B.3.11 - Cables Spec

Page 1 of 12
STANDARD SPECIFICATION FOR
INSTRUMENT CABLES AND RELATED ACCESSORIES
DOCUMENT NO : 44-LK-5100-00/J.02/0014-A4
Rev No. Issue Date Pages Rev Description Prepared Checked Approved
By By By
A 12-08-08 12 Issued for Comments / RCK GDR BSP

Approval
JACOBS ENGINEERING INDIA PRIVATE LIMITED
DOCUMENT NO :44-LK-5100-00/J.02/0014-A4 Date : 12.08.08
STANDARD SPECIFICATION FOR INSTRUMENT CABLES Page 2 of 12
AND RELATED ACCESSORIES Revision No. : A
TABLE OF CONTENTS
1.0 PURPOSE
2.0 SCOPE
3.0 TECHNICAL REQUIREMENTS
3.1 INSTRUMENT CABLES

3.2 DESIGN AND TESTING STANDARDS
3.3 CABLE CONSTRUCTION
3.4 CABLE DRUMS
3.5 IDENTIFICATION MARKS ON CABLES
3.6 CABLE GLANDS
3.7 JUNCTION BOXES
3.8 MULTI CABLE TRANSIT
4.0 RELATED DOCUMENTATION
5.0 ATTACHMENTS
1.0 PURPOSE
The purpose of this specification is to define the minimum requirements of design and
manufacture of instrument cables and related accessories.
2.0 SCOPE
The scope of work shall include design, manufacture, testing and supply of instrument
cables and related accessories. The inspection requirements shall be as per the
inspection plan.
3.0 TECHNICAL REQUIREMENTS
3.1 INSTRUMENT CABLES
This specification covers the requirements for instrument signal cables, thermocouple
extension cables, RTD cables and power / control cables.
3.1.1 Single pair shielded signal / alarm cables shall be used between field instruments /
switches and junction boxes / local control panels.
3.1.2 Single pair shielded thermocouple extension cables shall be used between thermocouple
head and junction boxes / transmitters / local control panel mounted instruments.
3.1.3 Single triad shielded signal cables shall be used between RTD head and junction boxes /
transmitters / local control panel mounted instruments.
3.1.4 For fieldbus compatible instrument single pair shielded cable shall be used between
instrument to junction box/ local panel and to control room. Foundation Field bus shall be
Type-A cable. Construction of same shall be as Per IEC 61158-2. Trunk cable shall be
used of 1 Pair, 5 Pair, 12 Pair.
3.1.5 Separate Multipair/ multitriad cables shall be used between junction boxes/ local control
panel and control room as per following applications.
4-20 mA signals (for conventional HART Transmitters)
Foundation Field signals
Thermocouple signals
Resistance Temperature Detectors (RTD) signals
Switch contacts / Proximity switch contacts
Gas detectors
3.1.6 Power cables shall be used between power supply distribution boards and power
consumers such as control panels, DCS / PLC cabinets, any instruments requiring power
supply, etc.
3.1.7 Control cables shall be used for solenoid valves.
3.1.8 For solenoid valve signals and power supply to instruments, junction boxes shall be
used.
3.1.9 The cable design shall generally follow BS 5308 Part-1 for various cables listed in clause
3.1.5 above. Thermocouple cables design shall comply with ANSI MC 96.1. The power
and control cables shall be generally as per BS 6346. For these cables, equivalent
IEC/IS specifications are also acceptable.
3.1.10 The insulation grade shall be 1100 V for all cables.
3.1.11 The primary insulation shall be cross-linked Polyethylene with temperature rating 70
deg.C conforming to BS- 5308 / IS 7098. Inner and outer sheath / jacket shall be made of
extruded fire retardant, low smoke,low halogen, low toxic, polymeric compound having
physical properties as per IS-5831 Type ST2.
3.1.12 All cables shall be armoured and suitable for operation when installed as follows:
- Directly buried in the ground
- Fastened to cable ladder rack or tray in the open air
- In underground ducts
- In overhead closed cable ducts
3.1.13 Running length of the cable shall be printed at least at every 5 metre interval. For
multipair/ multitriad cables, pair identification shall be provided with numbers at interval of
not more than 250 mm as per vendors standard.
3.1.14 Contractor shall ensure a minimum of 20% of quantity of each type of cables supplied as
spare including any special cable and in each multipair cables 20% pairs shall be kept as
spare.
3.1.15 A pair of communication wire shall be provided for multipair / multritraid cables. Each
2
wires shall be 0.5 mm of plain annealed single or multi-strand copper conductor with 0.4
mm thick 70 Deg.C XLPE insulation.
3.1.16 All cables shall be fire retardant and low smoke.
3.2 DESIGN AND TESTING STANDARDS
3.2.1 Instrument signal, RTD and thermocouple cables
DESCRIPTION STANDARDS
Conductors BS 6360/ IS 8130 for instrument signal and RTD cables
and
ANSI MC 96.1/IEC-60584-3 for thermocouple cables.
Insulation: Insulation shall be Cross-linked Polyethylene (XLPE)
XLPE as per BS 5308 / IS 7098.
Armour: Round wire armour galvanized steel as per

