.1.2 Uninterruptible power supply (UPS) systems shall be

designed and installed in accordance with SAES-P-103 and
17-SAMSS-516.

11.2.1.3 UPS power and utility power shall not share the same cable
or be routed in the same conduit.

11.2.2 Redundant UPS System

UPS systems powering critical instrumentation shall consist of

redundant UPS units. Critical instrument systems are defined as
systems which, upon loss of their supply power, would cause:
1) process failure in a non-failsafe mode, 2) area or plant shutdowns,
3) loss of custody transfer metering or accounting systems, or 4) other
adverse facility operating scenarios. Such systems shall include, but
not be limited to: ESD control; compressor control; safety monitoring
systems; boiler burner management and safety; process monitoring and
control; and custody transfer metering systems.
Exception:

Simplex UPS systems may be used on non-critical process and service

facilities such as Bulk Plants and GOSPs with the prior approval of the
operating facility Manager.

11.2.3 UPS Batteries

UPS battery requirements, such as capacity determination, installation

and charging systems, are detailed in SAES-P-103. The time during
which the battery bank shall supply power to the instrumentation
system shall depend on the application, but not be less than 30 minutes.

11.2.4 Backup Supply for Instruments with Volatile Memory

Backup power supply shall be required for instrumentation systems

containing volatile memory. For all such systems, the manufacturers'
recommendations shall be followed.

11.2.5 Remote Terminal Unit (RTU)

11.2.5.1 Remote Terminal Unit's shall be provided with battery

backup power supply systems. These may be an
Uninterruptible Power Supply (UPS) System or DC Power
System for sites supplied with AC utility power or a Solar

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Document Responsibility: Instrumentation Standards Committee SAES-J-902
Issue Date: 22 July 2013
Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

Photovoltaic (PV) Power System where AC utility power is

not available and as defined in SAES-P-103. These
systems shall be designed and installed in accordance with
the requirements set out in SAES-P-103. The required back
up time for these systems shall be determined in
consultation with the Proponent Department Manager and
shall consider the remoteness of the location, ease of access,
and reasonable maintenance personnel response time.
Commentary Note:

A UPS system shall be used to provide power to an RTU

where the RTU is associated with critical instrumentation,
as defined in Section 11.2.2.

11.2.5.2 Where bulk DC power is provided to the RTU and associated

instruments loads from positively grounded DC systems
designed per SAES-T-151 these systems shall be isolated
from each other by means of a suitably sized DC/DC
converter that provides complete input to output electrical
isolation between communication and instrumentation type
loads. The instrument load DC supply system shall be
designed to be a floating system and suitable ground fault
detection shall be provided as detailed in Section 17.6.

12 Signal/Control Wiring

12.1 General

12.1.1 Splices are not permitted in wiring. When wiring must be extended,
connections shall be made via terminal blocks in a junction box
installed aboveground.

12.1.2 Twist-on wire nut connectors shall not be used for making any
electrical instrumentation terminations or wiring connections.

12.2 Cable Types

Cables used for instrumentation signals shall be selected per Table 2.

For detailed cable construction, refer to 34-SAMSS-913.

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Document Responsibility: Instrumentation Standards Committee SAES-J-902
Issue Date: 22 July 2013
Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

Table 2 – Wire and Cable Minimum Requirements for Instrument Circuits

A. NEC Article 725 Class 1 Circuits (Notes 1, 2, 4, 8, 9, 10)

Instrument Field Instrument Field Junction Box
Circuit Example
Circuit Type To Junction Box To Marshaling Cabinet
16 AWG, 600 V, single twisted
Switches, Solenoids, pair, Type TC cable (Note-7) 18 AWG, 600 V,
120 VAC or
Relays, Limit ARMORED: twisted multi-pair
125 VDC
switches 16 AWG,600 V, single twisted cable, type TC
pair, TYPE MC or equivalent
B. NEC Article 725 Class-2&3 Circuits, Conduits & Cable Tray Installations (Notes 1, 2, 3, 4, 8, 10)
Instrument Field Instrument Field Junction Box
Circuit Example
Circuit Type To Junction Box To Marshaling Cabinet

Solenoids, Alarms, 16 AWG, 300 V PLTC/ITC, single

twisted pair or triad cable 18 AWG, 300 V
Switches, Relays,
24 VDC or less PLTC/ITC Twisted,
limit switched, ARMORED:
Discrete signals Multi-Pairs or Triads,
Secondary Motor 16 AWG, 300 V SWA, PLTC/ITC, Overall Shield
Control twisted single pair or triad cable

