ELECTRICAL & INSTRUMENTATION STANDARDS

SAES-P-104
SAES-P-111
SAES-P-107
TRANSFORMER TESTING
BREAKER TESTING
SAES-J-902
SAES-J-400
TUBE LEAKAGE TESTING
SAES-P-104
WIRING METHODS & MATERIALS
•Design and installation of power and control wiring & cable systems
Wire & Cable
LV CABLE MV CABLE HV CABLE
•Jacketed Cable •IEC 60502-2 Rated Voltage
1. NEC-600V-Dry 90C/Wet 69KV above
75C.Flame test UL 1277 •15-SAMSS-502 should comply
2. IEC 60502-1, rated 5KV with AEIC CS6 or
600/1000V.Flame test IEC through 35KV AEIC CS9
60332-3
• Unjacketed Cable
1. NEC-600V-Dry 90C/Wet
75C.Flame test UL 83 for
THHN/THWN,UL 44 for
XHHW
2. SASO 55 & IEC
60227,450/750V,Flame test
IEC 60332-1
Size of Conductors
Voltage SIZE in Size in AWG
mm2

600V & below(control) 2.5 14

600V & below(control) 4 12

5KV 10 8

15KV 35 2

35KV 50 1/0

69KV 120 4/0

N o t e : AW G - A m e r i c a n W i r e G a u g e
Connection & Terminations

 Compression type Crimping

• All compression connectors are tinned copper
• 4/0 AWG & large conductors should two-hole
design
 Types of connectors
• Insulated ring tongue
• Locking fork tongue
• Flanged fork tongue
• Pin type compression
• Enclosures
 Outdoor plant areas
 NEMA 250/NEMA ICS 6 Type 4 & 3,IEC 60529 Type
IP54.
 Copper free aluminum(0.4of 1% Copper maximum)
 Severe Corrosion Areas
 NEMA Type 4x
 Copper free aluminum(0.4of 1% Copper maximum)
 316 SS
 Dry type transformer
 NEMA Type 3R
 Enclosure volume-2000cm3
Conduit
Underground conduit

Direct Buried Conduit Concrete Encased Conduit

•Type DB_120 (minimum •Type DB_120 or EB-35

modulus of elasticity (minimum modulus of
5000,000psi) per NEMA elasticity 5000,000psi) per
TC6&8 NEMA TC6&8
•EPC-40-PVC per NEMA TC 2. •EPC-40-PVC per NEMA TC 2.

Severe corrosion Area

• PVC coated (minimum thickness of pvc-40mils(1mm) per NEMA

RN1
 •EMT-Electrical Metallic Tubing –ANSI C80.3
•Minimum Size of Conduit
• Electrical conduit- ¾”
• Instrumentation & Non –industrial - ½”
Types Of Conduit.
• RGS-Rigid steel Conduit
• Hot –dipped Galvanized
• PVC Coated
• LFMC Liquid Tight Flexible Metallic conduit.
Underground Cable Systems
Systems Voltage Direct Direct Buried Duct Bank
Buried(mm) PVC(mm) (mm)

600v & below 610 460 460

Over 600V to 35KV 920 610 460

Over 35KV 1070 760 460

 Trench Diagram

Note: A f t e r R e d t i l e s , l a y i n g t h e w a r n i n g t a p e
then backfill up to grade.
Cable Testing
•Low voltage cable

• Continuity test by Multimeter

• IR test for below 500V rated cable checked by
500VDC Megger
• IR test for above 500V to 1000V rated Cable
checked by 1000VDC Megger

•Medium & High Voltage cable

• Continuity test by Multimeter

• IR test for above 1000V rated cable checked by
5000VDC Megger
• Hi-Pot testing
Cable Separation

• There is no Minimum Cable separation for Same Voltage

level.
• Below 1000V up to 34.5KV Cable Minimum separation is
300mm
• Above 34.5Kv to less than 34.5Kv Cable Minimum
separation is 1000mm
• Redundant Feeders & cable Minimum separation is
1800mm
Conduit & Cable sealing –accordance with NEC articles 501 &
502

We have to using this type Glands.,

• Barrier type Glands with utilizing sealing Compound

• EEx d- Explosion Flameproof glands.
SAES-P-111
GROUNDING- Accordance with NEC Article 250

Design & Installation of Grounding Systems & Lighting Protection systems

Grounding Materials & Installation

•Be soft or Annealed Copper.

