Wire Cable Conduit PDF

Engineering Encyclopedia
Saudi Aramco DeskTop Standards
EVALUATING ABOVE-GRADE WIRE,

CABLE, AND CONDUIT INSTALLATIONS
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramcos employees.
Any material contained in this document which is not already in the public
domain may not be copied, reproduced, sold, given, or disclosed to third
parties, or otherwise used in whole, or in part, without the written permission
of the Vice President, Engineering Services, Saudi Aramco.
Chapter : Electrical
File Reference: EEX-206.02
For additional information on this subject, contact

PEDD Coordinator on 874-6556
Wire and Cable Systems

Evaluating Above-Grade Wire,
Cable, and Conduit Installations
CONTENT
PAGE
INTRODUCTION............................................................................................................. 4
ABOVE-GRADE INSTALLATION TECHNIQUES: CONDUIT, CABLE TRAYS,
AND EXPOSED CABLE ....................................................................................... 5
Conduit ................................................................................................................. 5
Rigid Steel ................................................................................................. 6
EMT ........................................................................................................... 7
Flexible Liquid-Tight................................................................................... 8
Cable Trays: Design, Construction, and Usage Requirements........................... 8
Aluminum................................................................................................... 9
Fiberglass ................................................................................................ 10
Exposed Cable: Uses and Routing Requirements............................................. 11
Metal-Clad/Armored................................................................................. 11
Routing Requirements ............................................................................. 12
DETERMINING CABLE TRAY INSTALLATION REQUIREMENTS.............................. 13
Loading............................................................................................................... 14
Magnetic Heating Effects.................................................................................... 18
Circuit Separation ............................................................................................... 19
Grounding and Bonding Requirements and Methods........................................ 22
Tray Separation .................................................................................................. 23
Supports/Fastenings........................................................................................... 24
Tray Routing/Protection Covers.......................................................................... 26
Fittings, Bends, and Drops ................................................................................. 27
DETERMINING CONDUIT INSTALLATION REQUIREMENTS.................................... 28
Conduit Types and Applications ......................................................................... 28
Conduit Sizing and Routing ................................................................................ 30
Conduit Fill............................................................................................... 30

Jam Ratio................................................................................................. 32
Cable Clearance Within the Conduit ........................................................ 33
Magnetic Heating Effects ......................................................................... 34
Conduit Clearances ................................................................................. 34
Fire Proofing ............................................................................................ 34
Conduit Bending ................................................................................................. 35
Minimum Bending Radii ........................................................................... 35
Conduit Threading .............................................................................................. 36
Indoor and Outdoor Conduit Terminations ......................................................... 38
Fittings ..................................................................................................... 38
Seals (Explosion Proof) ........................................................................... 39
Expansion Joints...................................................................................... 40
Conduit Supports................................................................................................ 40
DETERMINING CABLE PULLING REQUIREMENTS .................................................. 43
Rigging Procedures ............................................................................................ 43
Pulling Grips ............................................................................................ 47
Pulling Lines ............................................................................................ 48
Duct Lubricating....................................................................................... 49
Cable Pulling Parameters ................................................................................... 50
Maximum Pulling Tensions ...................................................................... 50
Sidewall Pressure .................................................................................... 64
Rigging Method Effects Calculation ......................................................... 68
DETERMINING HAZARDOUS AREA WIRING AND SEALING REQUIREMENTS ...... 73
Wiring ................................................................................................................. 74
Conduit Sealing .................................................................................................. 77
Cable Sealing ..................................................................................................... 80
List of Figures
ii

Figure 1: Aluminum Cable Tray Load/Span Class Designation (from NEMA VE-1) ..... 15
Figure 2: Fiberglass Cable Tray Load/Span Data (from NEMA FG-1) ......................... 16
Figure 3: Fiberglass Cable Tray Temperature Correction
for Allowable Working Load (from NEMA FG-1).................................................... 17
Figure 4: Minimum Circuit Separation Distances
for Signal Cabling in Cable Tray (from SAES-J-902) ............................................. 21
Figure 5: Conduit Sizing Requirements........................................................................ 31
Figure 6: Allowable Percentage of Conduit Fill (from NEC, Chapter 9) ........................ 32
Figure 7: Required Dimensions of Conduit Threads (from UL 6) ................................. 37
Figure 8: Maximum Distance Between Rigid-Metal Conduit Supports ......................... 42
Figure 9: Dynamometer Used to Measure Pulling Tension .......................................... 45
Figure 10: Basket Grip on Cable .................................................................................. 47
Figure 11: Pulling Eye on Cable ................................................................................... 48
Figure 12: Cable Configurations................................................................................... 53
Figure 13: Vertical Conduit Bends................................................................................ 59
Figure 14: Example Pulling Tension Calculation............................................................. 61
Figure 15: Sidewall Pressure on Cable During a Pull...................................................... 65
Figure 16: Inside Radius of Standard Conduit Elbows.................................................... 67
Figure 17: Sample Rigging Methods Effects Calculation ................................................ 68
iii

INTRODUCTION
In order to evaluate various types of approved Saudi Aramco
above-grade wire, cable, and conduit installations for applicability
of use, the Participant must have a thorough understanding of the
types of installation techniques that are available, the minimum
requirements of the various governing documents for each type of
installation, and the methods that are used to determine the
installation requirements for each type of installation.
The cable installation methods that are described in this Module
(e.g., cable trays and above-ground conduit) are all used for the
same reason: to install cable so that the cable will function safely
and adequately throughout its projected operating life. As such,
the optimal cable installation method should be selected for the
facility installation. The optimal cable installation method is
selected through an evaluation of the specific cable installation
requirements, installation topography, and the installation method
cost. In addition to the above-grade cable installation methods
that are outlined in this Module, the below-ground cable
installation methods that are covered in EEX 206.03 should also
be considered.
This Module provides information on the following topics that are
pertinent to evaluate above-grade wire, cable, and conduit
installations for applicable use:
o
Above-grade Installation Techniques: Conduit, Cable Trays,

and Exposed Cable.
Determining Cable Tray Installation Requirements
Determining Conduit Installation Requirements
Determining Cable Pulling Requirements
Determining Hazardous Area Wiring and Sealing

Requirements

ABOVE-GRADE INSTALLATION TECHNIQUES: CONDUIT, CABLE TRAYS, AND

EXPOSED CABLE
There are several different installation techniques that can be used
to install above-grade cable in Saudi Aramco facilities. Cable can
be installed in an enclosed channel (raceway), an open channel
(cable tray), or simply exposed to the elements. Rigid metal (bus
ducts) can also be used to conduct electricity over short distances,
but this method is limited and is not covered in this course. The
selected installation method is to a large degree a matter of the
Proponent's preference, however, the installation must comply
with the applicable Saudi Aramco Engineering Standard (SAES).
Standards, in the title Saudi Aramco Engineering Standards
(SAESs), is a term that refers to the minimum mandatory
requirements for the design, construction, maintenance, and repair
of equipment and facilities for Saudi Aramco.
This section of the Module describes the following above-grade
installation techniques:
o
Conduit
Cable Trays: Design, Construction, and Usage

Requirements
Exposed Cable: Uses and Routing Requirements
Conduit
A conduit is defined as a metallic or nonmetallic tube that is used
to protect electric wires and cables. Although there are various
types of nonmetallic conduit systems that are available for use,
Saudi Aramco allows only metallic-type conduit systems to be
used for above-grade conduit installations. The types of conduit
that are used in Saudi Aramco above-grade installations are rigid
steel, electrical metallic tubing (EMT), and flexible liquid-tight. Due
to the nature of Saudi Aramco cable installations (e.g., the cable
use and installation environment), intermediate metallic conduit
(IMC) is prohibited in all areas. Saudi Aramco considers the
additional cost of rigid steel conduit to be worth the added
protection that rigid steel offers over IMC.

Rigid Steel
Rigid-steel conduit is medium-thickness water pipe that has been

reamed out to eliminate burrs and rough edges. Hot-dipped,
galvanized, rigid-steel conduit is specified for all Saudi Aramco
installations in which rigid-steel conduit is used; hot-dipped,
galvanized, rigid-steel conduit is rigid-steel conduit that has been
dipped in molten zinc during the forming process. Rigid-steel
conduit is manufactured in standard lengths of approximately
three meters (ten feet) and is required to be threaded on both
ends. Additional details on the construction of rigid-steel conduit
systems that are used in Saudi Aramco above-grade installations
are provided in the section of this Module that is titled
"Determining Conduit Installation Requirements."
The requirements for the use of conduit and other equipment (e.g.,
cables and cable trays) are determined to some extent by the
possibility of fire or explosive hazards. The specific classes of
hazardous locations are described in the section of this Module
that is titled "Determining Hazardous Area Wiring and Sealing
Requirements," and they are briefly described here for
requirement clarification. A Class I classification describes a
location in which flammable gases or vapors could be present.
Class II and Class III are locations where combustible dusts or
fibers respectively exist. Each of these three classifications are, in
turn, broken down further into a Division 1 location in which danger
is imminent at any or all times, or a Division 2 location in which
danger is not present under normal conditions but is likely to arise.
The following are the requirements for the use of rigid-steel
conduit in Saudi Aramco above-grade installations:
o
Rigid-steel conduit should be used when conduit is to be

installed in Class I, Division 1 (hazardous) areas.
Rigid-steel conduit should be used when exceptional

mechanical protection is required.
Rigid-steel conduit should be used when conduit is installed

above ground in outdoor industrial facilities.

Rigid-steel conduit should be used when conduit is installed

in severe corrosive environments; the conduit should be
PVC-coated.
Rigid-steel conduit should be PVC-coated when it is

installed in offshore locations or when it is installed within
one kilometer (3500 feet) from the shoreline of the Arabian
Gulf or thee kilometers (10,500 feet) from the shore line of
the Red Sea.
EMT
EMT is similar in construction to rigid-steel conduit except that

EMT is constructed of a much thinner material. EMT can also be
referred to as thin-walled conduit. EMT is manufactured in
standard lengths of approximately 3 meters (10 feet). Unlike rigidsteel conduit, EMT is not threaded (due to its thin wall), and it is
joined by threadless couplings.
Additional details on the
construction of EMT systems that are used in Saudi Aramco
above-grade installations are provided in the section of this
Module that is titled "Determining Conduit Installation
Requirements."
EMT does not offer the same degree of mechanical strength as
rigid-steel conduit; therefore, the applications of EMT are limited
when compared to rigid-steel conduit. The following are the
requirements for the use of EMT in Saudi Aramco above-grade
installations:
o
EMT is acceptable only in non-hazardous (classified), indoor

locations.
EMT should not be used where corrosion can cause

damage.
EMT should not be used where it will be subjected to severe

physical damage.

Flexible Liquid-Tight
Flexible liquid-tight conduit is constructed of a single strip of

aluminum or galvanized steel that is spirally wound and
interlocked. An outer jacket is used to make the flexible conduit
assembly liquid-tight. The interlocked construction of flexible
liquid-tight conduit provides a round cross-section that has a high
degree of mechanical strength and great flexibility. Additional
details on the use of systems that include flexible liquid-tight
conduit in Saudi Aramco above-grade installations are provided in
the section of this Module that is titled "Determining Conduit
Installation Requirements."
The following are the requirements for the use of flexible liquidtight conduit in Saudi Aramco above-grade installations:
o
Flexible liquid-tight conduit should be used in all areas

(except those areas that are classified as Class I, Division 1)
for connections where vibration, movement, or adjustments
will occur.
Explosion-proof flexible couplings should be used instead of

flexible liquid-tight conduit in Class I, Division 1 (hazardous)
locations. When explosion-proof flexible fittings are
necessary, a Crouse-Hinds, EC Series, or equivalent
flexible conduit should be used.
Cable Trays: Design, Construction,

and Usage Requirements
Cable tray is defined as a unit or an assembly of units or sections
(and associated fittings) that is made of metal or some other
noncombustible material and that forms a continuous rigid
structure. Cable trays are used to support cables and raceways,
and they can be found in the form of ladders, troughs, and
channels. Although Saudi Aramco standards specify the use of
only copper-free, aluminum, ladder-type cable tray for Saudi
Aramco above-grade installations, fiberglass, ladder-type cable
tray is authorized for use in special applications with the approval
of the Proponent Operating Department Manager. This section
describes the design and construction of both aluminum and
fiberglass cable trays.

Aluminum
Aluminum ladder-type cable tray is a prefabricated metal structure

that consists of two longitudinal side rails that are connected by
individual transverse members at regularly spaced distances.
Only ladder-type cable tray is authorized for Saudi Aramco abovegrade installations. Because the aluminum cable trays could
potentially become energized, they are grounded. To facilitate the
transmission of fault current, and because cable trays are hung or
mounted in specific lengths, the cable tray lengths must be
bonded together. Bonding is the method of joining together the
cable tray lengths to ensure electrical continuity.
Ventilated, louvered, cable tray protective covers are required to
allow for mechanical protection and solar radiation deflection for all
outside cable tray installations. Cable tray covers should be made
of the same material that is used for the cable tray, and they
should not have a black or dark surface that is exposed to the sun.
Covers for aluminum cable tray should be fastened to the cable
tray with stainless steel banding. The maximum distance between
the stainless steel bands is one band for every 1.5 m (5 feet) of
cover length. There should always be at least two bands per
length of cable tray. Additional details on the construction of
aluminum ladder-type cable tray systems that are used in Saudi
Aramco above-grade installations are provided in the section of
this Module that is titled "Determining Cable Tray Installation
Requirements."
The following are the requirements for the use of aluminum
ladder-type cable tray in Saudi Aramco above-grade installations:
o
Cable tray is the preferred method of power distribution in

Class I, Division 2 (hazardous) areas.
Cable tray should not be used where it will be subjected to

severe physical damage.
If an outdoor cable tray installation contains only I&C cables,

the cable tray covers that are used can be of the solid
(unventilated) type.