Analog Signals 16 AWG, 300 V PLTC/ITC, single

4-20 mA DC, RTDs, twisted, shielded pair or triad cable
Frequency, Weigh Cells 18 AWG, 300 V
Pulse, or ARMORED: PLTC/ITC Twisted,
Transmitter Speed, Vibration, Individually Shielded
Turbine Meter, Smart 16 AWG,300 V SWA, PLTC/ITC
Digital single twisted, shielded pair or Multi-Pairs or Triads
Communication digital Transmitter
triad cable
16 AWG, 300 V PLTC/ITC, single
twisted, shielded, thermocouple 18 AWG, 300 V
extension pair cable PLTC/ITC, Twisted,
Thermocouple Individually Shielded,
Thermocouples ARMORED:
Measurement thermocouple
16 AWG, 300 V PLTC/ITC, SWA, extension multi-pair
single twisted, shielded, cable
thermocouple extension pair cable
EIA-422A Data Links,
Follow System
High Speed Follow System Manufacturer's
Data Links Manufacturer's
Communication Recommendation (Note-6)
Recommendation
networks

Notes on Table 2:
1. Cables installed in Zone 1 (Class -1, Div.-1) shall be listed as suitable for that classified area. In addition, cables
used in other classified areas shall meet the requirements outlined in NFPA 70 - 2005 (NEC), articles 501-505.
2. The minimum size for multi-pair/triad cable should be 18 AWG. The minimum wire size for single pair cable
shall be 16 AWG. A larger wire size shall be considered to overcome potential voltage drops. The maximum
voltage drop shall not exceed 5%.
3. Type ITC cable shall not be installed on either non-power limited circuits or powered limited circuits operating
at more than 150 volts or more than 5 amperes.

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Document Responsibility: Instrumentation Standards Committee SAES-J-902
Issue Date: 22 July 2013
Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

4. Differences in the manufacturer recommended cable and these requirements shall be resolved with
Instrumentation Unit/PID/P&CSD.
5. For control and marshaling cabinet wiring, refer to 34-SAMSS-820.
6. Maximum separation between redundant data links must be obtained within the operating plant. The use of a
single cable tray or conduit for primary and backup data links is not acceptable. Refer to Section 12.3.2.
7. Protection against reverse EMF shall be provided for inductive loads such as relays, solenoids, etc. This may
be accomplished by installing a diode across the coil for DC loads or a metal oxide varistor (MOV) across the
coil for AC inductive loads.
8. If a discrete loop length exceeds 1000 feet, 120 VAC signal shall not be used due to potential capacitive or
inductive coupling. In such cases, DC voltage shall be used.
9. Cables used in Class 1, Class 2 and Class 3 circuits shall meet the requirements of Article 725 of the National
Electrical Code (NEC). Class 1 circuit wiring is preferred when the circuit class is not identified.

12.3 Special Cables

12.3.1 Thermocouple Extension Cable

Thermocouple extension cable types are detailed in 34-SAMSS-913.

12.3.2 Data Links

All in plant process automation networks shall be redundant and shall

be routed in separate cables. The primary cable shall follow a different
route from the backup cable. Primary and backup data link cables shall
preferentially enter cabinets or consoles from opposite sides.

Copper data link cables shall be specified per system manufacturers'

recommendations.

In plant fiber optic data link cables shall be specified and installed per
SAES-Z-020. If these cables are routed in aboveground conduit, the
conduit shall be specified and installed per this standard and
SAES-P-104.

Data link cables shall not be routed in the same conduit, duct, or tray
with other instrument cables.
Exception:

Fiber Optic data link Cables may be routed with other instrumentation
cables – in existing trays or ducts with prior approval of the Supervisor,
Instrumentation Unit/PID/P&CSD. Fiber Optic cables installed in trays
shall be routed in PVC conduit and shall meet ANSI/ISA TR12.21.01 if
installed in classified areas.

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Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

12.4 Color Coding

Power and signal wiring shall be color coded as follows:

Phase Black
AC Supply Neutral White
Ground Green with yellow tracer
Positive Red or red sleeve over any color except green
DC Supply
Negative Black or black sleeve over any color except green
Positive Black
Signal Pair
Negative White
Positive Black
Signal Triad Negative White
Third Wire Red
Positive Per ANSI MC96.1
Thermocouple
Negative Per ANSI MC96.1

13 Routing

Instrumentation and control cables and data highways in the field may be routed either
aboveground, underground or a combination of both as detailed in this standard.

