Cable Specifications and Cable Installation:

Group – 1: Single Twisted pair/Triad, Unshielded

Conductor: Stranded, Circular Copper (Material) as per ASTM B8.
Conductor Size: # 16 AWG
insulation Material: Flame Retardant PVC or XLPO or XLPE minimum temperature rating
is 90o C (NEC 501-4 (b), NEC 502-4 (b).
Primary Insulation Voltage Rating: 300V for Type PLTC and type IT cable, 600V for
type TC Cable.
Primary Insulation Thickness: (0.38 mm for PLTC and ITC Cable), (0.64 mm for TC
cable).
Shield Thickness: 0.022 mm
Group 2: Single twisted pair/triad shield.
Shield Material: Aluminum foil bonded to non hygroscopic polyester (Mylar) tape.
Shield Thickness: 0.022 mm
Application: Helical, Minimum 25% overlap, to provide 100% coverage and electrical isolation
from conductors.
Group 3: Multipair / Triad, Unshielded or without overall shield thickness 0.022
mm.
communication Wire: Not required if required shall be manufacturer’s standard size, Insulation
same as primary insulation – Orange Color.
Group 4: Multipair / triad, Individual and overall shields.
Group 5: Thermocouple Extension wire conductor – solid thermocouple extension
wire as per ANSI MC 96.1
Conductor Size: # 16 AWG for singal pair, # 18 AWG for Multipair.
Color Code: ANSI MC 96.1(Temperature Measurement Thermocouple), (Yellow and Red) Negative
shall be Red color and magnetic
Terminal Block: As per minimum thickness of terminal block shall be 5 mm or higher with Spring
type terminal block are not acceptable, Terminal block shall be fire retardant halogen free, High
strength material such as polyamide on equivalent in accordance with UL94.
Lugs: Drawing / Color Codes / Ferruling will be done for easy identification with use of lugs. Lugs
are two types. One is crimping type and the other one is soldering type.
Type of Lugs: (1) Shanap Type (2) Pin Type (3) Ring Type (4) U Type
Gland Size: ½ inch, ¾ inch, 1 inch, 1½ inch, 2 inch.
Thread Type: ET (Equal Thread), BSP (British Standard Pitch), NPT (National Pipe
Thread).
Color Code of Instrument Cables:
AC Supply: Phase Black
Neutral White
Ground Green or Green with yellow tracer
DC Supply: Positive Red
Negative Black
Signal Pair: Positive Black
Negative White
Signal Tried: Positive Black
Negative White
Third Wire Red
Thermocouple: Positive as per ANSI MC 96.1 (Yellow)
Negative as per ANSI MC 96.1 (Red)
Type of Thermocouple:
T Type Thermocouple Copper + Constant -185 ~ 371 oC Blue – Red/White
J Type Thermocouple Iron + Constant -190 ~ 750 oC White – Red/White
K Type Thermocouple Cromel + Alumel -190 ~ 1250 oC Yellow – Red/ White
E Type Thermocouple Chromel + Constantan -196 ~ 982 oC Purple – Red/ White
S Type Thermocouple Platinum/Rhodium-Platinum -18.0 ~ 1760 oC Black – Red
R Type Thermocouple Pt87/Rh13 + Platinum -17.7 ~ 1704 oC Black – Red/ White
Pulling tension of FOC = 600 Pounds.
Fir Resisting: (CI: Circuit Integrity) Flame Retardant, for transmission of analog or digital signal to
instrument and control systems.
Insulation: Silicon Rubber
Armor: Zinc Coated round steel.
RE: Instrument Cable
2G: Insulation of Silicon
SI: Collective Screen
H: Inner Jacket of LSZH
SWA: Round Steel Wire Armor
 I/W: Outer Jacket of heat resistant PVC
FL: Reduced Flame Propagation
CI: Circuit Integrity
FB: Field Bus Cable
Y: Outer sheath of PVC
2X : Insulation of XLPE
PIMF: Pair Screen
HVAC: Heating Ventilation & Air Conditioning.
ISDN: Integrated Service Digital Network
LASER:Light Amplification by Stimulated.
Cable Bending Radius (j) = 10 x Cable Diameter
Tube Bending Radius (j) = 05 x Tube Diameter
Prevent Electromagnetic Electrostatic Interference from being endued into the inner wire conductor.