Fiberglass
Fiberglass ladder-type cable tray is an assembly of fiberglassreinforced plastic tray sections and accessories that form a rigid
structural system to support cable. The fiberglass ladder-type
cable tray is a prefabricated, sunlight (UV)-resistant, fiberglass
structure that consists of two longitudinal side rails that are
connected by individual transverse members at regularly spaced
distances. Only ladder-type cable trays are authorized for Saudi
Aramco above-grade installations. Outdoor, fiberglass cable tray
installations should use covers that are made of the same material
as the cable tray and that have provisions for ventilation.
Additional details on the construction of fiberglass, ladder-type
cable tray systems are provided later in this Module.
The following are the requirements for the use of fiberglass laddertype cable tray in Saudi Aramco above-grade installations:
o
Cable tray is the preferred method of power distribution in

Class I, Division 2 (hazardous) areas and in unclassified
areas.
Cable tray should not be used where it will be subjected to

severe physical damage.
If an outdoor cable tray installation contains only instrument

and control cables, the cable tray covers that are used can
be of the solid (unventilated) type.
10

Exposed Cable: Uses and

Routing Requirements
For some Saudi Aramco cable installations, the routing or design
of the cable installation may require the cable to be exposed (i.e.,
not enclosed in a raceway). When the cable will be exposed,
metal-clad (Type MC) or armored (in accordance with IEC 60502)
cable will be used. Type MC cable and armored cable are
permitted to be installed exposed only when the cable will not be
subject to damage by vehicular traffic or similar hazards. If a
cable type other than MC or armored cable is installed, the cable
should not be installed so that it is exposed above ground. Cable
types other than MC or armored cable should only be installed in
cable trays, conduit, or flexible liquid-tight conduit. This section of
the Module describes the construction, use, and routing
requirements of metal-clad and armored cable that is used in
Saudi Aramco installations.
Metal-Clad/Armored
Type MC cable is a factory assembly of one or more conductors

that are individually insulated. The assembly is enclosed in a
metallic sheath of interlocking tape or in a smooth, corrugated
tube. Type MC cable that is used for Saudi Aramco applications
should be supplied with a PVC-jacketed aluminum sheath that
meets UL 4 (0 to 2000 V) or UL 1072 (2001 to 35 kV)
specifications.
According to the NEC, the uses of Type MC cable include the
following applications:
o
o
o
o
o
o
o
o
o
o
o
Services, feeders, and branch circuits.

Power, lighting, control, and signal circuits.
Indoors or outdoors.
Where exposed or concealed.
Direct buried where identified for such use.
In cable tray.
In any approved raceway.
As an open run of cable.
As aerial cable on a messenger.
In hazardous locations as permitted by NEC (NFPA 70),
articles 501 through 504.
In dry locations.
11

Type MC cable is always specified with a PVC jacket, and is

therefore suitable for installation in wet locations.
Type AC (Armored Cable) cable that is described in NEC Article
333 is light-duty cable that is seldom used in Saudi Aramco
installations. The armored cable that is widely used in Saudi
Aramco installations is galvanized steel tape or steel wire-armored
cable that is manufactured in accordance with IEC Article 502.
The IEC-armored cable is heavy duty, and it is considered to be
equivalent to NEC Type MC cable. Suitable armored cable
terminators should be used to terminate and ground the armor,
and the armor should be mechanically joined (bonded) through the
installation so that is forms a continuous electric conductor. The
cable armor should be connected to all boxes, fittings, and
cabinets to provide effective electrical continuity throughout the
installation.
Routing Requirements
Specific installation routing requirements for Type MC cable are

listed below:
o
Type MC cable should be supported and secured at

intervals not greater than 1.83 m (6 feet) unless the cable is
fished. If Type MC cable is installed as a branch circuit in a
dwelling unit, the cable should be secured within 305 mm
(12 inches) of every outlet box, junction box, cabinet, or
fitting.
Type MC cable that is installed in a cable tray should comply

with the installation requirements for cable tray. Routing
requirements for cable tray are discussed in the section of
this Module that is titled "Determining Cable Tray Installation
Requirements."
The requirements for Type MC cable that is directly buried

are discussed in Module EEX 206.03, Evaluating
Underground Wire, Cable, and Conduit Installations.
Specific installation routing requirements for armored cable per

IEC 502 are the same as for Type MC cables.
12

DETERMINING CABLE TRAY INSTALLATION REQUIREMENTS

Generally, the only type of cable tray that is authorized for use in
Saudi Aramco installations is copper-free, aluminum ladder-type.
However, with the approval of the Proponent Operating
Department Manager, fiberglass ladder-type cable tray can be
used in special applications. When a cable tray is chosen by the
Electrical Engineer for use in a Saudi Aramco installation, there
are many factors that should be taken into consideration in the
selection of the type and size of the cable tray. The cable tray that
is selected should be able to adequately hold the cable (or group
of cables) in the installation for the maximum operating life of the
installation. The cable tray should be large enough to account for
future system growth, but it should not be too large that the tray
purchase becomes economically restrictive. There are also
requirements that involve the tray installation support structure,
grounding, bonding, and placement. This section of the Module
provides information on the following topics that are pertinent to
determining cable tray installation requirements:
o
Loading
Size/Fill
Magnetic Heating Effects
Circuit Separation
Grounding and Bonding Requirements and Methods
Tray Separation
Supports/Fastenings
Tray Routing/Protection Covers
Fittings, Bends, and Drops
13

Loading
Cable trays are classified in accordance with their allowable,
mechanical, working-load capacity per unit of span length; span is
the term that is used to describe the distance between the cable
tray supports. The allowable, mechanical, working-load capacity
of aluminum and fiberglass cable tray is determined through
division of the destruction load capacity of the cable tray (as
determined by testing) by a unitless 1.5 safety factor.
The mechanical loading requirements for aluminum cable tray, as
defined in NEMA VE-1, are classified in accordance with several
load/span class designations. There are three working load
categories and four support span categories for aluminum cable
tray systems. The working load categories that are specified for
aluminum cable tray are as follows:
o
Class A - 74.4 kg/m (50 pounds per linear foot)
Class B - 111.6 kg/m (75 pounds per linear foot)
Class C - 148.8 kg/m (100 pounds per linear foot)
The support span categories that are specified for aluminum cable
tray are as follows:
o
2.44 m (8 feet)
3.66 m (12 feet)
4.87 m (16 feet)
6.09 m (20 feet)
14

The table that is shown in Figure 1 lists the class designations that
are used to select aluminum, ladder-type, cable tray systems. The
class designation is selected through determination of the amount
of working load and the length of the support span.
Load/Span Class Designations

Working Load
Support
Span
Class
Lbs./ft
kg/m
Feet
Designation
50
75
100
74.4
111.6
148.8
8
8
8
2.44
2.44
2.44
8A
8B
8V
50
75
100
74.4
111.6
148.8
12
12
12
3.66
3.66
3.66
12A
12B
12V
50
75
100
74.4
111.6
148.8
16
16
16
4.87
4.87
4.87
16A
16B
16V
50
75
100
74.4
111.6
148.8
20
20
20
6.09
6.09
6.09
20A
20B
20V
Figure 1: Aluminum Cable Tray Load/Span Class Designation (from NEMA VE-1)
The mechanical loading requirements for fiberglass cable tray, as
defined in NEMA FG-1, are classified in accordance with three
working load class designations that are based on a support span
of 6.09 m (20 feet). The working load categories that are specified
for fiberglass cable tray are as follows:
o
Class A - 74.4 kg/m (50 pounds per linear foot)
Class B - 111.6 kg/m (75 pounds per linear foot)
Class C - 148.8 kg/m (100 pounds per linear foot)
15

Unlike the load/span class designations that are used for

aluminum cable tray, the mechanical loading (working load)
requirements for fiberglass cable tray vary as the support span
distance varies, as shown in Figure 2. The class of fiberglass
cable tray that should be used for a given installation is based on
the mechanical load that the cable tray must support and the
length of the support span that will be used.
Support
Span
Working Load in Lbs./Linear

Foot
In Feet
Class A
Class B
Class C
20
18
16
14
12
10
50
61
78
100
139
200
75
92
117
150
208
100
123
156
200
Figure 2: Fiberglass Cable Tray Load/Span Data (from NEMA FG-1)

The amount of mechanical load that a given cable tray will be
required to support is determined by the sum of the weight of the
cables that will be installed in the cable tray (in pounds per foot).
To account for future circuit growth, a 20 percent correction factor
is applied to the combined cable weight. Finally, an equivalent
weight is added to the corrected combined cable weight to
account for the effect of a 200-pound person standing on the cable
tray at the center of the span. Details on the procedure to
determine the amount of mechanical load that will be present on a
given span of cable tray are provided in Work Aid 1.
16

Because the strength properties of reinforced plastics are reduced

when they are continuously exposed to elevated temperatures, the
allowable working load of a fiberglass cable tray should be
reduced for Saudi Aramco installations in which the cable tray will
be exposed to an average ambient temperature of 50 degrees C.
The table in Figure 3 shows the approximate percent of strength
that the fiberglass cable tray will possess at various temperatures.
Temperature
in Degrees
C
Temperature
in Degrees F
Approximate
Percent of
Strength
24
38
52
66
79
93
75
100
125
150
175
200
100
90
78
68
60
52
Figure 3: Fiberglass Cable Tray Temperature Correction for Allowable Working Load
(from NEMA FG-1)
In addition to the mechanical loading requirements that have been
previously discussed, a completed cable tray system should be
able to withstand a horizontal wind force of 1.4 kPa (30 lbf/ft2),
which is approximately equivalent to a wind speed of 140 km/hr, or
87 mph.
To determine the cable tray sizes that should be used for a given
installation, the Electrical Engineer must evaluate the cable tray fill
requirements. The fill requirements differ depending on whether
the installation includes multiple-conductor cables that are rated
2000 V or less, single conductor cables that are rated 2000 V or
less, or single- and multiple-conductor Type MV or Type MC
cables that are greater than 2000 V.
17

The fill requirements for multiple-conductor cables that are rated

2000 V or less vary with the type of cable that is used (power,
lighting, control, and/or signal type cables) and the size of the
cables. The fill requirements for single conductor cables that are
rated 2000 V or less vary only with the size of the cables. The fill
requirements for single- and multiple-conductor Type MV or Type
MC cables that are rated for greater than 2000 V vary only with
the diameter of the cables that are installed in the cable tray.
To determine the correct cable tray size, the cable dimensions
(e.g., diameter or cross-sectional area) are added and the sum is
multiplied by a growth correction factor. For Saudi Aramco cable
tray installations, the growth correction factor recommended is 20
percent. The 20 percent growth correction factor ensures that the
cable tray can be used for an increase in load as a result of future
expansions. Work Aid 1 describes the procedure that is used to
determine the size of a cable tray based on the fill requirements.
Metallic raceways are susceptible to magnetic heating effects,
which include hysteresis heating and "induced current" heating.
Hysteresis heating is caused by the opposition that ferrous
raceways offer to a changing magnetic field. The heating occurs
due to energy losses within the raceway as the elementary
particles (each containing a magnetic field) that exist within the
raceway seek to align themselves to the changing magnetic field.
Because only aluminum and fiberglass cable tray is authorized for
use in Saudi Aramco installations, and because neither material is
ferrous, there will be no hysteresis heating effects. Although
magnetic hysteresis will not occur in a nonferrous material,
induced currents can exist in the nonferrous material if the material
is also an electrical conductor (such as aluminum).
Induced current heating caused by alternating magnetic field that
exists around the conductors in aluminum cable trays are not
significant enough to be a problem.
18

There are design requirements that can minimize magnetic

heating effects. If the phase conductors, neutral conductor (if
any), and equipment grounding conductor are grouped within the
same raceway, induced current heating can be minimized. When
a single conductor that carries an alternating current passes
through metal that has magnetic properties, the following actions
can be taken to minimize the magnetic heating effects:
o
Slots can be cut in the metal between the individual holes

through which the conductors pass.
All of the conductors can be passed through an insulating

wall that is large enough for all of the conductors of the
circuit.
Circuit Separation
Circuit separation requirements are established for safety and to
minimize the effects of induced currents in adjacent instrument
and control cables. Based on the voltages of the cables and the
type of cable that is installed in the cable tray (e.g., power, lighting,
control, and/or signal-type cables), the circuit separation
requirements affect cable routing. When the cable tray systems
that contain cables from different systems converge or use the
same route, the circuit separation and cable placement
requirements that must be observed are described below:
Cables for light and power systems that are rated 600 V or less
are permitted to occupy the same cable tray as long as all of the
conductors are insulated for the maximum voltage that will exist for
any of the cables that are within the cable tray. Cables for light
and power systems that are rated above 600 V are not permitted
to occupy the same cable tray as cables that are rated 600 V and
below unless one of the following conditions is satisfied:
o
The cables that are rated above 600 V must be separated

from the cables that are rated 600 V or below by a solid,
noncombustible, fixed barrier.
All of the cables must be Type MC or armored.
19

Conductors that are used for signaling, instrumentation, or

communication systems should not occupy the same cable tray as
the conductors of lighting, power, 120 V control, or 24 V dc and
above relay control systems.
If all of the cables are insulated for 600 V or more, power systems
control, metering, alarm, and relaying circuits that are associated
with one major piece of electrical equipment (such as a motor or a
transformer) can be run within a single cable tray. Inter-tripping
circuits that run between substations can also be run within one
cable tray with the following exceptions:
o
Circuits that are associated with alternate power sources for

primary selective, secondary selective, or spot network
substations should be kept separate.
Differential relay circuits should be kept separate from all

other circuits.
Circuit separation and placement requirements for instrument

cables in Saudi Aramco installations are shown in Figure 4. To
determine the minimum circuit separation distance that should be
maintained between two systems, the first system in the first
column and the second system in the first row should be located;
the intersection of the two systems in the table is the minimum
circuit separation distance. For example, the minimum circuit
separation distance that should exist between 125 V dc systems
and RTD systems in cable tray is 6 inches (150 mm).
If the insulation of the cables that are installed in the raceway is
rated for at least 450 to 750 V, there are no minimum circuit
separation requirements between power and/or control conductors
for dc or for ac circuits that carry power at voltages that are less
than 1000 V.
20