•Galvanized Steel.
•Be Insulated or PVC Jacketed.
•Standard Size of Grounding Conductors-25Sq.mm(4AWG),
35Sq.mm(2AWG), 70Sq.mm(2/0 AWG), 120Sq.mm(4/0 AWG)
•Above 35Sq.mm(2AWG) should be Stranded type grounding
Conductor.
•At CP areas Bare Copper Should not used because Copper will be
tarnish(Acid),So it will be corrode & not get proper conduction. So
at the area we use only Galvanized steel.
•GROUNDING ROD SIZE

Copper

• Length minimum 2.4mtrs

• Diameter minimum 16mm

GI
• Length minimum 2.4mtrs
• Diameter minimum 19mm
Grounding Connection
Below Grounding Connection Above Ground Connection

• By thermite welding or • By thermite welding or

Exo-Thermic welding Exo-Thermic welding
• Compression type • Compression type
connectors connectors bolted to
• Mechanical connectors bare steel.

Grounding electrode buried a minimum of 460mm, or

any road crossing area electrode buried a minimum
610mm
Concrete encased electrode will used bare copper
conductor
SUBSTATION NON FENCE EQUIPMENT
GROUNDING SUBSTATION GROUNDING GROUNDING
FENCE
GROUNDING

•Substation •Fence ground •Fence shall not •Above 1000V

grounding grid connected PVC coated. should give
conductor within 3mtr of • Fence ground double earthing
stranded type- fence grid connected must
70sq.mm(2/0AW •Fence shall within 1mtr of •Below 1000V-
G) connect to grid fence Single earthing.
not exceeding •Fence shall •Minimum
•S/S Fence ground 15mtr connect to grid conductor size
grid connected not exceeding 25sq.mm
within 5mtr of 15mtr
fence

Note: Fence grounding grid connected to

corner post and gate post with connectors
Grounding Requirements

• UL 467 - Grounding & Bonding Equipment.

• NFPA 70 - National Electrical Code
• NFPA 99 - Health care Facilities.

Lightning Protection Requirements

• NFPA 780- Lightning Protection Code

• UL 96 - Lightning protection components
• UL 96A - Installation requirements for lighting
Protection Systems
Ground Resistance Testing or Fall of Potential

• By using 3-Point tester method by Ground Tester

• Having 3 Probe 1.Ground Rod
2.Current
3.Potential
• By Varying potential 3times from ground rod spike to
Current Spike while get 3 reading of resistance
• Sum of 3 reading divided by 3,while we get
Individual road resistance.

Acceptance Values

• Individual Rod Resistance -below 25 Ω

• A/C Ground Grid - below 5 Ω
• D/C Ground Grid - below 1 Ω
TRNSFORMER TESTING
Dry Type Transformer Oil Type Transformer
•Winding Resistance for Primary & •Winding Resistance for Primary &
Secondary side by Multimeter Secondary side by Multimeter
•R-Y ,Y-B, B-R •R-Y ,Y-B, B-R

•IR for Primary & Secondary •IR for Primary & Secondary,
•R-G, Y-G, B-G for Low Voltage T/F •R-G, Y-G, B-G for Medium Voltage
by using 1000VDC Megger with T/F by using 5000VDC Megger for
1minute. Py with 3minute & Sy. For
1000VDC Megger with 1minute.

