Page 1 of 12STANDARD SPECIFICATION FOR INSTRUMENT CABLES AND RELATED ACCESSORIES DOCUMENT NO : 44-LK-5100-00/J.02/0014-A4 Rev No. A Issue Date 12-08-08 Pages 12 Rev Description Issued for Comments / Approval Prepared Checked Approved By By By RCK GDR BSP 0 SCOPE 3.7 3. : A .08 Page 2 of 12 Revision No.5 3.0 ATTACHMENTS Date : 12.1 3.4 3.0 RELATED DOCUMENTATION 5.0 PURPOSE 2.JACOBS ENGINEERING INDIA PRIVATE LIMITED DOCUMENT NO :44-LK-5100-00/J.02/0014-A4 STANDARD SPECIFICATION FOR INSTRUMENT CABLES AND RELATED ACCESSORIES TABLE OF CONTENTS 1.0 TECHNICAL REQUIREMENTS 3.8 INSTRUMENT CABLES DESIGN AND TESTING STANDARDS CABLE CONSTRUCTION CABLE DRUMS IDENTIFICATION MARKS ON CABLES CABLE GLANDS JUNCTION BOXES MULTI CABLE TRANSIT 4.3 3.6 3.08.2 3. Construction of same shall be as Per IEC 61158-2.JACOBS ENGINEERING INDIA PRIVATE LIMITED DOCUMENT NO :44-LK-5100-00/J.0 TECHNICAL REQUIREMENTS 3.7 Control cables shall be used for solenoid valves.1. The inspection requirements shall be as per the inspection plan.1. etc. 2.6 Power cables shall be used between power supply distribution boards and power consumers such as control panels. testing and supply of instrument cables and related accessories. 3.4 For fieldbus compatible instrument single pair shielded cable shall be used between instrument to junction box/ local panel and to control room.0 Date : 12. 3.8 For solenoid valve signals and power supply to instruments. junction boxes shall be used.1 INSTRUMENT CABLES This specification covers the requirements for instrument signal cables.1. 3. manufacture.3 Single triad shielded signal cables shall be used between RTD head and junction boxes / transmitters / local control panel mounted instruments. Foundation Field bus shall be Type-A cable. DCS / PLC cabinets. thermocouple extension cables.08 Page 3 of 12 Revision No.08. : A PURPOSE The purpose of this specification is to define the minimum requirements of design and manufacture of instrument cables and related accessories.1. 3.1.5 Separate Multipair/ multitriad cables shall be used between junction boxes/ local control panel and control room as per following applications. any instruments requiring power supply. RTD cables and power / control cables. 3. 3. • 4-20 mA signals (for conventional HART Transmitters) • Foundation Field signals • Thermocouple signals • Resistance Temperature Detectors (RTD) signals • Switch contacts / Proximity switch contacts • Gas detectors 3.02/0014-A4 STANDARD SPECIFICATION FOR INSTRUMENT CABLES AND RELATED ACCESSORIES 1.1.1 Single pair shielded signal / alarm cables shall be used between field instruments / switches and junction boxes / local control panels.1.1. . 12 Pair. 5 Pair.0 SCOPE The scope of work shall include design.2 Single pair shielded thermocouple extension cables shall be used between thermocouple head and junction boxes / transmitters / local control panel mounted instruments. 3. 3. Trunk cable shall be used of 1 Pair. Round wire armour galvanized steel as per IS 1554 Part 1 Extruded Fire Retardant.10 The insulation grade shall be 1100 V for all cables. • Insulation shall be Cross-linked Polyethylene (XLPE) as per BS 5308 / IS 7098. For these cables.1.low halogen. Inner and outer sheath / jacket shall be made of extruded fire retardant. • Light Transmission: 70% (minimum) as per IEC 1034.C conforming to BS.In underground ducts .1. polymeric compound having physical properties as per IS-5831 –Type ST2.5 mm of plain annealed single or multi-strand copper conductor with 0. For multipair/ multitriad cables.1.08.1.12 All cables shall be armoured and suitable for operation when installed as follows: . 3. PVC having physical properties as per IS 5831-Type ST2.1. low toxic. 3. 