RTD
Thermocouple
Milli- Volt
Pulse
RTD
Thermo
Couple
Milli-Volt
Pulse
4-20 mA
Analog
(24 VDC)
4-20 mA
Analog
(24 VDC)
24 VDC
48 VDC
125 VDC
120 VAC
>120
VAC
1 (25)
6 (150)
12 (300)
24 (600)
1 (25)
6 (150)
12 (300)
24 (600)
1 (25)
6 (150)
12 (300)
24 (600)
1 (25)
6 (150)
12 (300)
24 (600)
24 VDC
48 VDC
1 (25)
1 (25)
1 (25)
1 (25)
6 (150)
6 (150)
18 (450)
125 VDC
6 (150)
6 (150)
6 (150)
6 (150)
6 (150)
12 (300)
120 VAC
12 (300)
12 (300)
12 (300)
12 (300)
6 (150)
12 (300)
>120
VAC
24 (600)
24 (600)
24 (600)
24 (600)
18 (450)
12 (300)
12 (300)
Note that all values are shown in inches (millimeters)
Figure 4: Minimum Circuit Separation Distances for Signal Cabling in Cable Tray
(from SAES-J-902)
Cables that carry different signal types should also be routed so
that they cross each other only at right angles. Also, when dc
instrumentation and control signal cabling is routed past a source
of strong electromagnetic fields (such as transformers, motors,
and generators that are rated greater than 100 kVA), a minimum
spacing of 2 m (6 feet) should be maintained between the signal
cabling and the source of the electromagnetic field. When trays
that contain different systems converge or use the same route,
they should preferably be placed in the following order (from top to
bottom in different trays as required):
o
Power cables.
Control cables.
21

Alarm circuits.
Dc electronic cables and pneumatic tubing (the pneumatic

tubing should be separated from the dc circuit by a barrier).
Thermocouple cables.
Grounding and Bonding

Requirements and Methods
In most high-voltage power distribution cables, there are various
metallic support systems (e.g., shields and cable trays) that could
carry fault or induced currents. Equipment grounding describes
the manner of grounding the support system equipment. Bonding
describes the manner of electrically interconnecting the various
segments of the support systems. An equipment grounding
conductor is not the same as a grounded conductor in that a
grounding conductor carries only current during fault conditions
while the grounded conductor may carry current under normal
conditions. Cable trays must be grounded and bonded so that
freedom from dangerous electric shock voltages is ensured and
that sufficient current-carrying capability is provided to accept the
ground-fault current that is required by the overcurrent protection
system.
For Saudi Aramco installations, the entire cable tray system is
required to be mechanically and electrically connected to ensure
that there is a path for electric fault current. The acceptable
methods that are used to meet the grounding requirements for
aluminum cable trays are listed as follows:
o
Enclosures of MCCs, motor controllers, switchgear, and

other electrical devices that are fed from a cable tray system
should be structurally and mechanically connected and
bonded to the cable tray system.
With some exceptions, a conduit, cable tray, cable armor, or

cable shield should not be used as the sole means of
grounding equipment. For safety and reliability, a grounding
conductor should be installed in the same cable tray as the
power conductors.
22

A metallic cable tray should be grounded at both of its end

points.
The acceptable methods that are used to meet the bonding

requirements for aluminum cable trays are listed as follows:
o
To prevent any faults that may occur within the cable tray
system from arcing to ground, metallic cable trays should be
bonded to the plant grounding system at maximum intervals
of 25 m (84 feet).
Bonding can be accomplished through use of metallic

connections to the building or structural columns that
support the cable trays.
Bonding jumpers should be provided whenever a cable tray

is insulated from its metallic supporting structure or
whenever a cable tray expansion joint is used. Expansion
fittings (or joints) are required to accommodate expansion
and contraction due to ambient temperature changes. The
gap at expansion points depends on the spacing between
these joints.
Tray Separation
NEC Article 318 requires sufficient space around cable trays to
permit adequate access for installation and maintaining the cables.
Saudi Aramco standards no longer specify distances (tray
separation). The following separation distances were specified
before 1984 and can be used as guidelines if possible.
For separation between multiple horizontal cable tray systems, a
minimum of 50 mm (2 inches) of separation should be provided
between the cable tray side rails. A minimum of 25 mm (1 inch) of
separation should be provided between any vertical support and a
cable tray side rail.
23

No more than four 750 mm (30 inch) cable trays or four 600 mm
(24 inch) cable trays should be located adjacent to each other on
one horizontal tier. If more than four cable trays are required, a
450 mm (18 inch) spacing should be provided between each
group of four cable tray units so that access is provided to each of
the cable tray groups.
The separation between vertical-tiered cable trays should be at
least 450 mm (18 inches) with a minimum clear space of 300 mm
(12 inches); if the total combined width of a given cable tray tier
exceeds 900 mm (36 inches), the vertical space should be
increased by 150 mm (6 inches). If the total width of the cable tray
system exceeds 900 mm (36 inches), the vertical clearance
should be increased to 450 mm (18 inches).
The lower voltage cables are usually placed in the bottom cable
trays, and the higher voltage cables in the upper cable trays.
The vertical space between a cable tray and a ceiling, beam, or
other obstruction should be a minimum of 300 mm (12 inches).
When cable tray is located over any electrical gear, 600 to 900
mm (24 to 36 inches) of vertical separation should be maintained
from the top of the electrical gear to the bottom of the cable tray.
Supports/Fastenings
To ensure adequate support, cable tray supports should be
constructed from hot-dip galvanized steel. Cable tray supports
that are installed in severe corrosive environments should be
protected through use of one of the following methods:
o
PVC-coated at the factory.
Coated in the field prior to installation.
The following were requirements of the standards prior to 1984

and can be used as guidelines if possible.
24

Indoor ceiling hangars that are used for cable tray supports should
be made from 12 mm (1/2 inch) galvanized-steel rods. All
supports that are used for cable trays should provide a minimum
weight-bearing surface of 45 mm (1 and 3/4 inches) as well as
provisions for hold-down clamps and fasteners. The hold-down
clamps and fasteners should be used at all cable tray support
points. Vertical cable tray fasteners should not rely on friction to
secure the cable tray to its supports.
Cable trays should be supported from the structural steel of
pipeways and buildings with noncombustible racks or hangers.
Cable tray supports should to be spaced a maximum of 6 m (20
feet) on horizontal runs or 2.4 m (8 feet) on vertical runs. When
ceiling hangers are used to support the cable tray, the hangers
should be spaced no more than 3 m (10 feet) apart. Cantilever
cable tray sections should be limited to a length of 900 mm (3
feet); additional support should be provided for cantilever cable
tray sections that are greater than 900 mm in length.
Cable tray splice points should not be located directly over the
cable tray supports, and they should not be located at mid-span.
The ideal location for a cable tray splice point is within the one
quarter points of the span as measured from the cable tray
supports. For example, if there are 4 meters between cable
supports, the splice point should be within 1 meter of either cable
support. Splice plates, expansion joints, and connectors should
join the cable tray sections so that the rated vertical and horizontal
load of the cable tray is not diminished.
All cables should be fastened to the cable tray every 1.8 m (6 feet)
on horizontal cable tray runs, every 450 mm (18 inches) on
vertical cable tray runs, and every 450 mm (18 inches) on cable
tray bends (horizontal and vertical). Vertical cable tray systems
should provide suitable methods of cable support through the use
of cable hangers or metal clamps. Nylon cable ties can be used
for most fastening applications. Cable ties in outdoor locations
should be black, and they should also be resistant to UV radiation.
When circuits in cable trays are paralleled, single conductor cables
should be fastened in groups that include one conductor per
phase or neutral to prevent current imbalance.
25

Tray Routing/Protection Covers

The following can be used as guidelines, where possible.
For Saudi Aramco installations, there are certain requirements for
cable tray routing and cable tray protective covers.
Considerations that are taken into account when routing cable tray
systems are utilization of building walls as structural support and
the proximity to hazardous equipment, process equipment, and
grid-type walkways. Cable tray should be run parallel to the
building structure or the building walls as applicable. Also, cable
tray should not be routed any closer than 7.5 m (25 feet)
horizontally to any fire hazardous equipment or other types of
equipment that can produce temperatures that could damage the
cables that are installed in the cable tray, such as steam lines.
Cable trays should be located above all process piping and other
process facilities. When cable trays are routed under grid-type
walkways, barriers should be used to add additional protection to
the cable tray. When installed, these barriers should not hinder
cable tray ventilation. For cable tray locations to which future
cable installations will be added, extra space should be provided in
the cable tray. The extra space should allow for the future
installation of the same basic type of cable tray and should be
arranged so that the spare space will be unused and available for
the future installation.
The following circumstances would require the use of protective
covers on a cable tray system:
o
When cable trays pass through walls.
When cable trays are near areas that could be damaged by

workers or by nearby equipment.
When cable trays are routed outdoors.
When cable trays pass through a combustible partition or wall, the

cable tray should be completely enclosed in metal with a bushed
steel conduit sleeve or similar device. When cable tray entry
occurs in switch and control houses or when the cable tray passes
through a fire wall, the cables in the cable tray should be sealed
with Nelson Electric MCT or equivalent cable transits.
26

To allow for drainage, cable trays that enter a building should be

sloped away from the building at a minimum rate of ten millimeters
per meter of cable tray (1/8 inch per foot). A concrete curb or
metal kick plate should be provided for cable tray that passes
vertically through floors or platforms. To prevent contact with or
damage to the exposed cables, the tray should also be covered on
all sides to a distance of 1.8 m (6 feet) above the floor or platform.
Although the cable trays will be provided with covers, cables that
are installed in outdoor cable trays should have sunlight-resistant
(UV radiation-resistant) jackets. Ventilated, louvered cable tray
covers are required to provide mechanical protection and solar
radiation deflection for all outside cable tray installations. Covers
for aluminum cable tray should be fastened to the cable tray with
stainless steel banding at a rate of one band per 1.5 m (5 feet) of
cover length and at least two bands per length of tray. Cable tray
covers should not have a black or dark surface that is exposed to
the sun.
Fittings, Bends, and Drops
For Saudi Aramco cable tray installations, the cable trays require
the use of specific fittings, elbows, bends, and drops.
Recommendations: vertical and horizontal elbows should have a
minimum radius of 300 mm (12 inches), but they should not be
less than the minimum cable bending radii. For vertical drops that
are greater than 1.5 m (5 feet), outside vertical elbows and drop
out fittings should be used at the higher elevation. For vertical
drops that are greater than 4.5 m (15 feet), inside vertical elbows
should be used at the lower elevation. Horizontal elbows should
be used for changes of direction that occur at the same elevation.
27

DETERMINING CONDUIT INSTALLATION REQUIREMENTS

Prior to the installation of an above-grade conduit system, the
Electrical Engineer should examine the various factors that will
affect the installation. These factors include the type of equipment
that is to be installed, the installation method that will be used, and
the classification of the area in which the equipment will be
installed. The requirements of SAES-P-104 (Wiring Methods and
Materials) should be followed for Saudi Aramco above-grade
conduit installations.
The conduit installation method that is used (rigid-steel conduit,
EMT, or flexible liquid-tight conduit) will affect the routing
requirements of the installation. Other determinations, such as the
correct size of the conduit for the installation, must also be made
with respect to routing the conduit and cabling. The hazardous
classification of the installation location determine the sealing and
termination requirements. This section of the Module describes
the following aspects of determining conduit installation
requirements:
o
Conduit Types and Applications
Conduit Sizing and Routing
Conduit Bending
Conduit Threading
Indoor and Outdoor Conduit Termination
Conduit Supports
Conduit Types and Applications

The types of conduit that are available for use by Saudi Aramco in
above-grade conduit systems are rigid-steel conduit, EMT, and
flexible liquid-tight conduit. IMC is prohibited for use in Saudi
Aramco installations. The additional cost of rigid-steel conduit is
considered to be worth the added protection that it offers over
IMC.
28

Hot-dipped, galvanized, rigid-steel conduit is specified for all Saudi

Aramco installations in which rigid-steel conduit is used. The
application requirements of rigid-steel conduit systems have been
described previously in this module and are listed briefly as
follows:
o
Used for Class I, Division 1 areas.
Used when exceptional mechanical protection is required.
Used when conduit is installed above ground in outdoor

industrial facilities.
Used when conduit is installed in severe corrosive

environments
If installed in severe corrosive environments, the rigid-steel

conduit should be PVC-coated.
EMT does not offer the same degree of mechanical strength that
is offered by rigid-steel conduit, and it should not be used where it
is subjected to severe physical damage. EMT is only acceptable
in nonhazardous, indoor locations, and it should not be used
where corrosion can cause damage.
The applications of flexible liquid-tight conduit are limited to
connections in which vibration, movement, or adjustments will
occur. Flexible liquid-tight conduit is allowed for use in all areas
except Class I, Division 1 hazardous locations.
29

Conduit Sizing and Routing

Two critical aspects of a conduit installation are conduit sizing and
conduit routing. When the conduit size is chosen, the conduit
inside diameter should be large enough to install all of the cables
that were selected to be installed in that conduit without damage to
any of the cables. The conduit should also be large enough to
minimize any adverse heating effects on the conduit or on the
cables that are contained within the conduit. When the conduit is
installed, there are also routing and placement requirements that
should be met. The routing requirements are important to
minimize inter-conduit heating and conduit heating that results
when a conduit is routed near process facility equipment that
radiates heat.
Conduit Fill
Conduit fill is expressed as a percentage of the cross-sectional

area of the conduit that the cables are allowed to occupy, and it
depends on the number of conductors that are to be installed in
the conduit. The allowable percentage of conduit fill is based on
the combined heating effects of all of the cables that are installed
in the conduit. Knowledge of the allowable percentage of conduit
fill helps the Electrical Engineer to select the proper size of conduit
for a particular installation.
30