13.1 Aboveground Routing

Above ground instrumentation cables may be run on a cable tray or in a conduit as

detailed below. Aboveground is the preferred routing method within a process
facility.

13.1.1 Instrument to Field Junction Box

Cable between field instruments and junction box shall be routed

above ground utilizing one of the following options:

13.1.1.1 Cable and Conduit

Single twisted pair/triad cables, per Table 2, shall be

installed in steel conduits from the field instruments to the
field junction boxes. Low-point drains and breathers shall
be provided as required on all conduits. Conduit
installation shall be per Section 8.

13.1.1.2 Armored Cable and Tray

a) Armored instrumentation cable shall be routed on a
cable tray per Section 9.8. Single pair cables
(armored on non-armored) shall not be routed on
ladder cable trays.

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Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

b) The armored cable shall be routed independently of

existing overhead tray systems used for “home-run”
cables.
c) The unsupported end of the cable at the instrument
shall be looped; this loop shall take into account the
bending radius of the cable. The unsupported length
of cable at the instrument shall be the minimum
length required to provide the service loop.
Commentary Note:

This unsupported loop in the armored cable is

required to provide sufficient slack for cable gland
make-up and for easy removal of the cable from the
device for future instrument change-out.

d) The cable shall be either galvanized steel wire armor

or galvanized steel interlocking armor, per
34-SAMSS-913.

13.1.2 Field Junction Box to Control Room Marshaling Cabinets

13.1.2.1 Cables between field junction boxes and marshaling

cabinets may be routed in conduits, on trays, or direct
buried. For direct burial, the trench shall be constructed per
SAES-P-104. Twisted, multi-pair/triad cables per Table 2
shall be used for all homerun cables. The use of armored
cables for homerun application is not recommended.
However, if they are used, the cables shall be terminated
using glands per paragraph 6.2 at both ends. In addition,
the armor shall be grounded at both ends.

13.1.2.2 All signal wiring from field cables shall terminate in dedicated
‘marshaling cabinets.’ Marshaling cabinets shall comply with
34-SAMSS-820, Instrument Control Cabinets - Indoor.
Commentary Note:

A marshalling cabinet contains mainly terminal strips and

wire terminations.

Exception:

Wiring for millivolt, microamp, pulse, and frequency signals

under one Volt such as thermocouples, vibration elements,
load cells, thermistor elements and transmitters with pulse
outputs may be directly connected to the I/O unless
otherwise specified.

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Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

13.1.2.3 Each cable or group of cables leaving a specific junction

box and carrying similar signals shall contain a minimum of
20% spare of the used pairs or triads.

13.1.2.4 All spare pairs/triads of a multi-pair/triad cable shall be

terminated at both the field junction box and the marshaling
cabinet. Drain wires for spare shielded pairs/triads shall
also be individually terminated at these locations.

13.1.2.5 Cables entering the marshaling cabinet shall be cut to the

appropriate lengths. Coiling extra cable length or spare
pairs/triads beneath the marshaling cabinet is not acceptable.
Exception:

For wiring directly connected to the I/O, per the exception

item in Section 13.1.2.2, the spare pairs/triads may be
neatly coiled & taped beneath the cabinet.

13.1.2.6 All conductors/pairs, from each field cable, shall be

terminated adjacent to each other on the same terminal strip
in the marshaling cabinet.
Commentary Note:

The intent of this section is to prohibit the splitting out of

individual conductors/pairs from one field cable and having
them terminated on different terminal strips in the same
marshaling cabinet or terminated in separate marshaling
cabinets.

13.1.2.7 Cable entry into control buildings and similar buildings in

hydrocarbon processing plants shall be in accordance with
SAES-P-104, Section 15.4.

13.1.2.8 Emergency shutdown system (ESD) wiring shall have

dedicated cabling, junction boxes and marshaling cabinets.
Exception:

For offshore platforms only, ESD system wiring may be

terminated in the same junction box as general
instrumentation wiring. Terminals shall be segregated and
clearly labeled.

13.1.2.9 Wiring for intrinsically safe (IS) systems shall be

segregated and installed in dedicated conduit or cable tray
and terminated in dedicated junction boxes. For additional
details on IS wiring, refer to SAES-J-903.

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Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

13.1.3 Marshaling Cabinet to Control Room Instrumentation and Control

Systems

13.1.3.1 Cables connecting marshaling cabinet terminals to control

room instrumentation and control systems shall conform to
the requirements of Section 13.1.2, above. Where possible
and practical, pre-assembled cables with plug-in type
connectors shall be used for interconnections. Wiring lists
identifying pin connections shall be required for each pre-
assembled cable.