3. : A 3.1.08 Page 4 of 12 Revision No.11 The primary insulation shall be cross-linked Polyethylene with temperature rating 70 deg. 3. equivalent IEC/IS specifications are also acceptable.5 above. • Flammability test: As per IEC 332 Part-1 & Part-3 .02/0014-A4 STANDARD SPECIFICATION FOR INSTRUMENT CABLES AND RELATED ACCESSORIES Date : 12. Thermocouple cables design shall comply with ANSI MC 96.1.4 mm thick 70 Deg.5308 / IS 7098.In overhead closed cable ducts 3. RTD and thermocouple cables DESCRIPTION Conductors Insulation: XLPE Armour: Inner & Outer Sheath-PVC: STANDARDS BS 6360/ IS 8130 for instrument signal and RTD cables and ANSI MC 96. low smoke.1.C XLPE insulation.1/IEC-60584-3 for thermocouple cables.Fastened to cable ladder rack or tray in the open air . 3.2 DESIGN AND TESTING STANDARDS 3. Low Halogen.1 Instrument signal. 3.15 A pair of communication wire shall be provided for multipair / multritraid cables. 3. Each 2 wires shall be 0. Low Toxic.16 All cables shall be fire retardant and low smoke.1.JACOBS ENGINEERING INDIA PRIVATE LIMITED DOCUMENT NO :44-LK-5100-00/J.1. pair identification shall be provided with numbers at interval of not more than 250 mm as per vendor’s standard.14 Contractor shall ensure a minimum of 20% of quantity of each type of cables supplied as spare including any special cable and in each multipair cables 20% pairs shall be kept as spare.13 Running length of the cable shall be printed at least at every 5 metre interval. The power and control cables shall be generally as per BS 6346. Flammability and chemical properties shall be as follows: • Oxygen Index: 30 (minimum) at room Temp as per ASTM-D-2863-77 • Temperature Index: 250 Deg C (minimum) at Oxygen Index of 21 as per ASTM-D-2863.9 The cable design shall generally follow BS 5308 Part-1 for various cables listed in clause 3.2. Low Smoke.Directly buried in the ground . 1 / IEC-60584-2 BS 5308 Power and control cables DESCRIPTION Conductors Insulation-XLPE Armour Inner & Outer Sheath-PVC Testing and Dimensions of the cables STANDARDS IS : 8130 / BS 6360 • Insulation shall be Cross-linked Polyethylene (XLPE) as per BS 5308 / IS 7098. Electrolytic conductivity < 100 micro S/cm as per IEC 754-2 • Toxicity index: Maximum 05 Gases to be extracted – HCL.08.5 mm. BS 6469 / BS 6346 . Outer Sheath Colour: Blue Inner Sheath Colour: Black BS 5308 • Testing of the instrument signal and RTD cables. Electrolytic conductivity < 100 micro S/cm as per IEC 754-2 • Toxicity index: Maximum 05 Gases to be extracted – HCL. Inner Sheath and outer sheath thickness: Min.3.08 Page 5 of 12 Revision No. SO2. HF. HCL shall be first gas to be extracted. NO. Power Cables: Black Control Cables: Blue with black bands (4 bands at 90o apart) IS : 1554 Part I. A Corrosivity of combustion gases: pH-index> 4. Low Halogen. Inner sheath thickness and outer sheath thickness shall be as per IS:1554(P-1)1988 (should not be less than 0. HF. HBr. HCN as per NES-713.02/0014-A4 STANDARD SPECIFICATION FOR INSTRUMENT CABLES AND RELATED ACCESSORIES Date : 12. CO. : A Cat.3. Dimensions: 3. Round wire armour galvanized steel as per IS 1554 Part 1 Extruded Fire Retardant. should not be less than 0.2 ANSI MC96. HCN as per NES-713. • Light Transmission: 70% (minimum) as per IEC 1034. CO2. CO.5 mm). • Flammability test: As per IEC 332 Part-1 & Part-3 Cat. Flammability and chemical properties shall be as follows: • Oxygen Index: 30 (minimum) at room Temp as per ASTM-D-2863-77 • Temperature Index: 250 Deg C (minimum) at Oxygen Index of 21 as per ASTM-D-2863. SO2. Low Smoke.JACOBS ENGINEERING INDIA PRIVATE LIMITED DOCUMENT NO :44-LK-5100-00/J. PVC having physical properties as per IS 5831Type ST2. Low Toxic. CO2. A • Corrosivity of combustion gases: pH-index> 4.2. NO. Testing / Calibration of thermocouple cables. HBr. Inner sheath thickness and outer sheath thickness shall be as per IS:1554(P-1)1988. HCL shall be first gas to be extracted Inner Sheath and outer sheath thickness: Min. 53 mm dia (1. Cross-linked Polyethylene (XLPE) as per BS 5308 / IS 7098 Inner & outer sheath PVC.53 mm dia (1. RTD cables: ITEMS Conductor 1 Triad DESCRIPTION 2 Insulation • 7 stranded / 0. The drain wire resistance including shield shall not exceed 30 ohm/km. fire retardant. • 7 stranded / 0. 