The table in Figure 5 describes the various size requirements that

are specified for rigid-steel conduit, EMT, and flexible liquid-tight
conduit; the references for each requirement are also listed. The
size requirements include the minimum size of the conduit, the
maximum size of the conduit, and the allowable conduit fill.
Conduit Sizing
Requirements
Rigid-Steel Conduit
EMT
Flexible Liquid
Tight Conduit
Minimum Size
except instrument
panels, inside
buildings,
prefabriacted skids, or
non-industrial areas
Size
requirements are
the same as
those specified
for rigid-steel
conduit.
Size
requirements are
the same as
those specified
for rigid-steel
conduit.
Maximum Size
N/A
Allowable Conduit
Fill
Refer to Figure 6
Allowable
conduit fill
requirements are
the same as
those for rigidsteel conduit.
All conduit fill

requirements are
the same as
those specified
for rigid-steel
conduit.
Figure 5: Conduit Sizing Requirements

To determine the allowable fill, the Electrical Engineer should first
choose an applicable duct from the tables for selecting conduit
size that are shown in Work Aid 2. Once the size of the conduit is
selected, the total cross sectional area of all of the cables that will
be contained in the conduit should be determined through use of
the table of cable dimensions that is shown in Work Aid 2. Now
that the cross-sectional area of the cables has been determined
and the conduit has been chosen, the percentage fill of the conduit
can be determined. Work Aid 2 provides the tables and the details
on the procedure that is used to size conduit for Saudi Aramco,
above-grade installations. The allowable percentage of conduit fill,
based on the number of conductors that are to be installed in the
conduit, is shown in Figure 6. See NEC Chapter 9 for additional
information.
31

When conduit sealing fittings are used (type EYS or similar), the
wire fill of the conduit sealing must not exceed 25% based on the
conduit size (i.e., the ratio of the sum of the cross-sectional areas
of wires and multi-conductor cables to the internal cross-sectional
area of a conduit of the same trade size must not exceed 25%). If
the percentage of fill of the conduit sealing exceeds 25%,
oversized sealing fittings with reducers may be used in order to
use the highest permissible conduit wire fill.
Percent of Cross Section of Conduit and Tubing for Conductors
Number of Conductors
Over 2
All conductor types
5
3
31
40
Note. A multi-conductor cable of two or more conductors shall be treated as a

single conductor cable for calculating percentage conduit fill area. For cables
that have elliptical cross section, the cross-sectional area calculation shall be
based on using the major diameter of the ellipse as a circle diameter.
Figure 6: Allowable Percentage of Conduit Fill (from NEC, Chapter 9)
Jam Ratio
The natural weight of the cables that are contained in the conduit
will cause them to settle to the lowest part of the conduit that the
conduit space will allow. Depending on the size, configuration,
and number of cables, the cables could get jammed in the conduit
during installation. A useful unitless value that is used when
cables are installed in conduit is called the "jam ratio." The jam
ratio is used primarily during cable pulling tension calculations, and
it will be explained in detail in that section of this Module; but it is
also used in the conduit selection process, and, so, it will be
described briefly here. The jam ratio is the ratio of the conduit's
inside diameter to the diameter of the largest cable that will be
installed in the conduit. The jam ratio provides a factor that
describes the probability that the cable will jam during its
installation in the conduit. The equation below is used to calculate
the jam ratio:
Jam Ratio =
1.05 D
d
32

where:
"D" is the conduit inside diameter.
"d" is the diameter of the largest cable that is in the conduit.
"1.05" includes a correction factor of 5% that accounts for the
oval cross-section of conduit bends.
Cable Clearance Within the Conduit
If the jam ratio is greater than 3.0, jamming is not likely to occur,
and cable clearance can be ignored. If the jam ratio is between
2.5 and 2.8, jamming is probable; if the jam ratio is between 2.8
and 3.0, serious jamming is probable. If jamming is probable, the
Electrical Engineer should evaluate the need to increase the size
of the conduit.
Cable clearance is the distance between the uppermost cable in a
conduit and the inside top of the conduit. A gap should be present
between the uppermost cable in a conduit and the top of the
conduit to prevent rubbing during pulls and to allow for expansion
and contraction.
For a single cable installation, the cable clearance is calculated
through use of the following equation:
Clearance = D - d
where:
"D" is the conduit inside diameter.
"d" is the diameter of the largest cable that is in the conduit.
For a three cable installation (or three tripled conductors), the
cable clearance is calculated using the following equation:
D
(D - d)
d
Clearance = - 1.366(d) +
1-
2
2
D- d
33

The cable clearance should be maintained within a band of 6 to 25

mm (1/4 to 1 inch). If the cable clearance is less than 6 mm (1/4
inch), the cable clearance is not satisfactory, and the Electrical
Engineer should evaluate the need to increase the size of the
conduit.
Metallic raceways are susceptible to magnetic heating effects,

which include induced current heating and hysteresis heating. In
order to avoid magnetic heating effects, all phase and neutral
conductors of a three phase system must be in one conduit, or if
there are parallel conductors, each conduit must have all phases
and neutral.
Conduit Clearances
The conduit clearance is defined as the distance between the

outside surface of a conduit and walls, other conduit, or other
equipment. When routing conduit for above-grade installations,
proper conduit clearances should be established. The conduit
clearance is required to ensure that the conduit is not routed too
close to process facility equipment that radiates heat.
Conduit runs should be symmetrical and should be routed
vertically, horizontally, or parallel to structure lines. Conduit should
not be installed near ladder rungs or at platform levels so that the
conduit restricts passage or interferes with existing steps.
As a guideline, the minimum clearance for conduits that cross or
run parallel to process lines should be 150 mm (6 inches) for
uninsulated process lines and 100 mm (4 inches) for insulated
process lines.
Fire Proofing
Fireproofing is required for critical power and control cables that

are located above ground in a fire-hazardous zone, e.g., within 7.5
m (25 feet) horizontally of fire-hazardous equipment. Critical
power and control cables are cables whose loss would render
emergency shutdown, fire protection, or alarm systems
inoperative. Fire-hazardous equipment is defined as equipment
that processes, stores, or produces flammable materials. Fireproofing requirements are contained in SAES-B-006.
34

Fireproofing must provide a minimum of 15 minutes of protection

to the integrity of the circuit against temperatures of 1100C
(2000F) in accordance with UL 1709.
Conduit Bending
Conduit bending requirements for a given installation are designed
so that the conduit is not injured during the installation and so that
the internal diameter of the bent conduit is not effectively reduced.
No more than four quarter conduit bends (360 degrees total)
should be made in one run of conduit between pull points.
Minimum conduit bending radii requirements are based on the
minimum cable training radii for the cable that is to be installed in
the conduit and the physical size of the conduit.
Minimum Bending Radii
If a wire or cable is bent too much, the act of bending may cause
damage to the wire or cable that results in subsequent cable
failure. To prevent cable failure, a minimum bending radius
(curvature of bend) limits cable and wire bending. With large
power distribution cables, the construction of the cables (e.g.,
insulation and shielding) places additional restrictions on the
minimum bending radius that a cable can withstand before
damage to the cable will occur. As a cable passes, enters, or exits
a conduit, the cable will usually have to be bent. The act of
bending a wire or cable during the installation process is called
"training." The minimum bending radius of any cable should not
be exceeded when the cable is trained in a conduit.
To prevent damage to the cables during the installation process,
the minimum bending radii of the cables must also be considered
during cable installation. The minimum bending radii of the inner
surface of a given cable is determined through use of a calculation
in which a specific multiplication factor is multiplied by the overall
diameter of the cable.
35

Before the minimum bending radii of the conduit is specified, the

minimum cable training radii of the cables should be determined.
To ensure that damage will not occur to the cables when they are
trained, the minimum conduit bending radii should not be less than
the minimum cable training radii. The procedure that is used to
determine the cable minimum bending radii is provided in Work
Aid 2.
The minimum conduit bending radii is selected from a table based
on the size of the conduit that is used for the installation. A hand
bender can be used to make field bends for conduit that is sized at
1-1/2 inches or less. A bending machine should be used for
conduit that is larger than 1-1/2 inches.
Bends that are
accomplished with a hand bender are measured from the inner
surface of the conduit; bends that are accomplished with a
machine bender are measured from the center line of the conduit.
Work Aid 2 provides the procedure that is used to determine
conduit bending requirements for Saudi Aramco above-grade
installations.
Conduit Threading
Rigid-steel conduit is required to be threaded on both ends for
Saudi Aramco conduit installations. Because EMT has a thin wall,
individual sections of EMT are only permitted to be joined through
use of threadless couplings.
Rigid-steel conduit is manufactured in standard lengths of 10 feet
(3 m). During an installation, the conduit must be cut into proper
lengths. The proper length to which the rigid-steel is cut is
dependent on the location and conditions of the conduit
installation. After the conduit has been cut to the proper length, it
must be field-threaded and then chamfered (reamed) to remove
the burrs and sharp edges that are formed during cutting. All field
threads for rigid-steel conduit are required to be full and
continuous. A minimum thread engagement of five full threads
should be made at all fittings. Field threads should be cut with a
standard conduit cutting die that has a 3/4 inch taper per foot. All
conduit threads must be tapered; running threads are not
permitted for any application. Raw threads should be protected
from corrosion with CRC "Zinc-It" or an equivalent coating.
36

Rigid-metal conduit is available in sizes of 1/2 to 6 inches.

Conduit trade sizes are referred to as the approximate inside
diameter of the raceway. All fittings and knockouts on boxes are
identified by the trade size of the raceway for which the device is
intended. Figure 7 describes the required dimensions of conduit
threads for the various trade sizes of rigid-steel conduit. Critical
measurements include the effective length of the threads (L2), the
total length of the threads (L4), the pitch diameter at the end of the
conduit (E0), and the required number of threads per inch of
conduit.
L4 total length of
threadsa
Trade
size of
conduit
in inches
Number
of
threads
per inch
3/8
a
b
L2 effective length of
threads
E0 pitch diameter at
end of conduit
inches
mm
inches
mm
inchesb
mmb
18
0.60
15.2
0.41
10.4
0.612
15.5
14
0.78
19.8
0.53
13.5
0.758
19.3
14
0.79
20.1
0.55
14.0
0.968
24.6
11
0.98
24.9
0.68
17.3
1.214
30.8
11
1.01
25.7
0.71
18.0
1.557
39.5
11
1.03
26.2
0.72
18.3
1.796
45.6
11
1.06
26.9
0.76
19.3
2.269
57.6
1.57
39.9
1.14
29.0
2.720
69.1
1.63
41.4
1.20
30.5
3.341
84.9
1.68
42.7
1.25
31.8
3.838
97.5
1.73
43.9
1.30
33.0
4.334
110.1
1.84
46.7
1.41
35.8
5.391
136.9
1.95
49.5
1.51
38.4
6.446
163.7
A minus tolerance of one thread applies to the total length of threads L4

Plus and minus tolerances of one turn apply to the pitch diameter E0
Figure 7: Required Dimensions of Conduit Threads (from UL 6)
37

Indoor and Outdoor Conduit Terminations

Metal raceways should be mechanically joined to form a
continuous electric conductor; raceways should also be connected
to all boxes, fittings, and cabinets for effective electrical continuity.
Conduit terminations are used to complete the conduit system
through connection of the metal raceway (i.e., rigid-steel conduit or
EMT) to the boxes, fittings, and/or cabinets that are used in the
conduit system.
Conduit systems can terminate at service entrance fittings, panels,
pull boxes, or access fittings, and they can include the use of
insulated bushings and conduit seals. For example, indoor
conduit runs that terminate in the open should be equipped with
an insulating bushing. Outdoor conduit that terminates in the open
should be equipped with a service entrance fitting. Also, insulating
grounding bushings should be installed on conduit that is inside of
all boxes except where a threaded hub is provided as part of the
conduit thread connection.
Fittings
A fitting is an accessory that is provided for a conduit system.