Ø Design and installation of power and wiring system for instrumentation shall be in accordance
with NFPA 70 and NEC.

Ø Fireproofing of cable in fire hazardous area shall be in accordance with SAES-B-006 (Aramco
Standard).

Ø Shielded cables shall be used as required to reduce electrostatic noise. The shield shall be grounded
at one point only.

Ø Field Bus Cable shall Comply with IEC 61158-2 (Type A)

Ø Cable Insulation thickness 0.38 mm PLTC/ITC

Ø TC Cable thickness 0.64 mm

Ø Light blue color coding shall be used to identify intrinsically safe wiring the preferred practice is to
specify intrinsically safe interconnecting cable with blue outer jacket. Alternative blue sleeweves
slipped over the jacket.

Ø At all the points of termination may used to identify I.S. wiring.

Ø If used for connections of equipment to ground rods or ground grid to be minimum 25 mm2 (# 4
AWG).

Ø Intrinsically safe system shall be used in zone 0 hazardous area.

Ø Thermal send have to use in trench before started send bedding.

Guide Lines to identify T/C and T/C Extension wires:

For Extension wires having insulation color as per ANSI MC96.1 (American National Standard
Institute). The negative wire is always RED colored as per ANSI.

Cable Gland as per ARAMCO & Internation Standard:

Ø For Hazardous & Non Hazardous locations shall be in accordance with BS 6121 or BS 50262.

Ø Cable Gland: Cable glands are used to protect Mechanical damage. To give earth continuity and for
entering it a junction box & MCC etc. For PILC (Paper Insulation Copper Conductor) cables lead
covered are used because in refinery, hydrocarbon gases will damage the PVC insulation, for this
purpose lead cover is used, for these purpose plumbing type glands are used.

Ø In Explosion proof areas double compression glands are used to avoid these gasses entering in the
electric at apparatus.

Fastener Torque Value:

M8 14 ~ 16 NM

M10 26~ 33 NM
 M12 45~ 58 NM

Sizing of Cable as per ARAMCO & Internation Standard:

0.75 mm2 18AWG

1.0 mm2 17AWG

1.5 mm2 16AWG

2.5 mm2 14AWG

4.0 mm2 12AWG

6.0 mm2 10AWG

10 mm2 08AWG

16 mm2 05 AWG

25 mm2 04AWG

35 mm2 02 AWG

50 mm2 1/0AWG

70 mm2 2/0AWG

120 mm2 4/0AWG

Grounding System as per ARAMCO & Internation Standard:

Ø Ground rods 2.4 meter minimum length.

Ø Cathode protection material is used galvanized steel.

Ø Individual Ground rod maximum resistance should be 2.5 Ohm.

Ø For copper or copper jacketed steel rods is a minimum of 16 mm2 in diameter or 19 mm2 in
diameters.

Ø Earth Tester is used for measuring of earthling system.

Ø Underground wire for grounding to wire connections shall be cadweld or

thermoweld. Compression connector shall not be used.

Ø Shields wires shall be grounded only at the one point for the signal cables.

Ø Shields and armor of power cables shall be grounded at both ends.

Ø If used for connections of equipment to ground rods or ground grid be minimum 25 mm2 (# 4
AWG).

Ø Metallic cable trays shall be bonded at both end points and a minimum of every 25 Meter to the
local ground grid.

Ø If buried / used for grids or interconnections of ground rods to be minimum 70 mm2 (2/0AWG).

Ø Be copper or copper jacketed steel or galvanized steel or copper jacketed steel shall meet the
requirements of UL 476 (Underwriters Laboratories).

Ø Power Applications: Metal cable trays must be grounded and eclectically continuous systems as
per NEC article 318.
Ø Non-Power Applications: Cable tray systems containing conductors outside the scope of NEC
Article 250 (such as communications, data, signal cables, etc.)

Duct Banks:
Ø Consist of either hot dip galvanized rigid steel or PVC conduit, in case in concrete.

Ø 75 mm of concrete from the outside surface of the duct bank to any conduit or
reinforcing steel.