•Polarization Index •Polarization Index

(R10/R1).Checking for moisture, (R10/R1).Checking for moisture,
dirt & Insulation deterioration. dirt & Insulation deterioration.
•HV-LV & G, LV-HV&G, HV&LV-G •HV-LV & G, LV-HV&G, HV&LV-G

•Turns Ratio Testing for windings •Turns Ratio Testing for windings
Np/Ns, Np/Ns, to check all Taping
•Calculated Ratio=Measured Ratio Positions
will be same •Calculated Ratio=Measured Ratio
will be same
BREAKER TESTING

INSULATION CONTACT TRIP TESTING

RESISTANCE RESISTANCE

•I/P Terminal to O/P •Contact to Contact •Trip testing checked

Load terminal IR values resistance checked by by High Current
have to check by DLRO . Injector
Megger •Acceptance Values-
•Acceptance Values- 200micro-ohms(above
>50Megohms. 20% deviation shall be
investigated).
SAES-P-107
OVERHEAD DISTRIBUTION SYSTEMS

Design & Installation of Overhead distribution systems rated 34.5kv

or less-in accordance with ANSI/IEEE C2.

OHPL Conductor Shall be ACSR- Aluminum Conductor Steel

Reinforced .

OHPL line environmental conditions

Minimum Temp:0°C
Maximum Temp:50°C

If OHP Lines Exceed 5spans in length

• Sag & Tension Calculation
• Sag/Temperature Templates
• Plan & Profile drawings
• Span length not Exceed 90mtrs.
SUPPORTING STRUCTURE
• Hot dipped Galvanized steel Pole
• Seamless Aluminum alloy Pole
• Guy
• Messenger
• Anchor
Conductor & Minimum Clearance Requirements in meter.

Layout Description 34.5 13.8

KV KV
Conductor Spacing
•Horizontal 1 0.76
•Vertical 1.2 1

Jumper Conductor to grounded metal part 0.55 0.46

Conductor Vertical Ground Clearances
•Above desert area 8.5 8.5
•Above pipeline Crossing 9 9
•Above Paved roads 12 12

Pole horizontal Clearance to Edge of highway 10 10

 Guys, Messengers & Anchors Requirements

GUYS MESSENGERS ANCHORS

•Guy assemblies able •Messengers shall e •Screw anchor or Rock

to withstand all Stranded steel type Anchors
loading conditions •Anchor shall not loaded
•Down guy & support in excess of 35% of their
structure not exceed ultimate strength.
60° & not less than
37°

•Guy have reflective Guy & messengers •Anchors shall not extend
finished guy guards. Attachment hard ware above ground.
•Supporting structure performed type dead
shall be insulated with end fittings.
in Strain insulators.
INSULATOR REQUIREMENTS

• Post & Suspension type insulators

• Insulators bracket shall be metallic

Insulators Requirements
Insulators Standard
Requirements
Testing ANSI C29.1
Suspension Type Porcelain Insulators ANSI C29.2
Strain Type Porcelain Insulators ANSI C29.4

Line Post Type Porcelain Insulators ANSI C29.7

Station –Post Type Porcelain Insulators ANSI C29.9
Dead end Type Composite Insulators ANSI C29.13
Line Post Type Composite Insulators ANSI C29.18
CONDUCTOR SIZE & SERVICE AMPERS RANGE
CODE CONDUCTOR CONDUCTOR CONDUCTOR CONDUCTOR EMERG
WORD IN SQ.MM IN AWG IN Kcmil NORMAL ENCY
AMPS AMPS
RAVEN 53.5 1/0 105.6 200 300
QUAIL 67.4 2/0 133.1 260 335
PENGUIN 107.2 3/0 211.6 305 445
MERLIN 170.2 336.4 440 650
DRAKE 402.8 795.0 760 1105

CONDUCTOR LINE POSITION

PHASE HORIZONTAL VERTICAL
X OR A EAST /WEST CENTRE
Y OR B CENTRE BOTTOM
Z OR C WEST/SOUTH BELOW
SHIELD/GROUND TOP
ACCESSORY EQUIPMENT

• Transformer Py, Connection made with Hot line Clamps to bail

• Minimum height of pole mounted transformer from the grade-4.9m
• Load break Switches provided at sectionalizing points
• Fuse Cutouts provided for OHPL transformer