Fittings are used to perform mechanical connections to conduit
and associated conduit support equipment. Items, such as lock
nuts, bushings, conduit couplings, EMT connectors and couplings,
and threadless connectors, are considered to be fittings. Conduit
fittings should be made of cast or forged steel, cast iron, or
malleable iron that is either hot-dip galvanized or zinc
electroplated (as supplied by the manufacturer). Aluminum fittings
are not allowed for use in Saudi Aramco conduit installations.
Only malleable iron sealing fittings are to be used for new
installations, However, for repair purposes, gray, cast iron, splittype retro-fit sealing fittings are allowed.
For the connection of conduit, EMT, or other raceways (except
cable trays), a box or fitting should be installed at each conductor
splice connection point, outlet, switch, junction point, or pull point.
Conduit bodies are considered to be fittings and are allowed to
contain splices if they have adequate volume.
38

All conduit fittings should be accessible from a platform, ladder, or

stairwell. Cover openings should not be blocked by any structural
steel or pipe that would prevent access to the interior of the fitting
for maintenance.
For indoor and outdoor conduit terminations, there are certain
requirements that should be met. Indoor conduit runs that
terminate in the open should be equipped with an insulating
bushing. Outdoor conduit that terminates in the open should be
equipped with a service entrance fitting. Insulated grounding
bushings should be installed on conduits inside of all boxes except
where a threaded hub is provided as part of the conduit thread
connection.
Seals (Explosion Proof)
Explosion proof seals in a conduit system should only be provided

where required by the NEC. Non-required sealing is expensive
and an operational problem since for any future circuit
modifications the seal fitting must be cut out and, the conductors
spliced or removed. In additon, each conduit entering a process
unit control house should be sealed outside the point of entry for
above grade runs and inside at the point of entry for below grade
runs.
Seals, when required, should be located within 450 mm (18 in.) of
an enclosure.
Vertical or horizontal conduit runs which require sealing should be
sealed with combination vertical/horizontal seals, EYS or equal.
Explosion proof seals should be filled as follows:
(a)
(b)
(c)
(d)
A dam of fiber (Chico X or equal) should be made around

and between the wires to prevent the sealing compound
from entering a conduit run.
After fixing the dam, the sealing compound (Chico A or
equal) equal to the diameter of the conduit (but not less
than 5/8 inch) should be poured into the seal.
All sealing compound should be mixed with clean fresh
water.
Do not pour sealing compound into draining chambers of
EYD seals.
39

Wire fill of sealing fittings should not exceed 25% based on the
size of the conduit.
Expansion Joints
An expansion joint is a mechanical device that is used to allow for

the thermal expansion and contraction of a run of conduit.
Because a given run of conduit that is placed in an above-grade
conduit installation will be exposed to considerable temperature
fluctuations over a year, expansion joints should be considered.
However, expansion joints should not be used for long, vertical
conduit runs; the conduit should be offset whenever possible to
allow for the expansion and contraction of the conduit.
An expansion joint should be installed in any run of conduit that is
over 60 m (197 feet) in length. Additional expansion joints are
required at intervals of 120 m (394 feet) unless the conduit run is
supported by a steel structure such as a pipeway. When only one
expansion joint is used for a run of conduit, the expansion joint
should be located at the midpoint of the straight run. Multiple
expansion joints should be equally spaced in the straight run.
When a run of conduit is supported by a steel structure, the
conduit expansion joints should be provided at the same location
as the expansion joints that are provided for that steel structure.
Conduit Supports
A conduit support is a mechanical device that provides structural
strength for a vertical or horizontal conduit system. Conduit
supports should be constructed of cast or forged steel, cast iron,
or malleable iron, and they should be either hot-dip galvanized or
zinc electroplated as supplied by the manufacturer.
40

Conduit supports can be used for single conduit runs or for

grouped conduit runs. For single conduit runs on bare steel, Ubolts or one-hole malleable clamps (bolted to steel) should be
used. U-bolts should also be used for the conduit support
whenever the structure to which the conduit is mounted is subject
to vibration. Single conduit runs on concrete or masonry should
be supported with one-hole malleable clamps with expansion
bolts. If the conduit run is on hollow tile, one-hole malleable
clamps with toggle bolts should be used. Grouped conduit runs
should be supported with suitable field fabricated hangars or
Unistrut-type supports (or equivalent).
Except when expansion joints are included in a straight run of
conduit, the clamps and straps that are used for conduit supports
should be made specifically for the trade size of the conduit.
When expansion joints are used, one normal size conduit clamp
should be firmly attached at each midpoint between adjacent
expansion joints. Also, one normal size conduit clamp should be
firmly attached at the midpoints that exist between both ends of
the conduit run and the adjacent expansion joints. The clamp is
used to equalize the expansion and contraction that occur at each
expansion joint. All other conduit supports that are used when an
expansion joint is present should be oversized conduit clamps that
allow the conduit to move axially (along the axis). Clamps that rely
on friction for their support on the base structure (such as Korns
clamps) should not be used for the oversized clamps. In straight
conduit runs that include an expansion joint, U-bolt-type clamps
that are securely bolted to the base structure are acceptable for
use.
Conduit runs should not be supported from process lines or other
pipelines unless no other practical method is available. The
minimum clearance for conduit that crosses or runs parallel to
process lines is 150 mm (6 inches) for uninsulated process lines
and 100 mm (4 inches) for insulated process lines.
The maximum distance that is allowed between rigid-metal conduit
supports is dependent on the size of the conduit. The table in
Figure 8 contains the maximum distance both in meters (m) and in
feet (ft) for various conduit sizes.
41

To ensure that the conduit system remains rigid and vibration-free,

additional conduit supports may be required at bends, fittings, and
fixtures. Conduit supports should be located at a maximum of 1 m
(3 feet) from each outlet box, junction box, or fitting. In order to
allow the conduit to flex when a long horizontal run of conduit ends
in an angle or a bend, the next clamp around the angle or bend
should not be placed adjacent to the angle or bend.
Max Distance
Conduit Size (in.)
and
1
1 and 1
2 and 2
3 and larger
M
3
3.6
4.2
4.8
6.0
ft.
10
12
14
16
20
Figure 8: Maximum Distance Between Rigid-Metal Conduit Supports
42

DETERMINING CABLE PULLING REQUIREMENTS

To install a cable into a conduit, it must be pulled from one end of
the conduit to the other with a strong wire. When a cable is pulled
into a conduit, there are maximum pulling tensions that the cable
can withstand without damage. There are various types of pulling
equipment that can be used to pull a cable into a conduit. Each
different type of pulling equipment has a maximum pulling tension
(or pulling force) that it can withstand. The configuration of the
conduit, the type of cable that is to be installed, and the types of
pulling equipment that are chosen for the installation should all be
evaluated so that damage to the cable or to any installation
equipment does not occur.
Calculations to determine the
maximum pulling tensions that could occur with various conduit
configuration and pulling equipment combinations are performed
during the design phase of an installation. These calculations are
evaluated to ensure that maximum pulling tensions are not
exceeded during a cable installation pull.
There are various ways to reduce the pulling tension for a given
cable installation: the rigging equipment can be varied, the size of
the conduit can be increased, the conduit configuration (e.g., turns
or angles) can be altered, or the pull point frequency can be
changed. This section of the Module provides information on the
following topics that are pertinent to determining cable pulling
requirements:
o
Rigging Procedures
Cable Pulling Parameters
Rigging Procedures
During the design phase of the wire or cable installation, once the
installation type (e.g., conduit) and the cable route have been
chosen, the Electrical Engineer selects a rigging method and then
performs a pulling tension calculation. If the pulling tension
calculation indicates that maximum tensions could be exceeded
by the cable pull, design changes are made. Before the cable
pulling parameters and pulling tension calculations are described,
a description of the cable rigging equipment and methods is
necessary.
43

The method that is used to rig the cables for pulling in abovegrade conduit and cable tray systems depends on the length of
the pull and the size of the conductors to be installed. Smaller
conductors that are installed in a short run can most likely be
pulled in by hand. Pulling equipment will probably be required to
install larger conductors or to install conductors in long runs so
that a constant pulling tension can be maintained on the cables.
Suitable pulling equipment that is in good working condition should
be on hand for the pulling operation. Hydraulic pulling equipment
that has smooth, variable-speed control is
a good choice for cable installations in above-grade conduit
installations. To ensure that the maximum allowable pulling
tension for the installation is not accidentally exceeded, a steady
pulling rate should be maintained, whenever possible, during the
pull. Cable pulling speed should never exceed 15 m/min (50
feet/min) and, if at all possible, the cable should not be pulled
slower than 4.5 m/min (15 feet/min).
If the cables will be installed in a grouped conduit run, the conduit
that will be used for the installation of a single cable should be
identified throughout the entire length of the run to avoid cable
crossovers during the installation process. As much as possible,
the same relative position in the group should be maintained
throughout the run. In general, the longer cables should be
installed in the lower raceways, and the shorter cables should be
installed in the upper raceways to facilitate the ease of installation.
Before the pulling operation begins, the direction of the pull should
be checked to ensure that it is the direction that results in the
minimum pulling tensions and sidewall pressures. Care must also
be taken when moving the cable reels into their proper positions.
If the pull and cut method of installation is used, cable damage can
occur during the setup phase of a cable pull. The pull and cut
method is most often used for pulls at several different locations.
During cable installation, once the protective covering is removed
from the reel, the cable is particularly vulnerable to mechanical
damage.
44

The cable reels must be supported by an axle at the installation

location so that the cable can be pulled with minimum friction. The
pulling tension equations should take into account any friction that
results from the setup at the feed end of the conduit so that the
maximum allowable installation tension is not exceeded.
To measure the pulling tension that is applied to the cables, a
dynamometer is often used during the pulling operation. The
dynamometer can be connected at the feed end of the conduit or
at the discharge end of the conduit. An idler is attached to the
dynamometer at the feed or discharge end of the conduit, and the
pulling line and/or cable is routed over the idler to allow the tension
that is applied during the pulling operation to be measured. Figure
9 shows a method that could be used to attach the dynamometer
at the discharge end of the conduit. The equation that is used to
determine the tension on the cable in the conduit is also shown in
Figure 9. If the dynamometer is not zeroed with the idler attached,
the weight of the idler must be subtracted from the meter reading.
Figure 9: Dynamometer Used to Measure Pulling Tension
45

When several single-conductor cables are to be pulled into a

conduit or duct, the cable reels should be set up in tandem, and all
of the cables should be simultaneously pulled into the conduit or
duct. The cables should be continuously trained into the conduit in
such a manner that the cable will not drag on the edge of the
conduit. The cables should be fed into the conduit by hand or, for
large conductors, by a large diameter sheave (pronounced "shiv").
In addition to reducing friction, selection of the correct diameter
sheave for the job ensures that the minimum-bending radius of the
cable is maintained. Although quality sheaves are generally
treated as frictionless (no effect on pulling tension), extreme care
and good judgement should be exercised in their use. Short cable
bends, sharp edges at the feed to the raceway, and cable
crossovers should be prevented at the point where the cable
enters the raceway. The Electrical Engineer should ensure that
the diameter of the sheave that is used for the installation is large
enough that the sidewall pressure that is exerted on the cable
does not exceed limits. Sidewall pressure (SP) is defined as the
crushing force that is exerted on a cable as it is pulled around a
bend section of conduit or duct.
Supports should be used to alleviate stress on the cables where
they enter the conduit or cable tray. Cables should be laid out or
pulled into cable tray runs. When cable is pulled through a cable
tray, cable rollers, pulleys, and sheaves should be used to prevent
cable damage. If the pulleys, sheaves, and rollers that are used
for cable installation in cable trays are undersized, the cable can
be damaged if it bends below its minimum allowable bending
radius. If the rollers that are used for the installation are too widely
spaced, the cables can be damaged from abrasion against the
cable tray rungs. Rollers should be separated by a maximum
distance of 3 m (10 feet) during cable pulls in cable trays. Sharp
points in the cable tray, such as bent or burred metal, dropped
tools in the cable tray, and reversed bolts (heads on the outside of
the cable tray rather than on the inside of the cable tray), can
cause extensive cable damage during the cable pull, and they can
lead to early failure of the installed cables. The maximum pulling
tension equations that are listed in the following sections should
be followed for both conduit and cable tray systems.
46

The remainder of this section of the Module provides information

on the following topics that are pertinent to cable rigging
procedures:
o
Pulling Grips
Pulling Lines
Duct Lubricating
Pulling Grips
Pulling grips are used to fasten the pulling line to the cable that is
to be pulled into the raceway. There are two basic types of pulling
grips that are frequently used for cable installations: basket grips
and pulling eyes.
A basket grip is a flexible metal device that slips over the end of
the conductor that is to be pulled; a pulling line is attached to the
basket grip so the cable can be pulled through the raceway. The
basket grip has a web-like grip that tightens as tension is applied
to the pulling line. Long basket grips should be used to pull type
MC cables. To use the basket grip, the armor is removed for a
short distance, tape is applied over the armor and onto the
conductors, and the basket grip is placed onto the cable to allow
the grip to squeeze both the armor and the conductors. Figure 10
shows how a typical metal basket grip is installed onto a cable. To
avoid cable twist during the pulling operation, a swivel has been
installed onto the pulling line where it attaches to the basket grip.
Figure 10: Basket Grip on Cable
47

Because the conductor and the cable insulation are stressed

during the pulling operation, the parts of the cable that are directly
affected by the basket grip should be removed before a splice or
termination is installed. Sufficient slack must be present at the
pulling end so that the last 600 mm (2 feet) of cable beyond the
basket grip can be removed before the cable is spliced or
terminated.
Pulling eyes are sometimes used to pull larger sizes and long
sections of cable; pulling eyes allow for a higher pulling tension
than basket grips. A pulling eye is a steel eye that is usually
fastened directly to the cable conductors. Many manufacturers
supply a pulling eye or pulling bolt to the leading end of the cable
that is on the cable reel. Once the pulling operation is complete,
the pulling eye should be removed from the cable. Figure 11
shows how the cable conductors are securely fastened and
solder-wiped to the shank of the pulling eye. In Figure 11, a swivel
is used to connect the pulling line to the pulling eye to avoid cable
twist during the pulling operation.
Figure 11: Pulling Eye on Cable

Pulling Lines
A pulling line is used to pull the cable through the conduit or cable
tray during the cable installation. Pulling lines can be made of
rope or wire, and they are provided in various sizes. The type of
pulling line that is used for a given installation depends on the size
of the conductor to be pulled, the type of pulling grip to be used,
and the length of the pull.
48

The pulling line is typically drawn into a conduit with a steel fishing
wire or "snake." Fishing wire is a tempered-steel wire that has a
rectangular cross-section. Although the flat rectangular fishing
wire is preferred because of the ease with which it can be run
through a completed conduit system, galvanized-steel wire can
also be used for fishing. Any size wire from #14 up to #6 can be
used for fishing. When the fishing wire is drawn through the
conduit, the pulling line is attached to the fishing wire. The fishing
wire is then withdrawn from the conduit so that the pulling line is
completely drawn through the conduit system. Fishing wire is not
required to pull cables through cable tray systems.
After the pulling line is completely drawn through the affected
raceway, the pulling line is firmly attached to the pulling grip and to
the pulling device through an idler. The idler is attached to a
dynamometer to allow the tension on the pulling line to be
evaluated throughout the pull.
Duct Lubricating
To reduce friction during the pulling operation, lubrication should

be liberally and continuously applied to conduit. Increased friction
during pulling can also cause an increase in the pulling tension
that is applied to a cable during its installation. The use of
minerallac #100 or equal lubricant is recommended for duct
lubrication in Saudi Aramco above-grade conduit installations.
Duct lubricant should not be applied to the first and last 15 meters
(50 feet) of the cable for reasons of convenience and cleanliness
in splicing operations. Duct lubrication is not required during cable
tray installations.
49