IS 1554 Part 1
Inner & Outer Sheath-PVC: Extruded Fire Retardant, Low Smoke, Low Halogen,
Low Toxic, PVC having physical properties as per IS
5831-Type ST2. Flammability and chemical properties
shall be as follows:
Oxygen Index: 30 (minimum) at room Temp as per
ASTM-D-2863-77
Temperature Index: 250 Deg C (minimum) at
Oxygen Index of 21 as per ASTM-D-2863.
Light Transmission: 70% (minimum) as per IEC
1034.
Flammability test: As per IEC 332 Part-1 & Part-3
Cat. A
Corrosivity of combustion gases: pH-index> 4.3,
Electrolytic conductivity < 100 micro S/cm as per
IEC 754-2
Toxicity index: Maximum 05 Gases to be extracted
HCL, HBr, HF, CO, CO2, NO, SO2, HCN as per
NES-713. HCL shall be first gas to be extracted
Inner Sheath and outer sheath thickness: Min. Inner
sheath thickness and outer sheath thickness shall be as
per IS:1554(P-1)1988 (should not be less than 0.5 mm).
Outer Sheath Colour: Blue
Inner Sheath Colour: Black
Testing of the instrument BS 5308
signal and RTD cables.
Testing / Calibration of ANSI MC96.1 / IEC-60584-2
thermocouple cables.
Dimensions: BS 5308
3.2.2 Power and control cables
DESCRIPTION STANDARDS
Conductors IS : 8130 / BS 6360
Insulation-XLPE Insulation shall be Cross-linked Polyethylene (XLPE)
as per BS 5308 / IS 7098.
Armour Round wire armour galvanized steel as per
IS 1554 Part 1
Inner & Outer Sheath-PVC Extruded Fire Retardant, Low Smoke, Low Halogen, Low
Toxic, PVC having physical properties as per IS 5831-
Type ST2. Flammability and chemical properties shall be
as follows:
Oxygen Index: 30 (minimum) at room Temp as per
ASTM-D-2863-77
Temperature Index: 250 Deg C (minimum) at Oxygen
Index of 21 as per ASTM-D-2863.
Light Transmission: 70% (minimum) as per IEC 1034.
Flammability test: As per IEC 332 Part-1 & Part-3
Cat. A
Corrosivity of combustion gases: pH-index> 4.3,
Electrolytic conductivity < 100 micro S/cm as per IEC
754-2
Toxicity index: Maximum 05 Gases to be extracted
HCL, HBr, HF, CO, CO2, NO, SO2, HCN as per
NES-713. HCL shall be first gas to be extracted.
Inner Sheath and outer sheath thickness: Min. Inner