Ø Fabricated spacers shall be used at intervals not exceeding 2.4 Meter.

Ø The spacers shall provide a minimum conduit separation of 50 mm for 2 inch conduit.

Ø For equipment, devices, or appropriates certified as intrinsically safe, only those that
are certified are category EEx or AEx “ia” shall be used.

Ø All metal cable trays, enclosures used for intrinsically safe wiring shall be grounded to
the plant grounding system with a min of # 4AWG copper wire with green insulation.

Ø Cable Tray material shall be galvanized, carbon steel in indoor air condition area.

Ø Bare copper cable does not used in or on aluminum cable tray.

Conduit Installation:
Conduit fittings and accessories include conduits and pull boxes:

Ø Conduit over and gaskets

Ø Conduit Seal
 Ø Conduit Unions and Couplings

Ø Factory Elbows

Ø Drain

Ø Breathers

Ø Plugs

Ø Conduit Connectors reducers

Ø Expansion fittings

Ø Straps and Clamps

Ø Bushing

Ø Cable and duct seal, etc.

Tips for Conduit Installation:

Ø Conduit Expansion fitting shall be provided in indoor 30 Meter.

Ø Conduit Puller J/B shall be provided every 25 Meter.

Ø Pull Box to Pull Box maximum bends acceptable in 360 degree without 90 degree bend.

Ø Support (Bending) does not occur NEC-344

Ø Pull & JB are Installed & Securely fixed as per NEC-314.28

Ø All connection of conduit shall be made by the pipe thread with engagement of at least 5
threads in the effective threaded portion.

Ø The connection part shall be painted by the zinc primer.

Ø When EYS and EZS Series (Explosion proof Conduit Sealing Fittings only).

Ø Tips: 1- Sealing fittings are used to seal cables in conduit entering enclosures; a conduit
union shall be installed between the sealing fittings and the enclosure.

2- Restrict the passage of gases, vapors or flames from one portion of the electrical
installation to another at atmospheric pressure and normal ambient temperatures.

3- Limit explosions to the sealed off enclosure.

4- Limit pre-compression or pressure “piling” in conduit systems

Ø When EYD and EZD Series (Explosion proof conduit sealing fittings with drain).

Tips: 1- Drain to provide continuous, automatic drainage of condensate.

2- Large openings with threaded closures to provide easy access to conduit hubs for
making dams.

3- Integral bushings to protect conductor insulation from damage.

4- Taper tapped hubs to ensure ground continuity.

 Ø NPT type accordance with UL34E 34997 or CSA (Canadian Standard) LR 9795.

Ø Seal fitting shall not be less than ⅝ inch.

Ø Sealing compound shall be 35 oC to 85 oF.

Support for Rigid Metal Conduits:

Size Maximum Distance between Supports

½” ~ ¾ inch 3.0 Meter

1 inch 3.7 Meter

1 ½” ~ 1 ¾ inch 4.3 Meter

2 inch 6.0 Meter

Ø Seals are provided in conduit & cable system to minimize the passage of gases and vapors
and prevent the
passage of flame from one portion the electrical installation the conduit.

Bushings: Where a conduit enters a box, fittings or other enclosure a bushing shall be
provided to protect the wire from abrasion.

Bends:
Number in one run: There shall not be more than the equivalent of four quarter bends
(360 degree total) between pull point to point.

Mandrel Testing:
Testing of underground duct bank and bend radius of conduit is 90 degree. When union
cannot be avoided in underground conduit installation, unions shall be protected with
heat shrinkable sleeves.

Conduit and cable sealing shall be installed in accordance with NEC-505.10. Conduit
seals shall be installed within 450 mm (18 inches) from the enclosure.

PB: Pull Box

RGS: Rigid Galvanized Steel.

Split Conduits:
Split conduit Installation shall be used to repair existing conduits which contains existing cable these
conduits shall be installed in accordance with the manufacturer’s recommendations
or NEMA TCB2 User manual for the installation of order ground plastic conduits.

Ø We can use maximum bend in one conduit (Point to Point) 360 degree, but we have to
avoid 90 degree bend or sharp bends.

Ø If there is sharp bend so we can perform Mineral Test.