Cable Pulling Parameters

Cable pulling parameters include maximum pulling tension and
sidewall pressure calculations. The tension calculations take into
account the maximum allowable tension that can be withstood by
the pulling device and the conductors. The sidewall pressure
calculation takes into account the stress effects that a bend in the
conduit or cable tray has on the cable during the pulling operation.
The general procedure that is used to determine the cable pulling
tensions and parameters is to calculate the pulling tensions for the
entire length of the pull and then to determine whether the sidewall
pressure is too great at the conduit bends. When the pulling
tensions are calculated for the pull, the calculations are performed
twice: once for a pull in one direction and again for the pull in the
opposite direction. This section of the Module describes cablepulling parameters in terms the following topics:
o
Maximum Pulling Tension
Sidewall Pressure
Rigging Method Effects Calculations
Maximum Pulling Tensions
After the size of the raceway has been determined (based on

allowable fill, the jam ratio, and cable clearance), the maximum
tension for the pulling device and the maximum tension that can
be safely applied to the conductors should be calculated. The
most limiting maximum tension is used as the maximum allowable
pulling tension (Tm). Next, the pulling tension (T) that is actually
required to pull the cable through the raceway is calculated and
compared to the maximum allowable pulling tension. If the actual
pulling tension that is calculated for the pull exceeds the maximum
allowable pulling tension, the conditions of the pull should be
changed.
When the actual pulling tension exceeds the maximum allowable
pulling tension for the installation, the following actions should be
considered:
o
Increase the bending radii that will be used for the conduit
installation.
Decrease the allowable conduit fill.
50

Reduce the number of bends in the conduit.
Perform a reverse pull.
Perform the pull in stages.
Decrease the length of the pull.
The maximum allowable tension for the pulling device (Tdevice) is

dependent on whether the pulling device is a pulling eye or a
basket grip:
o
The maximum pulling tension that can be applied when a

pulling eye is used should not exceed 22 kN (5000 lbf) per
cable (assuming that each cable has its own pulling eye) for
single-conductor cables or 27 kN (6000 lbf) per cable for
multiple-conductor cables.
The maximum pulling tension that can be applied when a

basket grip is used over the outer jacket of a cable should
not exceed 4450 N (1000 lbf) per cable (assuming that each
cable has its own basket grip) in any case.
The maximum allowable tension for the cable (Tcable) is dependent

on whether single conductor cables or multiple conductor cables
are to be used in the installation. Different conductor sizes can be
pulled at the same time, but a simultaneous pull is not
recommended if the dimensions of the conductors are significantly
different. If different sizes of conductors are to be pulled into the
same run of conduit, care must be taken not to exceed the
maximum pulling tension of any one cable during the pull.
Because a pulling rope under tension could possibly cut previously
existing cables in conduit systems, pulling additional cables into an
existing conduit is generally not recommended.
However,
consideration should still be given to whether conductors that are
of different sizes should be pulled at the same time for a given
installation. The equations that are used to determine the
maximum allowable cable tension are as follows:
51

The maximum pulling tension that can be applied to a

single-conductor (copper conductor) cable is calculated
through use of the following equation:
T cable = 0.008
= 71
lbf
AREA (in cmil)
cmil
N
mm
AREA (in mm 2)
The maximum pulling tension that can be applied to multiple

conductors when there are three or less conductors (for
cables that are in parallel, multiplexed, or are multipleconductor cables) is calculated through use of the following
equation:
T cable = T c
Where Tc is the summation of the maximum pulling
tension for each individual cable.
o
The maximum pulling tension that can be applied to multiple

conductors when there are more than three conductors (for
cables that are in parallel, multiplexed, or are multipleconductor cables) is calculated through use of the following
equation:
T cable = 0.8 T c
Where Tc is the summation of the maximum pulling
tension for each individual cable.
Once the maximum allowable tension on the pulling device and
the maximum allowable tension on the cable have been
determined, the two values are compared, and the lowest of the
two values is designated as the maximum allowable pulling
tension for the installation (Tm). Next, the actual pulling tension for
the installation is calculated and compared to the maximum
allowable pulling tension.
52

The configuration of the cables that are being pulled into a conduit
system affects the pulling tension calculations; the weight
correction factor (w) is a calculated value that is used in the
tension equations to account for the effect of cable configuration.
Figure 12 shows the various cable configurations that can occur
for a single-cable installation, a dual-cable installation, a threecable installation (cradled or triangular configuration), and a cable
installation for more than three cables (complex configuration).
The three-cable installation configurations are of special interest.
Based on the result of the jam ratio (recall that the jam ratio is
equal to 1.05 times the D/d ratio), a three-cable installation will
have a cradled configuration or a triangular configuration. If the
jam ratio is less than 2.5 or if assembled cables (triplexed cables)
are to be pulled, the installation will result in a triangular
configuration.
Figure 12: Cable Configurations
53

The equations that are used to calculate the weight correction

factor are selected based on the configuration of the cables for the
installation. The weight correction factor equations are as follows:
o
The weight correction factor for a single-cable configuration

(including the case of a multiple-conductor cable) is as
follows:
w=1
The weight correction factor for a dual-cable configuration is

as follows:
w=
d
1-
D-d
The weight correction factor for three cables with a

triangular configuration is as follows:
w=
1
d
1-
D - d
The weight correction factor for three cables with a cradled

configuration is as follows:
w =1+
4 d
3 D- d
The weight correction factor for complex cable

configurations is as follows:
ww = 1.4
54

Another factor that is of critical importance to the tension

equations is the cable weight (W). Cable weight is the weight per
unit length of the cable that will be pulled through the raceway.
When cables are to be installed in parallel (at the same time), the
cable weight factor that is used in the pulling tension equations
should be the sum of the individual cable weight factors. If the
conductors are cabled (triplexed or quadraplexed), one percent
per conductor weight should be added.
Because weight is a measure of the force that is exerted on an
object in the direction of the earth's gravitational pull, the units that
are used for the cable weight factor are Newtons per meter (N/m)
or pounds-force per foot (lbf/ft or lb/ft); the correct units must be
used in the tension calculations. When values are given that are
not in the same units as the pulling tension equations, unit
conversion factors are used to convert the given cable weight for a
single cable to the correct units. The following examples show
how the cable weight factor (W) for a single 5 AWG copper
conductor is determined:
o
If the cable weight that is specified by the manufacturer is

102 pounds per 1000 feet, the cable weight factor (W) (in
pounds-force per foot) should be calculated. To convert
pounds per 1000 feet to pounds per foot, divide by 1000.
W=

102 pounds per 1000 feet, the cable weight factor (W) (in
newtons per meter) should be calculated. To convert
pounds per 1000 feet to newtons per meter, divide by 1000
and multiply by 14.6.
W=
102 lb 0.102 lb
=
1000 ft
ft
1.489 N
102 lb
14.6 =
1000 ft
m
55


152 grams per meter, the cable weight factor (W) (in
pounds-force per foot) should be calculated. To convert
grams per meter to pounds per foot, multiply by 0.0098 and
divide by 14.6.
W=
152 g 0.0098 0.102 lb
=
m
ft
14.6

152 grams per meter, the cable weight factor (W) (in
newtons per meter) should be calculated. To convert grams
per meter to newtons per meter, multiply by 0.0098.
W=
152 g
1.489 N
0.0098 =
m
m
The pulling tension that will exist for a given above-grade conduit
or cable tray installation is determined through use of various
equations whose use is dependent on the type and direction of the
pull; the pulling tension is evaluated along segments of the
raceway through use of the information from a layout drawing.
The variables that are used in the pulling tension equations are
defined as follows:
Tin
tension into a section (newtons or pound-force).
Tout =
tension out of a section (newtons or pound-force).
Tm
maximum allowable pulling tension for the installation

(newtons or pound-force).
weight correction factor (dimensionless).
coefficient of dynamic friction = 0.5 in all cases

(dimensionless).
total assembly weight (newtons per meter or poundforce per foot; 1 lbf = 4.45 N).
straight-section length (meters or feet).
56

Lm
maximum length of straight-section pull (meters or

feet).
straight-section angle from horizontal (radians).
bend-section angle (radians).
bend-section radius (meters or feet).
natural logarithm base.
The equations that are used to calculate the pulling tension that
will exist for the various conduit and cable tray configurations are
listed as follows:
o
Maximum Length of a Straight Section Pull: This equation is

used to calculate the maximum length for a straight section
pull that will not exceed the maximum allowable pulling
tension for the installation.
Lm =
Tm
wW
Horizontal Straight Section: This equation is used to

calculate the pulling tension that will be felt at the end of a
horizontal straight section pull.
T out = w WL + T in
o
Pulling Up a Vertical Straight Section: This equation is used

to calculate the pulling tension that will be felt at the end of a
vertical or incline straight section pull (pulling up).
T out = WL(sin + w cos ) + T in
57

Pulling Down a Vertical Straight Section: This equation is

used to calculate the pulling tension that will be felt at the
end of a vertical or decline straight section pull (pulling
down).
T out = - WL(sin - w cos ) + T in

o
Horizontal Bend Section: This equation is used to calculate

the pulling tension that will be felt at the end of a horizontal
bend; this equation does not represent the sidewall pressure
that is exerted on the cable.
Tout = Tin (cosh w ) + (sinh w ) Tin + (WR) 2

2
Horizontal Bend Approximations: It is common practice to

use the following approximation for a horizontal bend
provided that (Tin > 10 WR).
T out T in e
It is common practice to use the following approximation for

a horizontal bend when Tin > 10 WR and w 1.
T out w T in e
58

Figure 13 shows the difference between a vertical up-bend and a

vertical down-bend in conduit.
Figure 13: Vertical Conduit Bends

The following equations are used for vertical concave up-bends
and down-bends:
Pulling Up Through a Vertical Concave Up-Bend: This
equation is used to calculate the pulling tension that will be
felt at the end of a vertical concave up-bend when pulling up
through the bend. This equation does not represent the
sidewall pressure that is exerted on the cable.
T out = (T in e
WR
[2 w sin - (1 - (w ) 2) (e w - cos )]
-
2
1 = (w )
59

Pulling Down Through a Vertical Concave Up-Bend: This

felt at the end of a vertical concave up-bend when pulling
down through the bend. This equation does not represent
the sidewall pressure that is exerted on the cable.
T out = (T in e
WR
[2 w e w sin + (1 - (w ) 2) (1 - e w - cos )]
-
2
1 = (w )
Pulling Up Through a Vertical Concave Down-Bend: This

felt at the end of a vertical concave down-bend when pulling
up through the bend. This equation does not represent the
sidewall pressure that is exerted on the cable.
T out = (T in e
WR
[2 w e w sin + (1 - (w ) 2) (1 - e w - cos )]
+
2
1 = (w )
Pulling Down Through a Vertical Concave Down-Bend: This

felt at the end of a vertical concave down-bend when pulling
down through the bend. This equation does not represent
the sidewall pressure that is exerted on the cable.
T out = (T in e
WR
[2 w sin - (1 - (w ) 2) (1 - e w - cos )]
+
2
1 = (w )
Vertical Bend Approximations: (It is common practice to use

the following approximation for a vertical bend when Tin > 10
WR and = 0.5.)
T out T in e
It is common practice to use the following approximation for

a vertical bend when Tin >10 WR, = 0.5, and w 1.
T out w T in e
60

When the tension equations are examined, it can be seen that a

bend in a conduit or cable tray system multiplies the incoming
tension by some exponential factor. A 90-degree bend will have a
larger effect on the pulling tension than a 45-degree bend. When
pulling cable in conduit, the NEC allows no more than four quarter
conduit bends (360 degrees total) to be made in one run of
conduit between pull points. Also, the tension that is required to
pull in either direction through a bend must be calculated and
evaluated. The cable should be pulled through the bend in the
direction that exerts the least amount of tension. The example in
Figure 14 shows how the tension is calculated for a pull in either
direction through a conduit system. The tension is calculated for
both directions to determine the direction of pull that causes the
least amount of tension.
Figure 14: Example Pulling Tension Calculation
61

The initial conditions of the pull are as follows:

Tension at starting point = 0 N
Friction coefficient (u) = 0.5
Three THHN copper (1/C), size 4/0 cables are being pulled
through a 2-inch conduit
Conduit inside diameter (D) = 2.067 inches
Single cable outside diameter (d) = 0.626 inches
Weight of the cable is specified by the manufacturer as 711 lbs.
per 1000 feet
1.
Determine the weight correction factor (w). Since the weight

correction factor is based on the configuration of the cables
in the conduit, the type of configuration must be determined
from the jam ratio.
Jam Ratio =
1.05 D (1.05)(2.067)
=
= 3.47
d
(0.626)
Since the jam ratio is greater than 2.5, the three cables will
be a cradled configuration, and the weight correction factor
is determined with the following equation:
4 d
w = 1+
3 Dd
4
0.626
w = 1+
3 2.067 0.626
w = 1.25
2.
Determine the cable weight (W) for the installation. The

units N/m should be used because the length of the conduit
is specified in meters.
711 lb
31.14 N
(14.6)(3 cables) =
W =
m
1000 ft
62

