REVISION AND DISTRIBUTION SHEET

MODIFICATIONS TABLE

Rev CREATED CHECKED APPROVED DATE MODIFICATIONS STAT.

A S. Garg GaneshKumar Kong-Yow Lye 04.06.15 First issue

Description Latest Revision:

DISTIBUTION TABLE

S.No Department Discipline

1 Engineering Instrument, Mechanical, Process, Piping & Arrangement

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© ALSTOM 2015. All rights reserved. Reproduction, use or disclosure to third parties, without express written authority, is strictly
prohibited.
Table of Contents:

1. INTRODUCTION ................................................................................................................................................... 4
1.1. Objectives ......................................................................................................................................................... 4
1.2. Definitions, abbreviations ................................................................................................................................. 4
1.3. Reference Documents ..................................................................................................................................... 4
2. I&C CABLING PRINCIPLE .................................................................................................................................. 4
2.1. General ............................................................................................................................................................. 4
2.2. Geographical grouping ..................................................................................................................................... 4
2.2.1. Local junction boxes constitution ................................................................................................. 5
2.2.2. Trunk cables ................................................................................................................................ 5
2.2.3. Marshalling .................................................................................................................................. 6
2.2.4. Cabling of MCC ........................................................................................................................... 6
3. PROTECTION AGAINST ELECTRICAL DISTURBANCE............................................................................... 6
3.1. Routing of cables .............................................................................................................................................. 6
3.2. Cable shield (cable screen) ............................................................................................................................. 6
4. CONNECTING PRINCIPLE ................................................................................................................................. 7
5. APPENDICES........................................................................................................................................................ 8
5.1. Appendix 1 - DCS Cabling Principle................................................................................................................ 8
5.2. Appendix 2 – Detailed Cabling Principle for RTD and TC ............................................................................. 9
5.3. Appendix 3 – Cables Screen Earthing Principle ........................................................................................... 10

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© ALSTOM 2015. All rights reserved. Reproduction, use or disclosure to third parties, without express written authority, is strictly
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1. INTRODUCTION

1.1. Objectives
The purpose of this document is to describe the principles which will be applied for the cabling and
connection of I&C signals to the DCS for TOTAL PROYEK EPCC PANASBUMI KARAHA 1 X 30 MW-NETT.

1.2. Definitions, abbreviations

DCS Distributed Control System

MCC Motor Control Centre
JB Junction boxes
Trunk Cable A trunk cable is a long distance and multi-pair cable, enabling the transmission of a
significant number of hardwired signals between two distant areas. Please change this document name is General
Specification for I&C and Special Cable.
please submit earlier than the proposed issued date.
1.3. Reference Documents
 Cable standard specification - KRH/00/I/-------Q14/ES/001
 Cabling system - main concept - KRH/00/E/----------/DO/409
 Earthing and Lightning protection system Concept - KRH/00/E/----------/DO/411
 Junction boxes – technical specification - KRH/00/I/-------Q14/ES/002
Please change, this document name is Cabling
Connection - Main Concept
2. I&C CABLING PRINCIPLE

2.1. General
The herein cabling concept concerns all hardwired connections from field instruments, Motor Control
Centre, package equipment, to the Distributed Control System, taking into account intermediate
connections in junction boxes and Marshalling cabinets.
Please use 25% spare since multipair cables will use 16 or 24 pairs (spare pair cable is 4 or 6)

 Analogue signals correspond to 4-20mA powered from the 24VDC DCS process voltage, or by
alien equipment control voltage.
 Binary signals correspond to DCS potential free contact acquisition under 24VDC DCS
process Voltage, or to DCS 24VDC output with a power below 12W.

20% spare conductors will be foreseen in multi-pair cables trunk cables.

Appendices at the end, describes the cabling principle which will be implemented for the project.
Cable shall be segregated by signal types, i.e., analog and digital signal.
Electrical Power cable shall not be run in same tray/trunking or trench as instrument cabling signal.
2.2. Geographical grouping
In order to minimize the number of cables pulled in the field and in the electrical/electronic room,
signals from individual field instruments are gathered into multi-pair cables. Signal grouping is made by
means of Junction Boxes (JB) locally distributed, and installed close to field instruments.