13.1.3.2 Control room cabling/wiring must conform to NEC Articles

725-61 and 725-82 (2005 edition). Wiring requirements for
distributed control systems (DCS) are detailed in
23-SAMSS-010.

13.2 Underground

If requirements exist to protect against fire damage, underground routing may be

considered for branch cables with prior approval of the Supervisor, Instrumentation
Unit/PASD/P&CSD. For home-run cables, direct burial is allowed and shall be in
accordance with SAES-P-104, Wiring Methods and Materials, Section 10
Underground Cable Systems and Paragraph 13.1.2.1 of this standard.

13.3 Under Computer Floors

13.3.1 Instrumentation cables installed beneath raised computer-type floors in

control rooms shall be placed in ladder, trough or solid bottom cable
tray. Segregation and separation of the cabling shall be in accordance
with Section 14.
Exception:

Alternative installation methods may be used with the approval of the

operating facility Manager.

13.3.2 Where cable tray is used beneath raised computer-type floors in control
rooms, it shall be sized per Section 9.

13.3.3 Cable trays beneath raised floor shall be adequately identified using
suitable permanent tag plates. These tag plates shall be installed at
each end, tee connection and at three meter intervals. The tag plates
shall be located so that it is clearly visible. The tag plates shall
contain, as a minimum, the noise susceptibility level of the circuits
enclosed (per Section 14.1) source, and the destination.

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Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

14 Signal Segregation, Separation and Noise Reduction

14.1 Signal Segregation

14.1.1 Signal wiring (instrumentation cable) shall be categorized with noise

susceptibility levels (NSL) of ‘1’ or ‘2.’
Commentary Note:

Noise susceptibility level ratings and separation tables are derived from
IEEE 518 Guide for the Installation of Electrical Equipment to Minimize
Electrical Noise Inputs to Controllers from External Sources.
The IEEE 518 standard defines three (3) noise susceptibility levels for
instrumentation signals, however due to the signal levels commonly
used in Saudi Aramco's facilities it was deemed that two (2) noise
susceptibility levels were adequate.

14.1.1.1 Level 1 – High to Medium Susceptibility: Analog signals

of less than 50 V and discrete instrument signals of less
than 30 V.

Signal Types
a) Foundation Fieldbus
b) 4-20 mA and 4-20 mA with HART
c) RTD
d) Thermocouple
e) Millivolt/Pulse
f) Discrete input & output signals, e.g., pressure
switches, valve position limit switches, indicating
lights, relays, solenoids, etc.
g) All wiring connected to components associated with
sensitive analog hardware (e.g., strain gauge)
h) Copper data links (RS-232 or 485)

14.1.1.2 Level 2 – Low Susceptibility: Switching signals greater

than 30 V, analog signals greater than 50 V, and
120-240 AC feeders less than 20 amps.

Signal Types
a) Discrete input & output DC signals, e.g., pressure
switches, valve position limit switches, indicating

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lights, relays, solenoids, etc.

b) Discrete input & output AC signals, e.g., pressure
switches, valve position limit switches, indicating
lights, relays, solenoids, etc.
c) 120-240 AC feeders of less than 20 amps.

14.1.1.3 Level 3 – Power: AC and DC buses of 0-1000 V with

currents of 20-800 amps.
Commentary Note:

Level 3 – Power: is shown for the spacing requirements

between 'instrumentation cable' and 'electrical cable'.

14.1.2 Multi-pair/triad cable shall not be used to route more than one signal
type. In addition, junction boxes shall be segregated based on signal
type (e.g., each signal type shall have its dedicated junction box).

14.1.3 Cables with the same noise susceptibility level may be grouped in trays
and conduit (e.g., all level-1 cables may be routed in one cable tray).
Exception:

RS-232/485 and other copper communication cables (other than FF)

shall be routed in dedicated conduits and trays for functional
segregation purposes.

14.2 Signal Separation

14.2.1 Tray Spacing: Table 3 indicates the minimum distance in millimeters

between the top of one tray and the bottom of the tray above, or
between the sides of adjacent trays. This also applies to the distance
between trays and power equipment of less than 100 kVA.

14.2.2 Tray-Conduit Spacing: Table 4 indicates the minimum distance in

millimeters between trays and steel conduits.

14.2.3 Conduit Spacing: Table 5 indicates the minimum distance in

millimeters between the outside surfaces of parallel steel conduits.
This also applies to the distance between steel conduits and power
equipment of less than 100 kVA.