sheath thickness and outer sheath thickness shall be as
per IS:1554(P-1)1988, should not be less than 0.5 mm.
Power Cables: Black
Control Cables: Blue with black bands (4 bands at 90o
apart)
Testing and Dimensions IS : 1554 Part I, BS 6469 / BS 6346
of the cables
3.3 CABLE CONSTRUCTION
The various mechanical / electrical parameters indicated here are indicative and the
contractor shall be responsible to select / design the cables as per applicable standards.
3.3.1 Instrument signal cables (4 20 mA or switch contacts):
ITEMS DESCRIPTION
Conductor 7 stranded / 0.53 mm dia (1.5 mm2) stranded annealed tinned
i) Single Pair copper conductors of electrolytic grade copper.
2
7 stranded / 0.53 mm dia (1.5 mm ) annealed tinned copper
ii) 6/ 12 Pair conductors of electrolytic grade copper.
Insulation Cross-linked Polyethylene (XLPE) as per BS 5308/IS 7098.

Inner & outer PVC, fire retardant, low smoke, low halogen, low toxic, polymeric
sheath compound.
Pairs Two insulated conductors shall be uniformly twisted together to
form a pair at least 10 twists per metre.
Maximum DC Shall not exceed 12.3 ohms/ km at 20C for cables with 1.5 mm2
resistance conductor .
Mutual BS 5308 Part 1
capacitance
L/R ratio of BS 5308 Part 1
adjacent cores
/pairs
Shield Shield shall be aluminium backed mylar / polyester tape bonded
together with the metallic side down helically applied with either
side having 25% overlap and 100% coverage. The minimum
shield thickness shall be 0.05 mm in case of single pair and 0.075
mm in case of multipair cable.
Drain wire Drain wire shall be provided for individual pair and overall shield
with 0.5 mm2 multistranded bare tinned annealed copper
conductor continuously in contact with aluminium side of shield.
The drain wire resistance including shield shall not exceed 30
ohm/km. Electrostatic noise rejection ratio shall be over 76 dB.
Colour coding Individual pair core insulation : Blue & Black
Inner jacket : Black
Outer jacket : Blue for intrinsically safe application and blue
with black bands (4 bands at 90o apart) for non IS
applications.
3.3.2 RTD cables:
ITEMS DESCRIPTION
Conductor
1 Triad 2
7 stranded / 0.53 mm dia (1.5 mm ) annealed tinned copper
conductors of electrolytic grade copper.
6/ 8 Triad 7 stranded / 0.53 mm dia (1.5 mm2) annealed tinned copper
Insulation Cross-linked Polyethylene (XLPE) as per BS 5308 / IS 7098
sheath compound.
Triads Three insulated conductors shall be uniformly twisted together to

form a Triad at least 10 twists per metre.
resistance conductor .
Mutual BS 5308 Part 1
capacitance
adjacent triads
shield thickness shall be 0.05 mm in case of single triad and
0.075 mm in case of multitriad cable
2
with 0.5 mm multistranded bare tinned annealed copper
Colour coding Core insulation : Red, Yellow and Blue
Inner jacket : Black
Outer jacket : Blue for intrinsically safe application and blue
with black bands (4 bands at 90 apart).
3.3.3 Thermocouple cables:
ITEMS DESCRIPTION
Conductor
2
i) Single pair cable 16 AWG or 1.5 mm solid conductors
Conductor material should be as follows:
K type T/C Nickel / Chromium; Nickel / Aluminium (KX),
Class 1.