Exceptions to this principle may arise depending on the following reasons:

 Instruments are close to signal end users
Please describe that for signal grouping and segregation, analog junction boxes and digital junction
boxes will be provided please confirm.

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  A few number of signals is made available in an isolated area where no junction box is
required are?

 A significant number of signals are already grouped on terminal blocks in a local junction box,
or a cabinet part of a mechanical package

In particular, junction boxes won’t be used for the following signals already grouped in a restricted area
or equipment, such as:
 MV/LV Switchboards Please confirm for online ctrl valves, control actions and indication/
statuses cables shall be pulled from field to Control Room (DCS).
 Valve actuators
 DC Switchboard (Solenoid Valves interposing relays)
 MV motor temperature or vibration boxes
 Decentralised control equipment (skids, mechanical package,) including junction boxes and/or
interface signal cabinets.

2.2.1. Local junction boxes constitution

Junction boxes are constituted of terminal blocks mounted on DIN rails, housed in outdoor condition
protected boxes. Individual signals are connected on one side of the terminal blocks (field side), re-
grouped signals are available on the other side. Junction boxes are connected:
 On field side: to individual instruments by means of short distance cables with a low number of
pairs (typically 20 to 50m, and 1 or 2 pair cables).
 On the other side: to centralized equipment by means of long distance cables with a high
number of pairs (trunk cables, typically 16 & 24 pairs cables)

Measurement signals from 4-20 mA transmitters, control signals for modulating actuators, logic signals
from field switches are directly connected to local junction boxes.
All temperatures measurement (thermocouples and RTDs) are locally converted to 4-20 mA linearized
signals HART (refer to Appendix 2). Theses converters are in most cases included in the temperature
sensor head or equipment terminal box (motors, fans, pumps...).

When the environment (temperature, vibration …) does not allow the use of transmitters with head
mounted converters, remote converters shall be used. These converters will be installed in an
instrument box and connected to the probe by appropriate link. Refer to Junction box technical
specification.
When SPDT (single pole double throw) switches are provided, break and make contacts are
connected to the junction box, but only the used contact is further routed.

Please give document number. Please confirm that this document

shall be submitted to PGE. Please use 25% spare.

2.2.2. Trunk cables

Trunk cables will be multi-pair cables. 20% of spare conductors will be foreseen in trunk cables for
additional signals.
Trunk cables will be used to connect already grouped signals from field to centralized equipment.

On field side, trunk cables will be connected to junction boxes, or to sub-system control interface
boxes & cabinets. On the other side (centralized), trunk cables will be connected to DCS marshalling
cabinets.
Trunk cable spare conductors (or pairs) shall be connected on both sides to process terminals, in order
to be available for a further use.

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2.2.3. Marshalling
By providing an additional and intermediate connecting interface to the DCS, marshalling cabinets
enable to dissociate signals from trunk cables, and re-direct to DCS cabinets signals from various plant
areas. Please describe that for signal grouping and segregation, analog marshalling cabinets and digital
marshalling cabinets shall be provided please confirm.

Marshalling cabinets will be installed in the electronic room near to DCS cabinets.
Connection between marshalling and DCS cabinets will be made with multi-pair cables or special
cable. Cabling engineering will be performed in order to minimize the number of cables between
marshalling and DCS cabinets, and will preferably use multi-pair cables with a high number of pairs.
However, number of pairs will be decided in respect with the I/O allocation into DCS cabinets and
signals arrangement in trunk cables.

2.2.4. Cabling of MCC

MCCs are connected to DCS cabinets via marshalling cabinets. In general and when MCCs are of
withdrawable type, each MCC drive feeder is connected to the marshalling with a 8 pair cable.

AND ENVIRONMENTAL

3. PROTECTION AGAINST ELECTRICAL DISTURBANCE

The environment of a power plant is featured by :as follows condition which cable route shall consider to avoid,
 transient noise and inductance,
- hot environment area
 short-circuit and line breaks, - potential fire risk area
 grounding. - spillage liquid tank like Clean&Dirty Oil Tank
- escaping steam
To protect signals acquisition/restitution against the effects of these electrical disturbances, the
following principles have to be applied concerning cable routing, cable shielding and shield earthing.