14.2.4 When routing instrumentation and control signal cabling (level 1 or 2)

near sources of strong electromagnetic fields, such as large
transformers, motors and generators, defined for purposes of this
standard as greater than 100 kVA, a minimum spacing of 2 meters
shall be maintained between the cables and the devices.

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Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

14.2.5 For direct buried cable, or cables in PVC conduits, cable spacing shall
be as shown in Table 3.

14.2.6 When entering terminal equipment (e.g., motor control center) and the
spacing listed in tables 3, 4, or 5 cannot be maintained, parallel runs
shall not exceed 5 ft in the overall run.

14.2.7 Minimum separation requirements between various instrumentation

cables and fiber optic data link cables shall be per the manufacturer's
recommendation.

14.2.8 When routing Instrumentation cables (level 1 & level 2) near power
cables carrying higher loads than the limits specified in level 3, the
separation distances shall be 1.5 meters as a minimum.
Exception:

Due to space limitation on offshore platforms, the separation distance

between NSL-1&2 instrumentation cables and power cables above
NSL-3 shall not be less than 1 meter for parallel runs and 650 mm for
cable crossing at 90 degrees.

14.2.9 Power cables and instrumentation cables shall cross at right angles
(90 degrees) while maintaining the required separation distances per
the tables below.

Table 3 – Tray Spacing, millimeters (inches)

NSL * 1 2 3
1 0 (0) 150 (6) 650 (26)
2 150 (6) 0 (0) 200 (8)
3 650 (26) 200 (8) 0 (0)

Table 4 – Tray-Conduit Spacing, millimeters (inches)

NSL * 1 2 3
1 0 (0) 100 (4) 450 (18)
2 100 (4) 0 (0) 150 (6)
3 450 (18) 150 (6) 0 (0)

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Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

Table 5 – Conduit Spacing, millimeters (inches)

NSL * 1 2 3
1 0 (0) 75 (3) 300 (12)
2 75 (3) 0 (0) 150 (6)
3 300 (12) 150 (6) 0 (0)

* NSL = Noise Susceptibility Level

14.3 Noise and Signal Interference Reduction

14.3.1 Noise

Signal wiring shall be installed in a manner that will minimize

unwanted and unnecessary distortion of the signal. Unwanted voltages
are imposed on an electric signal transmission system by inductive,
capacitive or direct coupling with other circuits by leakage current
paths, or ground current loops. In addition, utilizing common return
lead for more than one circuit shall be avoided to minimize noise.

Twisting and shielding of instrumentation wiring shall also be used as

detailed below to minimize the noise impact on instrumentation signals.

14.3.2 Shielding

14.3.2.1 Shielded cables shall be used as required in Table 2 to

reduce electrostatic noise. The shield shall be grounded at
one point only, typically at the marshaling cabinet in the
control room or process interface building.
Exception:

Shield for grounded thermocouple shall be grounded in the

field, at the thermocouple end.

14.3.2.2 Cable shields must have a single, continuous path to ground.

Special grounding terminals in intimate contact with the DIN
Rail, jumper bars or preformed jumper combs designed for
the selected terminal blocks shall be used to consolidate
shield drain wires for connection to ground. Ground loops
and floating shields shall be avoided. Shield drain wires
shall not be daisy-chained to the ground connection.

14.3.2.3 For twisted shielded single pair/triad cables the outer jacket
shall be left intact up to the point-of-termination

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Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

(approximately three to four inches from terminal blocks).

The shield drain wire shall be insulated from jacket end to
terminal. Approximately, one inch of heat shrink tubing
shall be applied over the jacket end.

14.3.2.4 For individually shielded twisted multi-pair/triad cables

each pair/triad shall be heat shrink sleeve insulated from the
cable-jacket-end up to the point-of-termination to keep the
foil shielding intact and free from accidental grounds.
The shield drain wire shall be insulated from foil end to
terminal. Approximately, two inches of heat shrink tubing
shall be applied over the jacket end.

14.3.2.5 In installations where there is a transition from multi-pair or

multi-triad cables to individual pairs/triads for field device
connection in a junction box, the respective shield drain
wires shall be joined via terminal strip and shall not make
electrical contact with the junction box or any other circuit.
Using push-on type connectors or sandwiched shield bars
for shield drain wire connection is not acceptable.

14.3.2.6 The shield drain wire on the ungrounded end of the cable
shall be cut and insulated with a heat shrink sleeve to
prevent unintentional grounding.

14.3.2.7 Except for coaxial cables, instrument cable shields shall

never be used or considered as signal conductors.

14.3.3 Twisting

Twisted pairs/triads shall be used as required in Table 2 to reduce

electromagnetic noise.