Colour code: Nickel / Chromium: Green
Nickel / Aluminium: White
Pairs Two insulated conductors shall be uniformly twisted together to
form a pair at least 10 twists per metre. The lay length of adj-
acent pairs / Triads in case of Multipair cables shall not be equal,
to reduce cross-talk.
Mutual capacitance BS 5308 Part 1
adjacent pairs
Core inductance Shall not exceed 4 mH/km. However, for J-type thermocouple
inductance could be 8 mH/km.
shield thickness shall be 0.05 mm in case of single pair and
0.075 mm in case of multi pair cable
2
with 0.5 mm multistranded bare tinned annealed copper

Colour coding Outer sheath colour - Green
Inner sheath colour - Black
Note: All thermocouple extension cable shall be matched and calibrated in accordance
with IEC-60584-2 / ANSI MC 96.1
3.3.3 Control cables.
ITEMS DESCRIPTION
Conductor
2 Core / Multi-core 7 stranded / 0.53 mm dia (1.5 mm2) annealed tinned copper
type conductors of electrolytic grade copper.

sheath compound.
resistance conductor
Core Identification IS : 1554 / BS 6746
3.3.4 Power cables.
ITEMS DESCRIPTION
2
Conductor 7 stranded / 0.67 mm dia. (2.5 mm ) annealed tinned copper
The size of the conductor specified here is minimum. However,
the exact size of the conductor shall be selected based on the
length of cable and power consumption. For higher conductor
sizes, aluminium can be considered.
Core Identification IS-1554 / BS 6746
Colour coding Outer sheath colour Black
Neutral wire insulation colour Black
Phase wire insulation colour Red
Ground wire insulation colour - Green
3.3.5 Special Cables
3.3.5.1 Ethernet cables

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

62.5 / 125 micron multimode, graded index, glass silica fibre core, mechanical protection
provided by round galvanized steel armour with polyester laminated tape layered over
inner sheath. Outer sheath shall be orange.HDPE conduit shall be orange colour.
3.3.5.3 Foundation Fieldbus(FF) cables colour code:

FF Trunk cables shall be Orange with 4 Black longitudinal stripes at 90 deg apart.
FF Spur cables (IS) shall be Orange with 4 Blue longitudinal stripes at 90 deg apart.
3.3.6 Any other special cables such as co-axial cable or cables with glass insulation, required
for instruments shall also be supplied as per requirements. Vendor shall ensure that
these cables are armoured type and shall meet all other requirements specified in clause
3.3.1 through 3.3.5, as applicable.
3.3.7 Cable Testing:-

Vendor shall submit routine and Acceptance test certificates, in original at the time of
delivery of cables.
3.3.7.1 Type Test:-

Certificate from independent test house for the following tests shall be furnished by the
vendor for the FRLS low halogen sheathed cable.
a) Flammability Test as per IEC 60332, Part-III, Cat A.
b) Electrostatic noise Rejection test.
c) Oxygen Index, Temperature rating, light transmission, pH Index, electrical
conductivity and toxicity index for the cable
3.3.7.2 Routine Test and Acceptance test :-

Each of the following tests to be carried out by vendor during various stages of
manufacturing. Purchaser shall review the related documentations. In addition, the
following test shall be carried out for checking properties of low halogen FRLS sheathing
material.
a) Light Emission test as per IEC-1034. Acceptance norms shall be minimum 70%
b) Determination of the degree of acidity of gases evolved during combustion as
per IEC 754-2 (pH value to be minimum 4.3 and conductivity to be maximum 100
micro Siemens/cms
c) Toxicity Index as per NES-713. Value shall not exceed 5
d) Tear Resistance as per BS 7655 Section 6.1
e) Abrasion test method as per BS 6724 Annexure E
These tests shall be carried in presence of purchaser or his authorized representatives.