Ø Direct buried conduits (Underground) shall be threaded, rigid steel per accordance ANSI
C80.1 and addition it shall be hot dip galvanized and PVC coated as per NEMA
RN1 (minimum thickness of PVC 1 mm) or PVC conduit type DB-120 (Minimum
elasticity 500-000 PSI) as per NEMA TC6 & TC8 type.

Ø Concrete incase conduit shall be threaded, rigid steel as per ANSI C80.1 and in addition
it shall be hot dip galvanized.

Ø Conduit Installed exposed (not embedded in walls) above grounding in outdoor

industrial facilities shall be threaded rigid steel per ANSI C80.1 and in addition it shall be
hot dip galvanized.

Ø Conduit above ground in severe corrosive environments shall be as threaded, rigid

steel as per ANSI C80.1, in addition shall be factory PVC Coated (minimum thickness
of PVC 1 mm) as per NEMA RN-1.

Ø Electrical Metallic Tubing (EMT) is acceptable only in non-hazardous indoor

locations. EMT shall comply with the requirement of ANSI C80.3

Ø Intermediate metal conduit (IMC) is prohibited.

Ø The Minimum conduit size shall be ¾ inch, except for instrumentation wiring inside
building.

Ø Conduit and threaded conduit fitting shall have tapered (NPT) threads in accordance
with ANSI / ASME B1.20.1

ANSI C80.1 Rigid Steel Conduit-Zinc Coated

ANSI C80.3 Electrical Metallic Tubing – Zinc Coated (for indoor only)

Ø Process Piping shall be used to support conduits.

Ø Flexible conduit: shall be used at instrument end of the conduit to provide isolation
from vibration against thermal expansion of the rigid conduit systems.

Ø Conduit sealing shall only be poured at temp between 35 oF to 85 oF

Ø The sealing compound shall provide a seal against passage of gas or vapors through the
seal fittings.

Ø The minimum thickness of the sealing compound shall not be less than ⅝ Inch.

Ø Conduit seal fitting plug is painted with red color and non poured seal fitting are painted
with green color.

Ø Gap selling of expansion splice palate 25 mm (gap max)

Ø 50 oF or 10 oC gap is 9.5 mm (Standard)

Duct Bank Installation or Underground cable system:

Conduit size shall be as per design of duct bank to be installed with minimum gap from
wall to wall shall be 75 mm. Support of Conduit to be fixed every 2.4 Meter. Support
shall be PVC material anchor type.

Tray Installation:
Tray Installation: The publication is intended as practical guide for the proper
installation of cable system. Cable tray systems design and Installation shall
comply with NEC Article – 392 & 318,
NEMA VE1, NEME VE2 and NEMA FG 1 and follow safe practices as
described in NFPA 70E.
Tips for Cable Tray Installation:
Ø Cable tray specification shall be per NEMA VE1 the tray shall be per NEMA
VE2.
Ø The distance between consecutive rungs shall not exceed 229 mm (9 Inch).
Ø Cable Ties for Vertical Application shall be provided every 18 inch (after one
rung).
Ø Cable Tied for Horizontal application shall be provided every 27 inch (after
two rungs).
Ø Unless otherwise noted, the support interval shall be not more than 2.4
meters as per NEMA VE1.
Ø For the Vertical Application cable ties must be 316SS with PVC coated.
Ø The open gap between tray/conduit to the instrument maximum 350 mm.
Ø The cable tray system shall be installation with manufactures standards
fittings.
Ø Such as Clamps, Splicer Plates, Connector, Hangers, Reducer Plates,
Grounding Brackets Blind, Nut Bolts,
Washers etc.
Ø The channel cable tray material shall be copper free aluminum (Aluminum
with max of 0.4% copper).
Ø Channel cable tray width shall be 3, 4, or 6 inches with a minimum loading
depth of 1 ¼ inch.
Ø Non metallic cable tray permitted in corrosive area. Non metallic cable trays
shall be made of
flame retardant material.
 NSL: Noise Susceptibility Level
Level 1: High to Medium susceptibility analog signals of less than 50V and discrete
instrument signal of less than 30V.
Level 2: Low susceptibility switching signal greater than 30V, analog signals
grater then 50 V and 120 ~ 240 AC feeder less than 20 Amps.
Level 3: Power AC and DC buses of 0 ~ 1000 V with currents of 20 ~ 800
Amps.
Tray to Tray Spacing in mm:
NSL 1 2 3
1 0 150 650
Tray to Conduit Spacing in mm:
NSL 1 2 3
1 0 100 450
Conduit to Conduit Spacing in mm:
NSL 1 2 3
1 0 75 300
Tray to Tray:
Level 1 to Level 2 gap should be 150 mm
Level 2 to Level 3 gap should be 500 mm
Level 1 to Level 3 gap should be 650 mm
Tray to Conduits:
Level 1 to Level 2 gap should be 100 mm
Level 2 to Level 3 gap should be 350 mm
Level 1 to Level 3 gap should be 450 mm
Conduit to Conduit:
Level 1 to Level 2 gap should be 75 mm
Level 2 to Level 3 gap should be 225 mm
Level 1 to Level 3 gap should be 300 mm