15 Termination

15.1 Methods

15.1.1 The termination shall be channel (rail) mounted, strip-type terminal

blocks, with tubular box clamp connector and compression bar or
yoke, as detailed in Paragraph 15.2.

15.1.2 When screw-type terminals are provided on field instruments or other

electrical devices, solderless crimp/compression connectors shall be
used for connecting stranded copper conductors. Screw-type terminals
are defined as those in which the termination method involves the

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Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

direct compression of the conductor by the underside of the screw

head, and which do not contain the conductor within a clamp or yoke.
Insulated ring lugs or locking fork connectors, specifically designed to
hold the connector on the terminal in the event of loosening of the
terminal screw, shall be used on all such connections. Exposed
electrical connections at signal lamps and pushbuttons shall be
completely shrouded by removable, insulating covers.

15.2 Terminal Blocks

15.2.1 Terminal blocks shall be channel (rail) mounted, strip type, with tubular
box clamp connector and compression bar or yoke for wire termination.
As a minimum, the thickness of the terminals shall be 5 mm or higher.
Multi-deck and spring type terminal blocks are not acceptable.

15.2.2 Terminals and terminal block accessories (e.g., DIN rail mounting
brackets for electrical insulation, busbar support blocks, end brackets,
etc.) shall be fire retardant in accordance with UL 94, V0. Terminals
and accessories shall be made of halogen free, high strength material
such as polyamide or equivalent. Brittle materials such as melamine
shall not be used.

15.2.3 Fused terminals shall be equipped with blown fuse visual indication.
The disconnect levers for fused terminals and knife- switch terminals
shall be hinged.

15.2.4 Wires terminated on these terminal blocks shall not have the bare ends
coated with or dipped in solder (“tinned”). However, termination of
wiring that has individual strands of the copper conductor tinned
during manufacture (typical of shield drain wires or for corrosion
protection) is acceptable. Direct termination of the bare wire end is
acceptable. No more than two bare wire ends shall be connected to
each side of a single terminal block.

15.2.5 The use of crimp-on ferrules for this type of termination shall follow
manufacturer's guidelines. Ferrules shall be provided with plastic
insulating collars. Two-wire ferrules are acceptable. However, the use
of ferrules to daisy chain is not acceptable. Only one ferrule shall be
connected to each side of a single terminal block.

15.3 Terminal Strip Assemblies

15.3.1 Terminal strip spacing shall allow ample room for plastic wire ducts
and permit training and lacing of cables, and fanning of individual

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Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

wires to termination points. Each terminal strip shall be labeled above

or below with the terminal strip number, as shown on wiring diagrams.

15.3.2 Terminals for similar (AC or DC) current service shall be grouped
together and physically separated from terminals for different service
by means of dividers, separate mounting rails or separate enclosures.

15.3.3 Terminals for 120 VDC and 120 VAC power for field contacts shall be
segregated from other systems.

15.3.4 Terminal strips for ESD wiring shall be completely separate from all
other wiring including power, control and instrumentation.

15.4 Wire Ducts and Gutters

15.4.1 Plastic wire ducts with removable covers shall be installed in control
panels and marshaling cabinets as required to provide a means of routing
and organizing wiring between terminal blocks and instrument racks or
panels. A minimum of 50 mm (two inches) shall be maintained between
the duct and terminal strips to permit wire markers to be completely
presented without being obscured by the duct. Where space limitations
preclude the use of plastic wire ducts, wiring shall be neatly loomed and
secured with plastic spiral wrapping or tie-wraps and anchors.

15.4.2 Wire ducts for ESD wiring shall not contain any other types of wiring.

16 Identification

16.1 Wire Tagging

16.1.1 All wiring shall be tagged at each end. Each wire tag shall have two
labels. The first label (closest to the end of the wire) shall identify the
terminal number to which the wire is physically connected. The other
label shall be the terminal number of the connection of the opposite
end of the wire.
Commentary Note:

This section is specifying the source and destination information to be

imprinted on one (1) heat shrink sleeve. Sometimes, the term 'label' is
interpreted as requiring two separate wire tags, one containing the
source information and the other containing the destination information,
which is incorrect.

16.1.2 Where wires terminate on instrument or device terminals, the

instrument tag number and terminal designation (+) or (-), shall be
used in lieu of terminal strip identification.