3.
Determine the pulling tension from A to D.

a.
Because A is the starting point, TA = 0
b.
TB is calculated with the equation for a horizontal

straight section.
TB = w W L + TA = (1.25)(0.5)(31.14)(3) + 0 = 58.39 N
c.
TC is calculated with the equation for a horizontal

bend section. To determine if the approximation
equation can be used, TB is compared to (10WR). If
TB is greater than (10WR), the approximation can be
used:
10WR = (10)(31.14)(1) = 311.4
TC = TB (cosh w) + (sinh w) TB + (WR)2

2
TC = 58.39(cosh 0.9817) + (sinh 0.9817) (58.39) 2 + (31.14 1) 2

TC = 164.78 N
TC = 37.05 lb
d.
TD is calculated with the equation for a horizontal

straight section:
TD = wWL + TD = (1.25)(0.5)(31.14)(1) + 164.78 = 184.24 N = 42.42 lb

4.
Determine the pulling tension from D to A

a.
Because D is the starting point, TD = 0.
b.
TC is calculated with the following equation for a

horizontal straight line:
TC = wWL + TD = (1.25)(0.5)(31.14)(1) + 0 = 19.46 N = 4.37 lb
63

c.
TB is calculated with the equation for a horizontal bend

section. Because TC is less than (10WR), the
approximation equation cannot be used:
TB = TC (cosh w) + (sinh w) TC + (WR) 2

2
TB = (19.46)(cosh 0.9817) + (sinh 0.9817) (19.46) 2 + (31.14) 2

TB = 71.74 N
TB = 16.13 lb
5.
Compare the tension of the pull from A to D to the tension of

the pull from D to A. Because the tension for the pull from D
to A is the lesser of the two values, the cable should be
pulled from D to A.
Sidewall Pressure
The radius of a conduit or cable tray bend is limited by two factors:

the minimum training radii of the cable under static load and the
sidewall pressure that will be exerted on the cable during its
installation. Sidewall pressure (SP) is defined as the crushing
force (in Newtons or pounds-force) that is exerted on a cable as it
is pulled around a bend section of conduit or duct. For Saudi
Aramco cable pulling operations, the maximum SP for any conduit
installation should not exceed 4350 N/m times the radius of the
conduit bend in meters (300 lbf/ft time the radius of the conduit
bend in feet).
64

Figure 15 illustrates the SP that is exerted on a given cable as it is

pulled through a bend with some tension (Tout) and some bend
radius (R).
Figure 15: Sidewall Pressure on Cable During a Pull
65

SP is directly proportional to the pulling tension out of the bend

and is inversely proportional to the radius of the bend; that is, as
the pulling tension increases, the sidewall pressure also increases,
and as the bending radius decreases, the SP increases. The
equation that is used to calculate the SP that is exerted on a cable
is dependent on the configuration of the cables that are in the
conduit. The equations are as follows:
o
For a single conductor installation, the following equation

should be used to calculate the SP:
SP =
T out
R
For three cables that are in a cradled configuration, the following

equation should be used:
SP =
o
(3 w - 2) T out
3R
For three cables that are in a triangular configuration, the

following equation should be used:
SP =
o
w T out
2R
For more than three conductors, the more limiting case of a

triangular cable configuration to calculate the SP should be
used.
After the pulling tensions have been evaluated throughout the

raceway, SPs are calculated for each bend and are compared to
the maximum allowable SP limit. If the SP of any bend exceeds
the allowable limit, the radius of that bend should be increased.
The table in Figure 16 shows the inside radius of various sizes of
standard conduit elbows; the inside radius of the elbow is used as
the radius of the conduit bend (R) in the SP calculations. The
inside radius of standard aluminum and fiberglass cable tray
elbows are 305, 610, and 914 mm (12, 24, and 36 inches).
66

Standard Conduit Elbow Size in mm (ft.)

Conduit Size
(in.)
Std.
300 mm
12 in.
380 mm
15 in.
460 mm
18 in.
610 mm
24 in.
760 mm
30 in
915 mm
36 in.
1065 mm
42 in.)
1220
mm 48
in.
100
(0.33)
105
(0.34)
135
(0.44)
295
(0.96)
360
(1.21)
445
(1.46)
600
(1.96)
750
(2.46)
900
(2.96)
1055
(3.46)
1210
(3.96)
160
(0.55)
280
(0.94)
365
(1.19)
440
(1.44)
595
(1.94)
745
(2.44)
897
(2.94)
1050
(3.44)
1202
(3.94)
180
(0.62
285
(0.93)
360
(1.18)
435
(1.43)
590
(1.93)
740
(2.43)
895
(2.93)
1045
(3.43)
1200
(3.93)
215
(0.71)
275
(0.91)
355
(1.16)
430
(1.41)
585
(1.91)
735
(2.41)
890
(2.91)
1040
(3.41)
1195
(3.91)
235
(0.77)
350
(1.15)
425
(1.40)
580
(1.90)
730
(2.40)
885
(2.90)
1035
(3.40)
1190
(3.90)
295
(0.96)
420
(1.37)
570
(1.87)
720
(2.37)
875
(2.87)
1025
(3.37)
1180
(3.87)
335
(1.10)
410
(1.35)
565
(1.85)
715
(2.35
870
(2.85)
1020
(3.35)
1175
(3.85)
355
(1.17)
560
(1.83)
710
(2.33)
865
(2.83)
1015
(3.33)
1165
(3.83)
545
(1.79)
700
(2.29)
850
(2.79)
1005
(3.29)
1155
(3.79)
685
(2.25)
840
(2.75)
990
(3.25)
1145
(3.75)
Figure 16: Inside Radius of Standard Conduit Elbows
67

Rigging Method Effects Calculation
This section of the Module shows how to use the previously

mentioned calculations for a given installation to determine the
type of pulling device that can be used, the maximum pulling
tensions that can safely be applied to the cable, the actual pulling
tension that will be applied to the cable, and the SP that will be felt
by the cable during its installation. Figure 17 provides a sample
above-grade conduit installation and shows the calculations that
must be made to determine whether the installation is within the
various limits. A procedure is provided in Work Aid 3 to perform
the rigging method effects calculation.
Three THHN (1/C) 4/0 copper conductor cables
are being pulled throu a 2-inch conduit.
= 0.5
Weight of cable is 711 lb per 1000 ft.
The distance from A to B is 2 m.
D = 2.067 inches
The distance from C to D is 30 m
d = 0.626 inches
The distance from E to F is 3 m
Cable Area = 199 m2
Figure 17: Sample Rigging Methods Effects Calculation
68

All conduit bends are 90-degree bends that use a 36-inch sweep
elbow (inside radius of the elbow = 2.91 ft = 0.89 m)
Tension at starting point is assumed to be 200 N.
Basket grips will be sued to pull the cables through the conduit.
The conduit installation has already been satisfactorily evaluated
against the minimum cable training radius.
1.
The configuration of the cable is determined with the jam

ratio:
Jam Ratio =
1.05 D (1.05)(2.067)
=
= 3.47
d
(0.626)
Since the jam ratio is greater than 2.5, the cables will be a
cradled configuration
2.
The weight correction factor (w) is determined with the

following equation:
4 d
w = 1+
3 Dd
4
0.626
w = 1+
3 2.067 0.626
w = 1.25
3.
Determine the cable weight (W) for the installation. The

units N/m should be used because the length of the conduit
is specified in meters.
711 lb
31.14 N
(14.6) (3 cables) =
W =
m
1000 ft
69

4.
The maximum allowable pulling tension is determined as

follows:
Tdevice = 4450 N per cable for a basket grip x 3 cables =
13,350 N
Tcable = TC
TC =
71 N
Area = (71)(199) = 14,129 N
mm 2
Tcable = (3 cables)(14,129) = 42,387 N

5.
The tension for pulling from A to point F is calculated as

follows:
TA = 200 N
The equation for pulling down a vertical section must be
used to calculate TB.
TB = WL(sin w cos ) + TA
TB = 3(31.14)(2) sin / 2 (1.25)(0.5) cos / 2) + 200 N)
TB = 137.72 N
10WR = (10)(31.14)(.89) = 277.15 N

Since TB <10 WR, the approximation equation for a vertical
bend cannot be used to calculate TC. The equation for
pulling down through a vertical concave up-bend must be
used to calculate TC.
WR
TC = (TB )e w
2
1 + ( w)
[2 we w sin + (1 ( w) 2 ) (1 e w )
31.14(.89)
[3.336 + .6094]
TC = (137.72)e .9817
2
1 + (.625)
TC = 288.95
70

The equation for pulling through a horizontal straight section

must be used to calculate TD.
TD = wWL + TC = (1.25)(0.5)(31.14)(30) + 288.95 = 872.83 N

The equation for pulling through a horizontal bend section
must be used to calculate TE.
TE = TD (cosh w) + (sinh wu) TD + ( WR ) 2

2
TE = (872.83)(cosh .9817) + (sinh .9817) (872.83) 2 + ((31.14)(.89)) 2
TE = 2330.07
The equation for pulling through a horizontal straight section
must be used to calculate TF.
TF=wWL + TE = (1.25)(0.5)(31.14)(3) + 2330.07 = 2388.47 N
The tension at point F is less than the maximum allowable
tension (TM).
It is assumed for this sample calculation that the pulling
tension from F to A has already been evaluated and that it is
greater than the pulling tension from A to F; therefore, the
cable will be pulled from A to F.
6.
The maximum sidewall pressure at all bends is the same

because all of the bends have the same radius. The
maximum allowable sidewall pressure is calculated as
shown below:
SPMAX = (4350)(.89) = 3871.5
71

Because the conductors are in a cradled configuration, the

actual sidewall pressure is calculated with the following
equation:
SP =
(3w 2)TOUT
3R
SPC =
((3)(1.25) 2)(288.95)
= 189.39 N / m
(89)(.89)
The sidewall pressure at the first bend is within limits.
SPE =
((3)(1.25) 2)(2330.07)
= 1527.20 N / m
(3)(.89)
The sidewall pressure at the second bend is also within

limits.
72

DETERMINING HAZARDOUS AREA WIRING AND SEALING REQUIREMENTS

If fire or explosion hazards exist in a location because of
flammable gases or vapors, flammable liquids, combustible dust,
or ignitible fibers or flyings, the location is described as a
hazardous (classified) location. Details on how the electrical
classification locations are determined for a given installation are
provided in EEX 208, Design Criteria for Hazardous Areas. NEC
(NFPA 70) describes these locations with three separate
classifications: Class I, Class II, and Class III. A Class I
hazardous classification is used to describe a location where
flammable gases or vapors are or may be present in quantities
that are sufficient to produce explosive or ignitible mixtures in air.
A Class II hazardous classification describes a location where fire
or explosion hazards may exist because of the presence of
combustible dusts in air. A Class III hazardous classification
describes a location where fire or explosion hazards may exist
because of the presence of ignitible fibers or flyings in air.
Each of the three classifications of hazardous locations (Class I,
Class II, and Class III) can be broken down further into a Division
1 location or a Division 2 location (i.e., an area might be given a
Class I, Division 1 classification). A Division 1 classification
implies that danger is imminent at any or all times during the
course of normal operation. A Division 2 classification implies that
danger is not present under normal conditions but is likely to arise
from some reasonable, foreseeable, accidental occurrence.
For Saudi Aramco installations, a nonclassified location is defined
as follows:
o
A location that is completely outside of a Class I, Division 1

or Division 2 location.
An enclosed space that is within a Class I, Division 1 or

Division 2 location, does not contain a release source, and
is pressurized or purged by an inert gas or by air that is
taken from an unclassified location that complies with Type
X or Type Z purging. Purging is defined as the process of
supplying an enclosure with clean air or an inert gas to
displace the atmosphere that is currently within the
enclosure.
73

This section of the Module presents the wiring and sealing

requirements that must be met for Saudi Aramco above-grade
installations. The sections that follow discuss the requirements
that must be met for Saudi Aramco above-grade installations in
terms of wiring, conduit sealing, and cable sealing.
Wiring
Various resources state the specific requirements that wiring must
meet when it is placed in hazardous locations in Saudi Aramco
above-grade installations. The resources that are applicable to
Saudi Aramco hazardous installations include the following:
o
SAES-P-100 (Basic Power System Design Criteria)
NEC (NFPA 70) (The National Electrical Code)
The various NFPA-70 and Saudi Aramco requirements that must

be met for the wiring methods that are used in above-grade
installations for Class 1, Division 1 and Class 1, Division 2
hazardous locations are as follows:
Rigid-steel conduit is specified for Class 1, Division 1 hazardous
locations, or where exceptional mechanical protection is required.
Threaded rigid-metal conduit or type MI cable with termination
fittings that are approved for the location should be used. In Class
1, Division 1 locations, Crouse-Hinds-type EC series flexible
conduit or an equivalent type of flexible conduit should be used.
All boxes, fittings, and joints should be threaded for connection to
conduit or cable terminations and should be explosionproof.
Threaded joints should be made up with at least five threads fully
engaged. Type MI cables should be installed and supported in a
manner to avoid tensile stress at the termination fittings. Flexible
fittings (when required) should be approved for use in Class 1
locations.
74

For Class 1, Division 1 locations, flameproof enclosures (Ex d II)

are permitted when the following conditions are met:
o
All cables enter the enclosure through rigid-steel conduit

that has approved sealing fittings.
The overall enclosure not just its components is flameproof