Immediately after completion of the electrical test the ends of the cable shall be sealed to
prevent ingress of moisture with suitable of rubber/PVC caps.
3.4 CABLE DRUMS
3.4.1 Cables shall be drummed in continuous lengths on cable drums. For protection during
transport and storage, battens shall be fitted around the entire periphery of the drum.
3.4.2 Drum identification shall be painted black on both sides of drum with permanent oil paint.
The following information shall be given on the drums as a minimum:
- Drum identification number

- Voltage grade
- Type of cable.
- Number of cores and cross-sectional area
- Cable quantity
- Purchaser's order number and item number
- Total weight of cable and drum
3.5 IDENTIFICATION MARKS ON CABLES:
3.5.1 Signal Cables:
Outer Embossing: Following embossing should be in bold fonts at outer sheath at every
5 meter interval.
Type of Cable i.e. Signal Cable
No of Pairs i.e. 1, 6, 12 etc.
Core Size i.e. 1.5 sq mm etc.
Sequential meter marking shall be embossed at every 1 meter interval
Individual pairs Embossing and identification: Core no shall be printed on each core for
identification at regular interval of 250 mm or so. The pair numbers shall be available on
individual pair by method of polyester number tape also.
3.5.2 Control Cables: Following embossing should be in bold fonts at outer sheath at every 5
meter interval.
Type of Cable i.e. Control Cable
No of Cores i.e. 2, 4, 10, 12, 24 etc.
Core Size i.e. 1.5 sq mm
3.5.3 Thermocouple Cables:

Outer Embossing: Following embossing should be in bold fonts at outer sheath at every
5 meter interval.
Type of Cable i.e. T/C Cable
No of Pairs
Core Size i.e. 16 AWG
Temperature Range
Individual pairs Embossing and identification: Each core of pair shall be numbered for
identification at regular interval of 250 mm or so.
3.6 CABLE GLANDS
3.6.1 Cable glands required for glanding all cables at both ends shall be supplied by
contractor.
3.6.2 A minimum of 20% of cable glands shall be supplied as spare.
3.6.3 Cable glands shall be of SS 316 and double compression type suitable for armoured
cables.
3.6.4 All cable glands shall be weatherproof to IP-66. Flameproof glands wherever required
shall be supplied with Ex(d) certification suitable for Gas Groups IIA / IIB / IIC. All cable
glands shall be with LSF shrouds.
3.6.5 For all field items and junction box end, NPT threaded cable glands shall be used and for
control room / control panel end, cable glands shall be ET threaded types.
3.7 JUNCTION BOXES
3.7.1 Junction boxes shall be of die-cast aluminium alloy (LM-6) epoxy painted body.
All junction boxes shall be weatherproof to IP 66 as a minimum. Flame proof junction
boxes wherever required shall be supplied with Ex (d) certification. All flame proof JBs
shall be provided with labels for isolating power supply before opening cover. All JBs for
intrinsic safe signals shall be identified on name plate accordingly.
3.7.2 Junction box shall have screwed covers.
3.7.3 Junction box sizes shall be standardized to two types accommodate 44 terminals and 88
terminals. This includes separate terminals for shields and 20% spare terminals. All
2
terminals shall be suitable for 4mm conductors.
3.7.4 Each JB shall be provided with 2 multi-cable entries with one plugged with weather proof,
explosion proof plugs as required.
3.7.5 Plugs shall be Ex (d) certified for flameproof junction boxes.
3.7.6 Telephone sockets and plugs shall be provided in all junction boxes.
3.7.7 In general separate junction boxes shall be used for the following:
- Thermocouples / RTDs / SMART Transmitter / Positioner