PROTCTIVE DEVICES
SYSTEM VOLTAGES(KV) ARRETER RATING(KV)

4.16KV 6.0KV

13.8KV 12KV

34.5KV 27KV

NOTE: Pole Grounding electrode minimum

diameter-16mm,Length-3mtr
SAES-J-902
ELECTRICAL SYSTEMS FOR INSTRUMENTATION

Design criteria for the installation of power & installation systems for
Electrical Instrumentation
DATA LINK DRAIN WIRE HOME RUN CABLE
Used for connecting Non insulated wire in Junction boxes to
data processing intimate contact with Marshalling cabinets
equipment to any shield to ground of multi pair cable &
input, output, display point termination. Triad cable.
devices or other data
processing
equipment.

Severe corrosive areas:

• Outdoor offshore locations.
• Outdoor onshore locations within 1km of Arabian gulf
• Outdoor onshore locations within 3km of Red sea.
• Locations of chlorine plants, sulphur plants, wastewater
treatment, water treatment, R.O facilities.
Conduit & Cable sealing –accordance with NEC articles 505
• Compound Barrier seal with utilizing sealing Compound
• Certified flameproof (type d) cable glands.(316SS).
• Parallel thread –Metric
• Tapered thread-NPT
• Ensure 5 full threads.
 Enclosures
• Outdoor plant areas
NEMA 250/NEMA ICS 6 Type 4 & 3,IEC 60529 Type
IP54.
Copper free aluminum(0.4of 1% Copper maximum)
• Severe Corrosion Areas
NEMA Type 4x
Copper free aluminum(0.4of 1% Copper maximum)
316 SS
• Enclosure volume-2000cm3
 Power Supply
System Nominal Tolerance NEC Class
voltage level
Annunciator 24VDC 21-28VDC 1 or 2
Power 125VDC 113-137VDC 1 or 3
125VAC 110-126VAC 1 or 3

Shutdown & 24VDC 21-28VDC 1 or 2

Isolation Systems 125VDC 113-137VDC 1 or 3
power 125VAC 110-126VAC 1 or 3

Field switch 24VDC 21-28VDC 1 or 2

125VDC 113-137VDC 1 or 3
125VAC 110-126VAC 1 or 3

Analog signal 24VDC/4- 21-28VDC 1 or 2

20mA
Instrumentation 24VDC 21-28VDC 1 or 2
power 120VDC 110-126VDC 1 or 3
230VAC 218-242VAC 1 or 3
 Backup Supply Systems
• UPS Systems
• Redundant UPS system.
UPS Systems Redundant UPS system

• PLC • Process failure

• Burner management systems • Plant shutdowns
• MOV control circuit • VMS
• Master Station • ESD
• DCS • HIPPS
• VMS
• Computational devices
• ESD
• SCADA

 UPS Batteries-backup not less than 30 minutes

Signal & Control wiring

NEC Article 725 Class 1 circuits(note 1,2,4,8,9,10)

Instrument type Circuit example Field Instrument to Field JB t
Field JB Marshalling
cabinet

120/230 VAC Switches, Solenoids, 16AWG,600V Single 18AWG,600V twisted

/125VDC Relays, Limit twisted pair, type TC individually multi
Switches Cable, Type MC pair, type TC Cable.

NEC Article 725 Class 2 & 3 circuits(note 1,2,3,4,8,9)

Instrument type Circuit example Field Instrument to Field JB t
Field JB Marshalling cabinet

24VDC,Analog Switches, Solenoids, 16AWG,300V 18AWG,300V

signals,Frequency,puls Relays, Limit PLTC/ITC,SWA Single PLTC/ITC twisted
e,transmitter digital Switches, motor twisted pair, triad individually multi
communication control cable. pair, Triad's.
ckt,RTD,Vibration,Tur
bine meter

