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Instrumentation & Control

INSTRUMENT CABLES

This specification covers the requirements for instrument signal cables,

thermocouple extension cables, RTD cables and power / control cables.

Single pair shielded thermocouple extension cables shall be used between

thermocouple head and junction boxes / transmitters / local control panel
mounted instruments.

Single triad shielded signal cables shall be used between RTD head and junction
boxes / transmitters / local control panel mounted instruments.

For fieldbus compatible instrument single pair shielded cable shall be used
between instrument to junction box/ local panel and to control room.
Foundation Field bus shall be Type-A cable. Construction of same shall be as Per
IEC 61158-2. Trunk cable shall be used of 1 Pair, 5 Pair, 12 Pair.

Single pair shielded signal / alarm cables shall be used between field instruments
/ switches and junction boxes / local control panels.

Separate Multipair/ multitriad cables shall be used between junction boxes/ local
control panel and control room as per following applications. • 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

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consumers such as control panels, DCS / PLC cabinets, any instruments

requiring power supply, etc.

Control cables shall be used for solenoid valves.

For solenoid valve signals and power supply to instruments, junction boxes shall
be used

The cable design shall generally follow BS 5308 Part-1 for various cables above.
Thermocouple cables design shall comply with ANSI MC 96.1. The power and
control cables shall be generally as per BS 6346. For these cables, equivalent
IEC/IS specifications are also acceptable

The insulation grade shall be 1100 V for all cables.

The primary insulation shall be cross-linked Polyethylene with temperature

rating 70 deg.C conforming to BS- 5308 / IS 7098. Inner and outer sheath /
jacket shall be made of extruded fire retardant, low smoke,low halogen, low
toxic, polymeric compound having physical properties as per IS-5831 –Type
ST2.

All cables shall be armoured and suitable for operation when installed as follows:
– Directly buried in the ground – Fastened to cable ladder rack or tray in the
open air – In underground ducts – In overhead closed cable ducts

Running length of the cable shall be printed at least at every 5 meter interval. For
multipair/ multi-triad cables, pair identification shall be provided with numbers
at interval of not more than 250 mm as per standard.

Ensure a minimum of 20% of quantity of each type of cables supplied as spare.

A pair of communication wire shall be provided for multipair /

multritraid cables. Each wires shall be 0.5 mm2 of plain annealed single
or multi-strand copper conductor with 0.4 mm thick 70 Deg.C XLPE

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insulation.

CABLE DESIGN AND TESTING STANDARDS

Instrument signal, RTD and thermocouple cables

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Power and control cables

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CABLE CONSTRUCTION

The various mechanical / electrical parameters indicated here are indicative and
shall be select / design the cables as per applicable standards.

Instrument signal cables (4 – 20 mA or switch contacts):

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RTD cables:

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Thermocouple Cables:

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Note : All thermocouple extension cable shall be matched and calibrated in ac-
cordance with IEC-60584-2 / ANSI MC 96.1

Control cables:

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Power cables :

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Ethernet cables

EIA/TIA 568 A Category 5, 4 pair 0.5 mm2 (24 AWG) solid conductors, with
plastic foil wrapping. Overall screen to consist of aluminium bonded polyester
tape and tinned copper wire. Overall sheath shall be light grey PVC.

Fibre optic cable

62.5 / 125 micron multimode, graded index, glass silica fibre core, mechanical
protection provided by round galvanized steel armour with polyester laminated

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tape layered over inner sheath. Outer sheath shall be orange.HDPE conduit shall
be orange colour.

Foundation Fieldbus(FF) cables colour code:

FF Trunk cables shall be Orange with 4 Black longitudinal stripes at 90 deg

apart. FF Spur cables (IS) shall be Orange with 4 Blue longitudinal stripes at 90
deg apart.

Cable Testing:-

Acceptance test certificates is mandatory, along with newly procured cables.

Type Test:-

Certificate from independent test house for the following tests shall be furnished
for the FRLS low halogen sheathed cable.

a) Flammability Test as per IEC 60332, Part-III, Cat A.

b) Electrostatic noise Rejection test.

c) Oxygen Index, Temperature rating, light transmission, pH Index, electrical

conductivity and toxicity index for the cable

Routine Test and Acceptance test :-

Each of the following tests to be carried out during various stages of

manufacturing. related documentations shall be reviewed. In addition, the
following test shall be carried out for checking properties of low halogen FRLS
sheathing material.

Light Emission test as per IEC-1034. Acceptance norms shall be minimum

70%

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Determination of the degree of acidity of gases evolved during combustion as

per IEC 754-2 (pH value to be minimum 4.3 and conductivity to be maximum
100 micro Siemens/cms
Toxicity Index as per NES-713. Value shall not exceed 5
Tear Resistance as per BS 7655 Section 6.1
Abrasion test method as per BS 6724 Annexure E

These tests shall be carried in presence 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.

CABLE DRUMS

Cables shall be drummed in continuous lengths on cable drums. For protection

during transport and storage, battens shall be fitted around the entire periphery
of the drum.

Drum identification shall be painted black on both sides of drum with permanent
oil paint. The following information shall be given on the drums as a minimum:

Drum identification number

Voltage grade
Type of cable
Number of cores and cross-sectional area
Cable quantity
Purchaser’s order number and item number
Total weight of cable and drum

IDENTIFICATION MARKS ON CABLES:

Signal Cables:

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Outer Embossing: Following embossing should be in bold fonts at outer sheath

at every 5 meter interval.

Type of Cable i.e. Signal Cable

No of Pairs i.e. 1, 6, 12 etc.
Core Size i.e. 1.5 sq mm etc.

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. The pair numbers
shall be available on individual pair by method of polyester number tape also.

Control Cables: Following embossing should be in bold fonts at outer sheath at

every 5 meter interval.

Type of Cable i.e. Control Cable

No of Cores i.e. 2, 4, 10, 12, 24 etc.
Core Size i.e. 1.5 sq mm

Sequential meter marking shall be embossed at every 1 meter interval

Thermocouple Cables:

Outer Embossing: Following embossing should be in bold fonts at outer sheath

at every 5 meter interval.

Type of Cable i.e. T/C Cable

No of Pairs
Core Size i.e. 16 AWG
Temperature Range

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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.

CABLE GLANDS

Cable glands shall be of SS 316 and double compression type suitable for
armoured cables.

All cable glands shall be weatherproof to IP-66. Flameproof glands wherever

required shall be supplied with Ex(d) certification suitable for Gas Groups IIA /
IIB / IIC. All cable glands shall be with LSF shrouds.

For all field items and junction box end, NPT threaded cable glands shall be used
and for control room / control panel end, cable glands shall be ET threaded
types.

JUNCTION BOXES

Junction boxes shall be of die-cast aluminium alloy (LM-6) epoxy painted body.
All junction boxes shall be weatherproof to IP 66 as a minimum. Flame proof
junction boxes wherever required shall be supplied with Ex (d) certification. All
flame proof JB’s shall be provided with labels for isolating power supply before
opening cover. All JB’s for intrinsic safe signals shall be identified on name plate
accordingly.

Junction box shall have screwed covers.

Junction box sizes shall be standardized to two types accommodate 44 terminals

and 88 terminals. This includes separate terminals for shields and 20% spare
terminals. All terminals shall be suitable for 4mm2 conductors.

Each JB shall be provided with 2 multi-cable entries with one plugged with
weather proof, explosion proof plugs as required.

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Plugs shall be Ex (d) certified for flameproof junction boxes.

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