- Non SMART Transmitters (Analog Transmitters for Anti-surge control etc.)
- Switches / Push Buttons
- Solenoid valves
- Power
- Alarm
- Shutdown
- Gas detector
( Separate JBs for intrinsic safe, non-intrinsic safe circuits )
In general all alarm signals shall be taken to DCS and all shutdown signals to PLC.
Accordingly separate junction boxes shall be provided to Alarm and Shutdown signals.
3-way junction boxes shall be used for connecting the field transmitter, field mounted
analog I.S. indicator in series with control room receiver.
3.8 MULTI CABLE TRANSIT
3.8.1 The cable entry into the Satellite Rack Room/control room, analyser rooms/ shelters shall
be through Multi Cable Transit Blocks (MCT). The MCTs shall be sized, supplied and
installed at site by contractor. The required cutout sizes and frames sizes shall be
calculated and shall be co-ordinated with control room contractor.
3.8.2 The MCT frames shall be of Standard RGB type of Brattberg or Roxtex and of steel
construction. The maximum height of frame shall not exceed 600 mm unless otherwise
specified. The MCT frames provided should be suitable to withstand blast intensity for
which blast proof control room has been designed. The MCT shall be supplied complete
with insert blocks, spare blocks, stay plates, end-packing etc.
3.8.3 Contractor shall size and provide MCT considering 50% spares for each cable size/cable
OD. Contractor shall also provide 50% spare insert blocks in each cable size / O.D. as
loose supply. Intrinsically safe cables, low power cables, non-intrinsically safe cables and
power cables for instruments (110 V AC or above) shall be suitably separated from each
other cables within the MCT frame and shall be routed through separate MCT blocks.
3.8.4 Separate MCT frame shall be considered for electrical cables. The MCT shall be
installed as per the recommended practice of supplier. No spare space shall be left
uncovered in the frame and shall be filled with dummy block of suitable size.
4.0 RELATED DOCUMENTATION
Nil
5.0 ATTACHMENTS
Nil

B.3.11 - Cables Spec

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

B.3.11 - Cables Spec

Uploaded by

Copyright:

Available Formats

Page 1 of 12

STANDARD SPECIFICATION FOR

INSTRUMENT CABLES AND RELATED ACCESSORIES

A 12-08-08 12 Issued for Comments / RCK GDR BSP

3.0 TECHNICAL REQUIREMENTS

3.1 INSTRUMENT CABLES

4.0 RELATED DOCUMENTATION

3.0 TECHNICAL REQUIREMENTS

3.1 INSTRUMENT CABLES

3.1.7 Control cables shall be used for solenoid valves.

3.1.10 The insulation grade shall be 1100 V for all cables.

3.1.16 All cables shall be fire retardant and low smoke.

3.2 DESIGN AND TESTING STANDARDS

3.2.1 Instrument signal, RTD and thermocouple cables

Armour: Round wire armour galvanized steel as per

3.2.2 Power and control cables

Inner Sheath and outer sheath thickness: Min. Inner

3.3 CABLE CONSTRUCTION

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

Insulation Cross-linked Polyethylene (XLPE) as per BS 5308/IS 7098.

3.3.2 RTD cables:

Triads Three insulated conductors shall be uniformly twisted together to

3.3.3 Thermocouple cables:

Insulation Cross-linked Polyethylene (XLPE) as per BS 5308 / IS 7098

conductor continuously in contact with aluminium side of shield.

3.3.3 Control cables.

Insulation Cross-linked Polyethylene (XLPE) as per BS 5308 / IS 7098

3.3.4 Power cables.

3.3.5 Special Cables

3.3.5.1 Ethernet cables

3.3.5.2 Fibre optic cable

3.3.5.3 Foundation Fieldbus(FF) cables colour code:

3.3.7 Cable Testing:-

3.3.7.1 Type Test:-

3.3.7.2 Routine Test and Acceptance test :-

These tests shall be carried in presence of purchaser or his authorized representatives.

3.4 CABLE DRUMS

- Drum identification number

- Total weight of cable and drum

3.5 IDENTIFICATION MARKS ON CABLES:

3.5.1 Signal Cables:

3.5.3 Thermocouple Cables:

3.6 CABLE GLANDS

3.6.2 A minimum of 20% of cable glands shall be supplied as spare.

3.7 JUNCTION BOXES

3.7.2 Junction box shall have screwed covers.

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

- Thermocouples / RTDs / SMART Transmitter / Positioner

3.8 MULTI CABLE TRANSIT

4.0 RELATED DOCUMENTATION

You might also like