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Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

16.1.3 Wire tag information shall be permanently marked in block alpha

numeric or typed on tubular, heat-shrinkable, slip-on sleeves.
Wrap-around, snap-on or self-adhesive wire markers shall not be used.
Handwritten wire tags are not acceptable.
Exceptions:

1) Alternate wire tagging schemes, which conform to established local

practice, may be used for extensions to existing facilities with the prior
approval of the operating facility Manager.

2) Plastic sleeves that are specifically designed to fit on a specific wire

gauge and come with pre-printed alpha/numeric inserts (such as
Grafoplast Trasp System) may be used for wire tags with prior approval
of the operating facility Manager.

16.1.4 A clear heat shrink sleeve shall be installed over the wire tag for all
instruments that use rust preventive grease on its threaded wiring
access cover.

16.1.5 Spare pairs/triads in multi-pair/triad cables shall be labeled “Spare” in

addition to the destination and source terminal numbers. The “Spare”
designation shall be on a separate wire tag installed on the twisted pair
and not part of the source/destination tag.
Commentary Note:

We do not allow the “Spare” designation to be printed on each

source/destination wire tag because this would require new tags to be
made when the conductors are utilized. This is inefficient since the
source/destination designations do not change.

16.2 Cable Tagging

16.2.1 All cables shall be tagged, at each end, with a cable-tag.

16.2.1.1 Homerun cables shall be tagged with the assigned “IC”

cable number.

16.2.1.2 The cable tagging philosophy for cables routed from

junction boxes to field instruments shall be defined by the
Proponent Representative.
Commentary Note:

Some Proponent facilities prefer to tag the instrument

cables with the instrument cable number (e.g., IC-1249)
where other facilities prefer to tag the cables with the
instrument tag number (e.g., TT-1249).

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Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

16.2.2 Cable-tags outside junction boxes and marshalling cabinets shall be

316 SS with permanently marked alphanumeric characters i.e., raised
or stamped characters. The cable-tag shall be securely attached to the
cable with stainless-steel cable ties. Where cable tags are required
inside junction boxes or marshalling cabinets (i.e., cables extended in
conduits), weather resistant, high quality plastic cable tags secured
using cable ties per Paragraph 5.7.2 may be used.

16.3 Terminal Reference

16.3.1 Each row of terminals shall be uniquely identified alphanumerically,

e.g., TS-101, TS-102, etc.

16.3.2 The terminals in each row shall be sequentially numbered starting at

number one (1).

17 Grounding

17.1 General

17.1.1 Electrical systems must be connected to ground for the protection of

personnel and equipment from fault currents (AC safety ground) and to
minimize electrical interference in signal transmission circuits
(Instrument DC & Shield ground).

17.1.2 Two grounding systems are required for instrumentation systems:

a) Safety Ground for personnel safety.
b) Instrumentation DC & Shield Ground.

17.1.3 Both safety ground and instrumentation DC & Shield ground must
conform to NEC, Article 250.

17.1.4 Grounding system recommendations and requirements provided by

manufacturers of instrumentation and control systems (e.g., distributed
control systems and ESD Systems) shall also be taken into consideration.

17.1.5 For all grass root projects, process automation grounding scheme shall
be per Library Drawing DC-950150-001.

17.1.6 For all grass root projects, safety grounding wires shall be green with
yellow tracers. Instrumentation DC & Shield grounding wires shall be
green.

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Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

17.2 Safety Ground

17.2.1 All exposed non-current-carrying metallic parts that could become

energized with hazardous potentials must be reliably connected to the
equipment grounding circuits. This assures that hazardous potential
differences do not exist between individual instrument cases or between
an instrument case and ground. Therefore, all metal equipment and
enclosures within a panel or series of panels (i.e., instrument cases,
hinged doors, racks, etc.) shall be bonded with bonding jumpers and
connected to a safety ground bus with a minimum copper wire size of
12 AWG. Two copper conductors, 25 mm² minimum, shall be
connected from the safety ground bus to a single tie point on the safety
ground grid in a closed loop configuration. Safety ground connections
must be made such that when a case-grounded instrument is removed,
the integrity of the rest of the safety ground system is maintained.