Impulse Tubing Installation:

Impulse lines for remote device should be as short as possible, 3 feet for
close-coupled transmitters and preferable not more than 20 feet (6
meters). For liquid measurement the lines should slope down at least 1
inch per foot from the orifice taps.
Tubing: Stainless steel tubing shall seamless, annealed, minimum wall
thick 1.24 mm as per ASTM A269 Gras IP – 316L.
 Impulse Tubing Installation Tips:
Slop of Impulse tubing: Minimum of 1inch for every 1 meter towards tapping point.

Bend: Minimum bends length around 70 mm.

Test Pressure of Impulse Line: 1.5 Times of the working pressure with 3 minute.

Instrument Tubing size: ½ inch x 0.89 mm (wall thickness) = 0.035 Inches.

Piping and Impulse tubing shall be support as follows:

Size Maximum Distance between su

Tube 300 mm
Less than ½ inch

½ 1800 mm
inch Tube & Pipe

¾ inch Pipe 2400 mm

1 inch Pipe 3000 mm

Air distribution System:

Ø All main and branch headers shall be sloped {minimum 64 mm per 30 Meter
(2.5 inches per 100 feet)}
and provided with low point drains.
Ø Supply takeoffs to individual instruments (a line serving up to a maximum of
four devices) shall connect to the top of the branch header through a
takeoff-line-size, full-bore isolation valve.
Ø The minimum size of supply takeoffs is ½ inch.
Ø Twenty percent (20%) spare takeoff fittings and block valves shall be
installed on the branch header.
Ø Instrument air piping shall not be pocketed. Instrument air piping shall not
be installed underground.
Ø The Piping route shall avoid a harmful effect from a heat source (keep 150
mm minimum distance)
and not be under the process piping and equipment, which is covered by the
hot
or cold insulation materials.
Air Piping Maximum shall be No of Users as follows:

Pipe Size Maximum No of Users

 ½ inch 1~4

¾
5~9
inch

1 inch 10 ~ 15

1 ½ inch 16 ~ 80

2 inch 81 ~ 150

3 inch 151 ~ 300

Enclosures:
Indoors and Outdoors Plant Area:
Indoors: With in the Perimeter of the Process Unit (NEMA 250 /
NEMA ICS6)
Outdoor: Out side the Perimeter of Process Area (IP54)
Ø Severe Corrosive Environment (Industrial Area) NEMA Type 4X or IP66.
Ø Non Industrial Area IP34.
Ø Name Plate Shall is attached to the cabinets using stainless screws.
Ø Indoor Cabinets shall be made of metal.
Ø The Cabinet shall be a NEMA Type 1 as per NEMA 250 and NEMA ICS6.
Ø NEMA ICS6: Enclosures for Industrial Controls and System.
Ø The Max Door Width shall be 900 mm (36 Inch)
Ø The Marshalling cabinets from the front surface to the surface of rear
terminal block, shall not be more than
46 cm (18 Inch).
Ø A minimum of prime, undercoat & finishing coat of enamel or polish is
required.
Ø Interior cabined color shall be white or of light color such as light gray off.
Ø Name plate for cabinets and panels letter height and spacing shall follow
ISA RP 60.6
Ø Name Plate shall be made from laminate Plastic, white – Black – White
(Information engraved into the black core) with white surface.