2 • 7 stranded / 0.53 mm dia (1. low toxic.5 mm2 conductor .02/0014-A4 STANDARD SPECIFICATION FOR INSTRUMENT CABLES AND RELATED ACCESSORIES 3.2 DESCRIPTION • 7 stranded / 0. Drain wire shall be provided for individual pair and overall shield with 0.5 mm ) annealed tinned copper conductors of electrolytic grade copper. low toxic. BS 5308 Part 1 BS 5308 Part 1 Shield shall be aluminium backed mylar / polyester tape bonded together with the metallic side down helically applied with either side having 25% overlap and 100% coverage.08 Page 6 of 12 Revision No. Shall not exceed 12. Cross-linked Polyethylene (XLPE) as per BS 5308/IS 7098. polymeric compound.1 Instrument signal cables (4 – 20 mA or switch contacts): ITEMS Conductor i) Single Pair ii) 6/ 12 Pair Insulation Inner & outer sheath Pairs Maximum DC resistance Mutual capacitance L/R ratio of adjacent cores /pairs Shield Drain wire Colour coding 3.08. low smoke.53 mm dia (1. polymeric compound. 3. Two insulated conductors shall be uniformly twisted together to form a pair at least 10 twists per metre. PVC. fire retardant.5 mm ) annealed tinned copper conductors of electrolytic grade copper. low halogen.05 mm in case of single pair and 0.3 Date : 12.5 mm2) annealed tinned copper conductors of electrolytic grade copper. : A CABLE CONSTRUCTION The various mechanical / electrical parameters indicated here are indicative and the contractor shall be responsible to select / design the cables as per applicable standards. Electrostatic noise rejection ratio shall be over 76 dB. The minimum shield thickness shall be 0.075 mm in case of multipair cable.JACOBS ENGINEERING INDIA PRIVATE LIMITED DOCUMENT NO :44-LK-5100-00/J. low smoke.5 mm2) stranded annealed tinned copper conductors of electrolytic grade copper.3.3.3 ohms/ km at 20ºC for cables with 1. 6/ 8 Triad . • Individual pair core insulation : Blue & Black • Inner jacket : Black • Outer jacket : Blue for intrinsically safe application and blue with black bands (4 bands at 90o apart) for non IS applications. low halogen.5 mm2 multistranded bare tinned annealed copper conductor continuously in contact with aluminium side of shield. Shall not exceed 4 mH/km. The drain wire resistance including shield shall not exceed 30 ohm/km.08 Page 7 of 12 Revision No. Class 1.5 mm multistranded bare tinned annealed copper conductor continuously in contact with aluminium side of shield. Thermocouple cables: ITEMS Conductor i) Single pair cable DESCRIPTION Insulation Cross-linked Polyethylene (XLPE) as per BS 5308 / IS 7098 Colour code: Nickel / Chromium: Green Nickel / Aluminium: White Two insulated conductors shall be uniformly twisted together to form a pair at least 10 twists per metre. Nickel / Aluminium (KX).5 mm2 conductor .05 mm in case of single triad and 0.05 mm in case of single pair and 0. Shield shall be aluminium backed mylar / polyester tape bonded together with the metallic side down helically applied with either side having 25% overlap and 100% coverage. • Core insulation : Red.3 ohms/ km at 20ºC for cables with 1.JACOBS ENGINEERING INDIA PRIVATE LIMITED DOCUMENT NO :44-LK-5100-00/J.5 mm solid conductors Conductor material should be as follows: K type T/C – Nickel / Chromium. for J-type thermocouple inductance could be 8 mH/km. The minimum shield thickness shall be 0.3.5 mm multistranded bare tinned annealed copper .3 Date : 12. BS 5308 Part 1 BS 5308 Part 1 Shield shall be aluminium backed mylar / polyester tape bonded together with the metallic side down helically applied with either side having 25% overlap and 100% coverage. : A Three insulated conductors shall be uniformly twisted together to form