17.2.2 Enclosures for field instruments shall be grounded as follows:

17.2.2.1 Instruments Operating at Greater than 50 Volts

The enclosures for instrument devices operating at

120 VAC or 125 VDC shall be grounded per SAES-P-111.

17.2.2.2 Instruments Operating at Less than 50 VDC

The enclosures of instrument devices operating at 50 VDC

or less may be grounded using one of the following options:
a) Connecting the enclosure directly to the grid using
25 mm² ground wire.
b) Connecting the enclosure to a grounded instrument
stand or other supporting structure, provided that the
instrument device is properly fastened and the
mounting clamp is mechanically and electrically in
intimate contact with the stand.
c) Using the conduit as a ground conductor, provided
that the conduit system is continuous and properly
grounded. A bonding jumper shall be used across any
flexible conduit at the instrument end. All conduit
fittings shall be listed as suitable for grounding.
d) Using the cable armor (assuming armored cable is
used) provided that the following criteria are met:

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1) The armor construction is suitable as a

grounding path per the NEC.
2) The cable glands, on each end of the armored
cable, shall be designed to bond the armor to the
gland (i.e., listed as suitable for grounding).
3) The armored cable runs in one continuous length
from a properly grounded junction box to the
device being grounded, i.e., no splices are
permitted.
4) The armored cable is not in direct contact with
the soil for any portion of the run.

17.3 Instrument DC & Shield Ground

17.3.1 The purpose of instrument DC & Shield ground bus bar is to reduce the
effect of electrical interference upon the signal being transmitted.
A DC & Shield ground bus bar shall be provided within each cabinet
for consolidating instrument signal commons and cable shield drain
wires. This ground bus shall be isolated from the safety ground system
and from the body of the cabinet except at the plant reference point as
shown in Library Drawing DC-950150-001.

17.3.2 Each instrument signal common shall be connected to the isolated

instrument DC & Shield ground bus with copper wire sized to carry the
expected fault current or 12 AWG, whichever is larger using a screw-
type compression ring lug. Two insulated copper conductors, 25 mm²
minimum, shall be connected from the instrument DC & Shield
ground bus within each cabinet to a single tie point on the Master
Instrument Ground bar (MIG) within the control building in a closed
loop configuration. The resistance from the isolated instrument DC &
Shield ground bus to the plant ground grid shall be less than 1 ohm.
Exception:

For offshore platforms, AC and DC & Shield ground bus bars within
standalone cabinets can be directly connected to dedicated and
separate points on the platform overall grounding grid. The sizes of the
grounding wires shall be per Library Drawing DC-950150-001.

17.4 Grounding within Control and Process Interface Buildings

17.4.1 In cases where there are many ground buses such as in control or process
interface buildings, isolated instrument DC & Shield ground bars from
all cabinets shall be consolidated into a Master Instrument Ground Bus

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Document Responsibility: Instrumentation Standards Committee SAES-J-902
Issue Date: 22 July 2013
Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

(MIG) located within that building. Similarly, AC ground bus bars shall
be consolidated into a Master Safety Ground Bus (MSG).

17.4.2 The Master instrument ground bar shall be connected to the PAS
Master Reference Ground (MRG). The MRG should then be
connected in a loop configuration to a single point on the plant
grounding grid as shown in Library Drawing DC-950150-001.

17.4.3 Master Safety ground shall be connected directly to the plant

grounding grid, as mandated by IEEE 1100. The connection to the
plant grid shall be in a loop configuration as detailed in Library
Drawing DC-950150-001.

17.4.4 Instrument cable shields shall be connected to the instrument DC &

Shield ground bus in accordance with Paragraph 14.3.2.

17.4.5 Bonding cabinet AC or DC & Shield ground bus bars in a daisy-chain

connection is not acceptable.

17.4.6 The connections of the ground wires to the ends of the cabinet bus bars
and to the building master ground bars (MIG & MSG) shall be via
suitable screw-type compression ring lugs.

17.5 Special Considerations

Some equipment (data highways, computers, distributed control systems, etc.)

may require special provisions for grounding. Manufacturers' recommendations
should be carefully evaluated at all times.

17.6 Ground Fault Detection

17.6.1 When critical control systems, i.e., emergency shutdown (ESD)

systems, utilize fully floating DC power where both positive and
negative buses are isolated from earth ground, a selective ground fault
detection system shall be incorporated to detect leakage current from
field I/O wiring to ground.

17.6.2 Due care must be taken to ensure that circuits from one ground fault
selector switch will not be cross-connected to circuits from any other
ground fault selector switch (e.g., at common annunciator points, lamp
test connections).

17.7 Lightning Protection

Lightning protection shall be provided where required in SAES-P-111.

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Document Responsibility: Instrumentation Standards Committee SAES-J-902
Issue Date: 22 July 2013
Next Planned Update: 3 July 2016 Electrical Systems for Instrumentation

Revision Summary
3 July 2012 Revised the “Next Planned Update.” Reaffirmed the content of the document, and reissued
with minor revision.
22 July 2013 Minor revision to clarify of some of the requirements in response to questions received from
various project teams and changing the primary contact info.

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