Thermocouple Thermocouples 16AWG,300V 18AWG,300V

Measurement PLTC/ITC,SWA Single PLTC/ITC,SWA Single
twisted,shielded,thermo twisted,shielded,therm
couple extension pair ocouple extension pair
cable. cable.
Instrument cable splices are not permitted-if any slices means connection
through TB in a JB.
 Cables Colour Coding
Supply Cables Colour
AC Supply Phase Black
Neutral White
Ground Green with yellow tracer

DC Supply Positive Red

Negative Black
Signal Pair Positive Black
Negative White
Signal Triad Positive Black
Negative White
Third cable Red

Thermocouple Positive ISA MC96.1

Negative ISA MC96.1

 Signal Segregation

• Level 1
• Level 2
• Level 3
 LEVEL 1 LEVEL 2 LEVEL 3

• High to medium • Low susceptibility AC & DC Buses of 0-1000V

susceptibility • Analog signals >50V with 20-800A
• Analog signals <50V • Digital Signal >30V
• Digital Signal <30V

Signal Types Signal Types

• Foundation Fieldbus • Discrete I/P & O/P
• RTD signals –Pressure
• Thermocouple switches, valve position
• Millivolt/pulse limit switchs,indicating
• Discrete I/P & O/P lights,relays,solenoids
signals –Pressure • 120-240VAC feeders
switches, valve <20A
position limit
switchs,indicating
lights,relays,solenoids.

• Same Susceptibility level cables no separation needed.

 Signal Cables separation
NSL Below grade TRAY -CONDUIT CONDUIT SAPCING

Level 1&2 150mm 100mm 75mm

Level 2&3 200mm 150mm 300mm

Level 3&1 650mm 450mm 300mm

 Grounding

• Grounding for protection of personnel & equipment from fault

• Minimize the electrical interference in signal

 Two Grounding Systems for Instrumentation systems

• Safety ground for personnel safety
• Instrumentation DC & Shield Ground.
SAES –J-400
TEMPERATURE
Design & installation Temperature Instrumentation systems.

 Installation Requirements:
• All instruments & connection locate to provide safe access for
installation & maintenance
• Local controllers located no more then 1.5m
• Temperature transmitters located no more than 3m.

 Temperature Instruments
• Thermowells
• Thermocouple instruments
• RTD
• Temperature Transmitter
• Temperature switch
 Thermowells
• Temp <535℃-not require ANSI Class 900,Higher flanges.
• Temp>535 ℃- require ANSI Class 900,Greater Flange.
• Thermowell will tapered & machined from barstock material.
• 316SS
• Flanged Thermowells with ASME B16.5 flanges.
 Thermocouple Instrument
• As per ISA MC96.1
• Thermocouple type E, Type J, Type K.
• Type J-Corrosion Iron wire.
• It's Insulted with packed magnesium oxide with ¼ inch outer
diameter.& 316SS Sheath.
 RTD –Resistance Temperature Detector
• Using for greater accuracy
• RTD measuring approximately 800 ℃(1500F)
• Platinum RTD-IEC 60751
• 0.00385 Ω/ Ω/ ℃
• Platinum 100 shall be 100 Ω at 0℃
• It's Insulted with packed magnesium oxide with ¼ inch outer
diameter.& 316SS Sheath

 Temperature Transmitter
• Temperature Transmitters meet NFPA 70 NEC hazardous area
classification
• Transmitter shall provide I/P &O/P signal isolation.
• Transmitters with smart electronics, it provide accuracy &
rangeability, remote calibration.
 Temperature Switch
• Local Application only
• Electric switch contacts shall be snap acting, SPDT switch.
• Switch may be installed directly on the RTD Element.

 IMPULSE TESTING or TUBE LEAKAGE TESTING

• The instrument piping & tubing installation shall ensure the

reliable & accurate operation of the instruments involved, &
sufficient access for maintenance ,calibration & testing.
• Tubing to & from non-indication instruments have plugged tee
or equivalent test point for calibration & testing purpose
• All the Threaded connections shall be tapered ASME B1.20.1

Testing Pressure: 1.1*Design pressure

=testing pressure+5%PRV
Supply pressure Water with 45% chlorine