Example 1:

Area classification Class I (Zone 0 /

Division1)

Symbol for equipment built to American Standards A

Type(s) of protection designation Exia

Gas classification group (not required for protection Techniques indicated in

NEC 505.6, FPN No. 2) IIC

Temperature classificationT6

Example 2:

Type of Protection:
Zone ‘0’
– Ex ‘ia’ and Ex ‘s’ (Specifically certified for use in Zone ‘0’).

Zone ‘1’
– Any type of protection suitable for Zone-0 and Ex‘d’, Ex ‘b’, Ex ‘p’, Ex ‘e’.

Zone ‘2’

– Any type of protection suitable for Zone–0 or Zone-1 and Ex ‘N’ or ‘n’, Ex
‘o’, Ex ‘q’.

Designation Technique Z

Ex ‘d’ Flame proof or Explosion proof

Ex ‘e’ Increased Safety

Ex ‘N’ or ‘n’ None Sparking

Ex ‘ia’ Intrinsic Safety

 Ex ‘ib’ Intrinsic Safety

Ex ‘p’ Pressurization

Ex ‘o’ Oil Immersion

Ex ‘q’ Sand or Powder filled

Ex ‘s’ Special Protection

Gas Group:

Representative Gas IEC U

Methane I

Propane IIA

Ethylene IIB

Hydrogen IIC

Carbon Disulphide IIC

Intrinsic Safe Meters:

In hazardous area only I.S. meters such Meggers, Vibration meters and
Temperature meters shall not be used unless the hot permits obtained.

Safety Barriers: (Zenner Barriers) Diode shunt barriers are used in

intrinsically safe zone to limit the current and voltage.

Grounding System:
round Definition:

ed and non-exposed non-current carrying by the metallic parts that could be energized its
hazards. That’s why all safety ground must connect to the plant ground
system.
Circuit / IS Ground Definition:
Reduce the electrical Interruption being the signal transmission.

Signal / Circuit / IS Ground:

G + Y (Green + Yellow)

Safety Ground:
G (Green)

Comparing NEC 500 to ATEX

ATEX: EX II 2 G EEX ia IIC T4

“II” designates the tool is approved for all non-mining areas. “2” represents a
rating for Zone 1 and above. “G” designates atmosphere, in this case gas vapors and mist.

EEx Explosion protection based on European ex-regulation.

ia The type of protection, the energy in a device is reduced to a safe value.

Gas Group “IIC” indicates compatibility with the most dangerous gas group.

Maximum temperature of a surface that may be in contact with the ex-atmosphere under
T4
conditions. T4 rating is 35 C.

FM Classification: N.I. Class 1. Div 2, Groups A-D

Non-incendive aparatus, internal energy is limited so a specified atmosphere cannot be ign

Class I For use of gases, vapors and liquids (not dust , fibers of filings)

Certified for use division 2, explosive atmospheres not normally present, may rarely exist f
duration.

Groups A-D Rated for use with explosive gasses as defined y group A-D, including acetylene, hydrogen

Note: European ATEX and North America NEC-505 classification are

nearly identical excepting the AEx v/s EEx marking.
Hazardous Location Classifications:

NEC IEC Environment

Class I – Explosive gases or vapors are present.

Class II – Combustible dusts are present.

Class III – Ignitable fibers or flying are present.

A location where a hazardous concentration of gases or vapors exists approxim

Division 1 Zone 0
% of the time (subject to interpretation as above).

A location where a hazardous concentration of gases or vapors exists approxim

Division 1 Zone 1
of the time (subject to interpretation as above).

A location where a hazardous concentration of gases or vapors exists approxim

Division 2 Zone 2
% of the time (subject to interpretation as above).

Group A Group IIC A hazardous atmosphere containing acetylene or other similar gases or vapors

Group B Group IIC A hazardous atmosphere containing hydrogen or other similar gases or vapors

Group C Group IIB A hazardous atmosphere containing ethylene or other similar gases or vapors.

Group D Group IIA A hazardous atmosphere containing pentane or other similar gases or vapor.

Group E – A hazardous atmosphere containing metal dust, such as aluminum.

Group F – A hazardous atmosphere containing carbon black, coal, or coke dust.