3.1. Routing of cables

I&C cables are routed in dedicated cable trays or conduit, separated from MV/LV cables.
Cables of data processing signals (bus, serial link and optical network cables) are laid on specific
ways.

3.2. Cable shield (cable screen)

In order to protect signals from electromagnetic disturbances, cables are screened:
 Between sensor and local junction box one pair cable, individual screen.
 For Digital signals between local junction box and marshalling cabinet Multi-pair cable, overall
screen.
 For Analog signals between local junction box and marshalling cabinet Multi-pair cable,
individual & overall screen.
 Between marshalling cabinet and the DCS cabinet multi-pair cable, overall screen

Cables shields shall be earthed at one point only, in order to avoid earth loops and resulting current
circulation in cable shields.
Therefore, cable shields (with associated bounding wires) will be insulated from the earth all along the
signal route, from sensors up to marshalling cabinets, where they are connected to the earth. Cable
shield electrical continuity must also be ensured from signal origin to destination (marshalling
cabinets).

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 consider to add new paragraph Cable Armoured, to protect cable against mechanical disturbance, and
describe for application in this project.

Unshielded parts of the cables must be minimized. Shield connection to the earth must be kept as
short as possible.
Shields of cables pulled between DCS and marshalling cabinets are also connected to earth at
marshalling side (one earthing point).
For shield connection details, refer to Appendix 3. In all cases, pairs are twisted over their full run
length.

4. CONNECTING PRINCIPLE
Connection in local junction boxes is performed through screw or spring-cage terminals.
Terminals will be foreseen for shield bonding wire to carry out the shield electrical continuity between
sensors individual cables and trunk cables.
Connection in marshalling cabinets is done with spring-cage terminals. One side of the terminal blocks
is dedicated to process connections (trunk cables), the other side is dedicated to DCS connections
(leads).

Connection on DCS connecting boards is performed through spring-cage terminals.

In marshalling cabinets, trunk cable spare conductors are connected on terminals (process side), and
leads spare conductors (DCS side) are connected to earth.
In junction boxes, trunk cables spare conductors are connected to “process” terminals. Conductors in
sensors individual cables are connected to earth.The use of cabling ends on conductors is not
required.
space

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 5. APPENDICES

5.1. Appendix 1 - DCS Cabling Principle

CONTROL DESK
CENTRALIZED
CONTROL

EMERGENCY
STOP P.B
OPERATOR VDU'S

WORKSTATION
KEYBOARD

Please describe that for signal grouping and segregation, analog

marshalling cabinets and digital marshalling cabinets shall be provided.
ETHERNET Process
Bus
MODBUS
RELAYING

TCP(If any)
DCS IO racks & CONTROLLER
ROOM

MARSHALLING CABINET
ELECTRICAL

ALSPA INTERFACE MV / LV
ROOM

CONTROSTEAM
RELAYS (DC DISTR SWITCHBOARDS
ST controller
SWB) (CONTROL/MEASURE)

Please describe that for signal grouping and segregation, analog

junction boxes and digital junction boxes shall be provided.

DECENTRALIZED
JUNCTION
EQUIPMENT (PLC)
BOX

improve for
better tidy
CONTROL
TRANSMITTER
THERMOCOUPLE

RTD

MOTOR
LOCAL

JUNCTION
BOXES

SENSORS MANUAL SOLENOID

VALVES VALVES MOTORIZED
LEGEND VALVES MOTOR
WINDING
Hardwired link OR
BEARING
Serial link /Modbus TCP TEMP

Network (Bus) /Ethernet

Video link

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5.2. Appendix 2 – Detailed Cabling Principle for RTD and TC

N pairs to DCS
N pairs to DCS

Junction box JB

N pairs

C C
1 pair
1 pair
1 pair
1 pair
c c
C = T° converters

Individual Temperature
box signal cables

Temperature
C C signal cables

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5.3. Appendix 3 – Cables Screen Earthing Principle

5.3.1. Analog Signals

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5.3.2. Digital Signals

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