a Triad at least 10 twists per metre. The minimum shield thickness shall be 0. to reduce cross-talk. Electrostatic noise rejection ratio shall be over 76 dB.02/0014-A4 STANDARD SPECIFICATION FOR INSTRUMENT CABLES AND RELATED ACCESSORIES Triads Maximum DC resistance Mutual capacitance L/R ratio of adjacent triads Shield Drain wire Colour coding 3. However. The lay length of adjacent pairs / Triads in case of Multipair cables shall not be equal.08.075 mm in case of multitriad cable Drain wire shall be provided for individual pair and overall shield 2 with 0. Yellow and Blue • Inner jacket : Black • Outer jacket : Blue for intrinsically safe application and blue with black bands (4 bands at 90° apart).075 mm in case of multi pair cable Drain wire shall be provided for individual pair and overall shield 2 with 0. Shall not exceed 12. BS 5308 Part 1 BS 5308 Part 1 Pairs Mutual capacitance L/R ratio of adjacent pairs Core inductance Shield Drain wire 2 • 16 AWG or 1. the exact size of the conductor shall be selected based on the length of cable and power consumption. Cross-linked Polyethylene (XLPE) as per BS 5308 / IS 7098 PVC. The size of the conductor specified here is minimum. The drain wire resistance including shield shall not exceed 30 ohm/km.1 3. low toxic.67 mm dia.5. Outer sheath colour .3.3 Foundation Fieldbus(FF) cables colour code: .5 mm2) annealed tinned copper conductors of electrolytic grade copper.5 mm2 conductor IS : 1554 / BS 6746 Power cables.4 DESCRIPTION • 7 stranded / 0.53 mm dia (1. 3. mechanical protection provided by round galvanized steel armour with polyester laminated tape layered over inner sheath.Green 3. Outer sheath shall be orange.Black Note: All thermocouple extension cable shall be matched and calibrated in accordance with IEC-60584-2 / ANSI MC 96. Shall not exceed 12. Electrostatic noise rejection ratio shall be over 76 dB. graded index. Overall screen to consist of aluminium bonded polyester tape and tinned copper wire. ITEMS Conductor 2 Core / Multi-core type Insulation Inner & outer sheath Maximum DC resistance Core Identification 3. fire retardant. 4 pair 0.3. with plastic foil wrapping.3. However. Overall sheath shall be light grey PVC.5 mm2 (24 AWG) solid conductors. (2.2 Fibre optic cable 62.3 ohms/ km at 20ºC for cables with 1.5 mm ) annealed tinned copper conductors of electrolytic grade copper.3. Cross-linked Polyethylene (XLPE) as per BS 5308 / IS 7098 IS-1554 / BS 6746 Outer sheath colour –Black Neutral wire insulation colour – Black Phase wire insulation colour – Red Ground wire insulation colour .JACOBS ENGINEERING INDIA PRIVATE LIMITED DOCUMENT NO :44-LK-5100-00/J.02/0014-A4 STANDARD SPECIFICATION FOR INSTRUMENT CABLES AND RELATED ACCESSORIES Colour coding Date : 12. low smoke. polymeric compound.1 Ethernet cables EIA/TIA 568 A Category 5.5 Special Cables 3. : A conductor continuously in contact with aluminium side of shield. ITEMS Conductor Insulation Core Identification Colour coding DESCRIPTION 2 7 stranded / 0. 3.08 Page 8 of 12 Revision No.5. glass silica fibre core.3 Control cables.3.3.5 / 125 micron multimode.HDPE conduit shall be orange colour.5. aluminium can be considered. For higher conductor sizes.08.Green Inner sheath colour . low halogen. a) b) c) d) e) Light Emission test as per IEC-1034.7.3 and conductivity to be maximum 100 micro Siemens/cms Toxicity Index as per NES-713.3.2 Routine Test and Acceptance test :Each of the following tests to be carried out by vendor during various stages of manufacturing.08 Page 9 of 12 Revision No. 3.1 Abrasion test method as per BS 6724 Annexure E These tests shall be carried in presence of purchaser or his authorized representatives. Immediately after completion of the electrical test the ends of the cable shall be sealed to prevent ingress of moisture with suitable of rubber/PVC caps.1 Cables shall be drummed in continuous lengths on cable drums. Cat A. Acceptance norms shall be minimum 70% Determination of the degree of acidity of gases evolved during combustion as per IEC 754-2 (pH value to be minimum 4.2 Drum identification shall be painted black on both sides of drum with permanent oil paint.1 through 3. pH Index. Part-III.3. For protection during transport and storage. 