(Ex d II explosionproof) as a whole.
For Class 1, Division 2 hazardous locations, cable tray is the

preferred method of power distribution in unclassified areas.
Threaded rigid-metal conduit or type MI, MC, MV, TC, or SNM
cable with approved termination fittings (in cable tray) should be
used. To avoid tensile stress to the conductors, cable in cable tray
should be installed at the termination fittings. Boxes, fittings, and
joints are not required to be explosionproof in Class 1, Division 2
locations except under the following conditions:
o
Switches, circuit breakers, and the make-and-break

contacts of pushbuttons, relays, alarm bells, and horns
should meet the requirements that are specified for Class 1,
Division 1 locations (see above). General purpose
enclosures are permitted, however, if the current interrupting
contacts are hermetically sealed against the entrance of
gases or vapors, or are in circuits that do not release
sufficient energy to ignite a specific ignitable atmospheric
mixture under normal circumstances.
Circuit breakers, motor controllers, and switches that are

intended to interrupt current in the normal performance of
their function should be provided with enclosures that are
approved for Class 1, Division 1 locations. However,
general purpose enclosures can be used if the interruption
of current occurs in a hermetically-sealed chamber, if the
make and break contacts are immersed in oil, or if the
interruption of current occurs in a factory-sealed
explosionproof chamber that is approved for the installation.
When provisions must be made for limited flexibility, flexible metal

fittings should be used. In Class 1, Division 2 locations,
flameproof enclosures (Ex d II) and increased safety apparatus
(Ex e II) are permitted.
75

In addition to the specific requirements for wiring methods that

were listed above, the equipment that is used in hazardous
locations and that is required by NEC (NFPA 70) to be approved
(except for conduit sealing fittings) are required to be UL-labeled,
listed, or certified. Any of the following organizations may be used
to meet labeling, listing, or certifying requirements:
o
USA
Underwriters Laboratories, Inc. (UL) labeled

or listed, or Factory Mutual Research
Corporation (FM) certified.
Canada
Canadian Standards Association (CSA)

certified.
UK
British Approvals Services for Electrical

Equipment in Flammable Atmospheres
(BASEEFA) certified.
France
Centre d'Etudes et Rechereches de

Charbonnages de France (CHERCHAR)
certified.
Germany
Physikalisch Technische Bundesanstalt

(PTB) certified.
Switzerland
Schweizerischer Elektrotechnischer Verein

(SEV) certified.
Italy
Centro Elettrotecnico Sperimentale Italiano

(CESI) certified.
76

The labeling, listing, or certification of electrical equipment in

hazardous locations should be based on the latest version of the
following standards and procedures:
o
UL 886 (Outlet Boxes and Fittings for Use in HazardousClassified-Locations).
FM procedures.
CSA standards.
CENELEC EN 50 014 and EN 50 018 (for flameproof

enclosures Ex d II) or EN 50 014 and EN 50 019 (for
increased safety apparatus Ex e II).
Conduit Sealing
In a horizontal conduit run, a differential pressure could cause
flammable gases to be transmitted from a classified area to an
unclassified area through the conduit system. In a vertical conduit
run, gas vapors can move through a conduit system without a
pressure differential. Conduit seals are used to prevent the
passage of flammable gases through the conduit system, and they
are also used to prevent the passage of flames from one portion of
the electrical installation to another portion of the electrical
installation through the conduit system. Conduit seals are made
by filling a specialized sealing fitting with a sealing compound.
The resources that describe the conduit sealing requirements that
should be met for Saudi Aramco above-grade hazardous
installations are listed as follows:
o
SAES-P-104 (Wiring Methods and Materials)
SAES-J-902 (Electrical Systems for Instrumentation)
NEC (NFPA 70) (The National Electrical Code)
77

Specific NEC (NFPA 70) and Saudi Aramco requirements for

conduit sealing in Class I hazardous areas are outlined in the
following paragraphs.
When conduit seals are used (for both classified and unclassified
locations), some general requirements must be met. For Class 1
and nonclassified locations, wire fill of standard conduit sealing
fittings should not exceed 25 percent based on the size of the
conduit. Explosionproof seals should be used only when required
by NEC (NFPA 70). Each conduit that enters a process unit
control house should be sealed outside at the point of entry for an
above-grade conduit run. When conduit seals are required, the
seals should be located within 450 mm (18 inches) of an
enclosure. Vertical or horizontal conduit runs that require sealing
should be sealed with combination vertical/horizontal seals (Type
EYS or equivalent). A conduit run that crosses hazardous location
boundaries below ground must be sealed at both ends of the
conduit that emerge from the ground.
For Class 1, Division 1 locations, seals are required when conduit
runs enter an enclosure for switches, circuit breakers, fuses,
relays, resistors, or other apparatus that may produce arcs,
sparks, or high temperature. Fittings that are installed between
the seal and the enclosure must be explosionproof. Seals are
required when conduit that is of 2-inch size or larger enters an
enclosure or fitting that houses terminals, splices, or taps.
A seal is required in each conduit run that leaves the Class I,
Division 1 area. The seal can be placed on either side of the area
boundary, but it should be designed and installed to minimize the
amount of gas or vapor that passes through the boundary in the
conduit. No unions, couplings, boxes, or fittings are allowed in
the conduit between the sealing fitting and the point at which the
conduit leaves the Class I, Division 1 area. Metal conduit that
does not have unions, couplings, boxes, or fittings and that passes
completely through a Class 1, Division 2 area with no fittings less
than 305 mm (12 inches) beyond each boundary is not required to
be sealed if the termination points of the unbroken conduit are in
nonclassified locations.
78

For Class 1, Division 2 locations, seals are required for

connections to explosionproof enclosures. Seals are required in
each conduit that passes from a Class 1, Division 2 location into a
nonclassified location. The seal can be placed on either side of
the boundary, but it should be designed and installed to minimize
the amount of gas or vapor that may have entered the conduit
system from the Class 1, Division 2 area from being
communicated to the conduit that is beyond the seal. Rigid-metal
conduit should be used between the sealing fitting and the point at
which the conduit leaves the Division 2 area, and a threaded
connection should be used at the sealing fitting. Unions,
couplings, boxes, or fittings are not allowed in the conduit between
the sealing fitting and the point at which the conduit leaves the
Class 1, Division 2 area.
If the termination points of the unbroken conduit are in
nonclassified locations, metal conduit that contains no fittings,
boxes, couplings, or unions and that passes completely through a
Class 1, Division 1 location with no fittings less than 305 mm (12
inches) beyond each area boundary is not required to be sealed.
Conduit systems that terminate at an outdoor nonclassified
location where a transition is made to cable tray or type MI cable is
not required to be sealed where the conduit system passes from
the Class 1, Division 2 area into the non-classified area. The
conduits should not terminate in an enclosure that contains an
ignition source.
Conduit sealing fittings that are used in Class I hazardous areas
should be constructed so that sealing compound can be pushed
deep into the conduit sealing fitting. The minimum depth of the
sealing compound should be equal to but not less than the internal
diameter of the conduit. The depth of the sealing compound
should never be less than 15.9 mm (5/8 inches) at any point
between the conduit openings. In conduit sealing fittings that are
used for vertical mounting, the required depth of the sealing
compound should be measured from the top of the lower conduit
stop and the lowest edge of the tapped opening for introducing the
sealing compound into the conduit sealing fitting.
79

The construction of the conduit sealing fitting should provide a

tight seal and retain the sealing compound in place. The sealing
compound should form a permanent seal under service conditions
and should not be adversely affected by the hazardous vapors of
the location in which the sealing compound will be used. When an
opening is used for the introduction of the sealing compound into
the conduit, a plug that has at least five full tapered threads is
considered satisfactory for closing the opening.
Conduit sealing fittings are required to be labeled, listed, or
certified by Underwriters Laboratories, Inc. (UL), Factory Mutual
Research Corp. (FM), or the Canadian Standards Association
(CSA). The labeling, listing, or certification of electrical equipment
in hazardous locations should be based on the latest version of
the following standards and procedures:
o
UL 886 (Outlet Boxes and Fittings for Use in HazardousClassified-Locations).
FM procedures.
CSA standards.
CENELEC EN 50 014 and EN 50 018 (for flameproof

enclosures EEX D II), or EN 50 014 and EN 50 019 (for
increased safety apparatus EEX E II).
Cable Sealing
In addition to conduit seals, the NEC (NFPA 70) has requirements
for cable seals. Conduit seals are used to prevent the passage of
gases through the conduit around cables or single conductors.
Cable seals are used to prevent the passage of gases through
multiple-conductor cables. Seals that are installed in Class I
hazardous areas are intended to prevent the passage of
flammable gases or flames from one portion of an electrical
installation to another portion of the electrical installation. Seals in
Class II hazardous areas are intended to prevent combustible dust
from entering an otherwise dust-tight enclosure.
80

Multiple-conductor cables are considered to be similar to a conduit

system that contains several insulated conductors. In addition to
the spaces between the strands of the individual conductors, there
may be spaces between the individual conductors of a cable
(referred to as the cable core). The cable core may be filled in or it
may be relatively open. If the cable core is constructed so that it
performs the function of a conduit seal, the cable can be
considered to be incapable of passing gases or vapors through its
core and will be so designated.
The NEC (NFPA 70) and UL requirements for cable sealing fittings
are somewhat similar to those requirements that are listed in the
previous section for conduit sealing fittings. The requirements that
must be met for Saudi Aramco above-grade hazardous
installations are as follows.
For Class 1, Division 1 locations, each multiple conductor cable in
conduit is considered as a single conductor if the cable is
incapable of transmitting gases or vapor through the cable core.
These cables should be sealed under the same conditions as the
conditions that were stated for conduit seals in Class 1, Division 1
areas.
Cables that have a gas/vapor-tight continuous sheath that are
capable of transmitting gases or vapors through the cable core
should be sealed if they are located in a Division 1 location. The
cables are sealed after the jacket and any other coverings are
removed so that the sealing compound will surround each
individual insulated conductor and the outer jacket.
For Class 1, Division 2 locations, cable seals are required for
cables that enter enclosures that are required to be approved for
Class I locations, and the cables should be sealed at the point of
entrance to the enclosure.
Multiple-conductor cables that have a gas/vapor-tight continuous
sheath should be sealed with an approved fitting if they are
located in a Division 2 area. The cables are sealed after the jacket
and any other covering has been removed so that the sealing
compound will surround each individual insulated conductor in a
manner that will minimize the passage of gases and vapors.
81

Cables that have a gas/vapor-tight continuous sheath and that will

not transmit gases or vapors through the cable core in excess of
the quantity that is permitted for the seal fitting are not required to
be sealed except at the entrance of enclosures that are required to
be approved for Class 1 locations. The minimum length of the
cable run should not be less than the length that limits gas or
vapor flow through the cable core to the rate that is permitted for
seal fittings. The permitted rate for seal fittings is 198 cubic
centimeters per hour of air that is at a pressure 1493 Pascals
(0.007 cubic feet per hour of air that is at a pressure of 6 inches of
water).
Cables that have a gas/vapor-tight continuous sheath should not
be required to be sealed except at the entrance of enclosures that
are required to be approved for Class I locations. If the cable is
attached to process equipment or devices that can cause a
pressure in excess of 1493 Pascals (6 inches of water) to be
exerted at the cable end, the cable should be sealed. If the
pressure exerted at the ends of the cable exceeds 1493 Pascals,
however, a seal, barrier, or other method should be provided to
prevent the passage of flammables into an non-classified area.
Cables that have an unbroken gas/vapor-tight continuous sheath
should be permitted to pass through a Class 1, Division 2 location
without seals.
Cables that do not have a gas/vapor-tight
continuous sheath should be sealed at the boundary of the
Division 2 and nonclassified location in such a manner as to
minimize the passage of gases or vapors into a nonclassified
location.
82

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Engineering Encyclopedia

Saudi Aramco DeskTop Standards

EVALUATING ABOVE-GRADE WIRE,

For additional information on this subject, contact

Wire and Cable Systems

Saudi Aramco DeskTop Standards

Wire and Cable Systems

Saudi Aramco DeskTop Standards

Wire and Cable Systems

Saudi Aramco DeskTop Standards

Wire and Cable Systems

Above-grade Installation Techniques: Conduit, Cable Trays,

Determining Cable Tray Installation Requirements

Determining Conduit Installation Requirements

Determining Cable Pulling Requirements

Determining Hazardous Area Wiring and Sealing

Saudi Aramco DeskTop Standards

Wire and Cable Systems

ABOVE-GRADE INSTALLATION TECHNIQUES: CONDUIT, CABLE TRAYS, AND

Cable Trays: Design, Construction, and Usage

Exposed Cable: Uses and Routing Requirements

Saudi Aramco DeskTop Standards

Wire and Cable Systems

Rigid-steel conduit is medium-thickness water pipe that has been

Rigid-steel conduit should be used when conduit is to be

Rigid-steel conduit should be used when exceptional

Rigid-steel conduit should be used when conduit is installed

Saudi Aramco DeskTop Standards

Wire and Cable Systems

Rigid-steel conduit should be used when conduit is installed

Rigid-steel conduit should be PVC-coated when it is

EMT is similar in construction to rigid-steel conduit except that

EMT is acceptable only in non-hazardous (classified), indoor

EMT should not be used where corrosion can cause

EMT should not be used where it will be subjected to severe

Saudi Aramco DeskTop Standards

Wire and Cable Systems

Flexible liquid-tight conduit is constructed of a single strip of

Flexible liquid-tight conduit should be used in all areas

Explosion-proof flexible couplings should be used instead of

Cable Trays: Design, Construction,

Saudi Aramco DeskTop Standards

Wire and Cable Systems

Aluminum ladder-type cable tray is a prefabricated metal structure

Cable tray is the preferred method of power distribution in

Cable tray should not be used where it will be subjected to

If an outdoor cable tray installation contains only I&C cables,

Saudi Aramco DeskTop Standards

Wire and Cable Systems

Cable tray is the preferred method of power distribution in

Cable tray should not be used where it will be subjected to

If an outdoor cable tray installation contains only instrument

Saudi Aramco DeskTop Standards

Wire and Cable Systems

Exposed Cable: Uses and

Type MC cable is a factory assembly of one or more conductors

Saudi Aramco DeskTop Standards

Services, feeders, and branch circuits.

Wire and Cable Systems

Type MC cable is always specified with a PVC jacket, and is

Specific installation routing requirements for Type MC cable are

Type MC cable should be supported and secured at

Type MC cable that is installed in a cable tray should comply