3. as applicable. 3. Number of cores and cross-sectional area Cable quantity Purchaser's order number and item number .JACOBS ENGINEERING INDIA PRIVATE LIMITED DOCUMENT NO :44-LK-5100-00/J. in original at the time of delivery of cables.4.3.3. In addition. 3.7.1 Type Test:Certificate from independent test house for the following tests shall be furnished by the vendor for the FRLS low halogen sheathed cable. b) Electrostatic noise Rejection test.08. Purchaser shall review the related documentations. c) Oxygen Index. a) Flammability Test as per IEC 60332.3. battens shall be fitted around the entire periphery of the drum. Value shall not exceed 5 Tear Resistance as per BS 7655 Section 6. light transmission.7 Cable Testing:Vendor shall submit routine and Acceptance test certificates.3. The following information shall be given on the drums as a minimum: - Drum identification number Voltage grade Type of cable. : A FF Trunk cables shall be Orange with 4 Black longitudinal stripes at 90 deg apart. 3.4. Temperature rating.4 CABLE DRUMS 3.02/0014-A4 STANDARD SPECIFICATION FOR INSTRUMENT CABLES AND RELATED ACCESSORIES Date : 12.6 Any other special cables such as co-axial cable or cables with glass insulation. Vendor shall ensure that these cables are armoured type and shall meet all other requirements specified in clause 3. FF Spur cables (IS) shall be Orange with 4 Blue longitudinal stripes at 90 deg apart. electrical conductivity and toxicity index for the cable 3. the following test shall be carried out for checking properties of low halogen FRLS sheathing material.5. required for instruments shall also be supplied as per requirements. 1. Control Cable No of Cores i. 3. All cable glands shall be with LSF shrouds.e.3 Cable glands shall be of SS 316 and double compression type suitable for armoured cables. Type of Cable i.5 sq mm Sequential meter marking shall be embossed at every 1 meter interval 3.08.1 Signal Cables: Outer Embossing: Following embossing should be in bold fonts at outer sheath at every 5 meter interval.JACOBS ENGINEERING INDIA PRIVATE LIMITED DOCUMENT NO :44-LK-5100-00/J.e. 10. 3.5.4 All cable glands shall be weatherproof to IP-66. NPT threaded cable glands shall be used and for control room / control panel end. cable glands shall be ET threaded types. 24 etc.e.1 Cable glands required for glanding all cables at both ends shall be supplied by contractor. 2. 3.5 For all field items and junction box end.e. : A Total weight of cable and drum 3.6.6. 3. Type of Cable i. Sequential meter marking shall be embossed at every 1 meter interval Individual pairs Embossing and identification: Core no shall be printed on each core for identification at regular interval of 250 mm or so.6.e. . 1. Flameproof glands wherever required shall be supplied with Ex(d) certification suitable for Gas Groups IIA / IIB / IIC. Type of Cable i.e. 12.08 Page 10 of 12 Revision No.2 A minimum of 20% of cable glands shall be supplied as spare. 3.5. 12 etc. Core Size i. 3.5. Signal Cable No of Pairs i.3 Thermocouple Cables: Outer Embossing: Following embossing should be in bold fonts at outer sheath at every 5 meter interval. 4.6 CABLE GLANDS 3.2 Control Cables: Following embossing should be in bold fonts at outer sheath at every 5 meter interval. 6.02/0014-A4 STANDARD SPECIFICATION FOR INSTRUMENT CABLES AND RELATED ACCESSORIES - Date : 12. 1.e.6. T/C Cable No of Pairs Core Size i. The pair numbers shall be available on individual pair by method of polyester number tape also.5 IDENTIFICATION MARKS ON CABLES: 3.e. Core Size i. 16 AWG Temperature Range Sequential meter marking shall be embossed at every 1 meter interval Individual pairs Embossing and identification: Each core of pair shall be numbered for identification at regular interval of 250 mm or so.6.5 sq mm etc. 08 Page 11 of 12 Revision No. This includes separate terminals for shields and 20% spare terminals.7 JUNCTION BOXES 3. 3.D. 3. 3. 3.7 In general separate junction boxes shall be used for the following: Thermocouples / RTDs / SMART Transmitter / Positioner Non SMART Transmitters (Analog Transmitters for Anti-surge control etc. All JB’s for intrinsic safe signals shall be identified on name plate accordingly. The maximum height of frame shall not exceed 600 mm unless otherwise specified. stay plates.1 Junction boxes shall be of die-cast aluminium alloy (LM-6) epoxy painted body.08.7.3 Contractor shall size and provide MCT considering 50% spares for each cable size/cable OD.7.6 Telephone sockets and plugs shall be provided in all junction boxes. The MCT shall be supplied complete with insert blocks.3 Junction box sizes shall be standardized to two types accommodate 44 terminals and 88 terminals. non-intrinsic safe circuits ) In general all alarm signals shall be taken to DCS and all shutdown signals to PLC.1 The cable entry into the Satellite Rack Room/control room.JACOBS ENGINEERING INDIA PRIVATE LIMITED DOCUMENT NO :44-LK-5100-00/J.4 Each JB shall be provided with 2 multi-cable entries with one plugged with weather proof.02/0014-A4 STANDARD SPECIFICATION FOR INSTRUMENT CABLES AND RELATED ACCESSORIES Date : 12.8. analyser rooms/ shelters shall be through Multi Cable Transit Blocks (MCT).7.7.5 Plugs shall be Ex (d) certified for flameproof junction boxes. - 3.8. low power cables.S. 3-way junction boxes shall be used for connecting the field transmitter.8 MULTI CABLE TRANSIT 3.7. spare blocks.2 The MCT frames shall be of Standard RGB type of Brattberg or Roxtex and of steel construction. 3. Intrinsically safe cables. 3. Contractor shall also provide 50% spare insert blocks in each cable size / O. All junction boxes shall be weatherproof to IP 66 as a minimum. . The MCT’s shall be sized.) Switches / Push Buttons Solenoid valves Power Alarm Shutdown Gas detector ( Separate JB’s for intrinsic safe. explosion proof plugs as required. indicator in series with control room receiver. Flame proof junction boxes wherever required shall be supplied with Ex (d) certification. The required cutout sizes and frames sizes shall be calculated and shall be co-ordinated with control room contractor. end-packing etc. Accordingly separate junction boxes shall be provided to Alarm and Shutdown signals.7.7. The MCT frames provided should be suitable to withstand blast intensity for which blast proof control room has been designed. 3. All flame proof JB’s shall be provided with labels for isolating power supply before opening cover. : A 3.8. All 2 terminals shall be suitable for 4mm conductors. field mounted analog I. supplied and installed at site by contractor. as loose supply.2 Junction box shall have screwed covers. non-intrinsically safe cables and power cables for instruments (110 V AC or above) shall be suitably separated from each other cables within the MCT frame and shall be routed through separate MCT blocks. 3. 08 Page 12 of 12 Revision No. No spare space shall be left uncovered in the frame and shall be filled with dummy block of suitable size.02/0014-A4 STANDARD SPECIFICATION FOR INSTRUMENT CABLES AND RELATED ACCESSORIES Date : 12. The MCT shall be installed as per the recommended practice of supplier.JACOBS ENGINEERING INDIA PRIVATE LIMITED DOCUMENT NO :44-LK-5100-00/J.0 ATTACHMENTS Nil . 4.08.8. : A 3.0 RELATED DOCUMENTATION Nil 5.4 Separate MCT frame shall be considered for electrical cables.
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