Engineering Standards : Specification Rev.

G Page
Instrument Cabling, Number: 1 of 11
Marshalling& Junction 02/54/032 Date:
Box Genl Requirements 13/11/2010

CONTENTS

TITLE PAGE NOS

1.0 GENERAL ......................................................................................................... 2

2.0 DEFINITIONS, SERVICE CONDITIONS, CODES AND STANDARDS ............ 3

3.0 INSTRUMENT CABLES ................................................................................... 6

4.0 EARTHING AND BONDING SYSTEMS ........................................................... 9

5.0 MARSHALLING AND JUNCTION BOXES ...................................................... 9

6.0 CABLE TRAY AND RACKING ....................................................................... 11

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1.0 GENERAL

1.1 Scope

The scope of this specification is to provide general guidelines to the Vendor for
the procurement of instrument cabling and auxiliary cabling junction boxes.

1.2 Equipment Selection

1.2.1 Equipment for use in potentially hazardous atmospheres shall be

selected in accordance with IP code part 15. All equipment selected for
use in potentially hazardous areas shall be certified by ATEX,
BASEEFA/CENELEC or international equivalent for use in each
classified area with the appropriate gas group and temperature class.

1.2.2 For Zone 0 and 1 areas, the preferred method of protection shall be via
the use of Intrinsically Safe (IS) equipment.

1.2.3 For Zone 2 areas preference shall be given to IS equipment excepting

solenoid valves which shall be `EExd' (flameproof).

1.2.4 Other types of protection selected shall be subject to approval by the

Operator.

1.2.5 The use of equipment proposed for application where suitably certified
equipment is not available shall be subject to approval by the Operator.
Where necessary, such equipment shall be submitted for independent
assessment before approval. A document of conformity shall be
prepared which details the consideration made in assessing the safety
of the equipment.
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2.0 DEFINITIONS, SERVICE CONDITIONS, CODES AND STANDARDS

2.1 Definitions

`Operator' - shall mean Akakus Oil Operations(AOO).

`Inspector - shall mean any person, company or body appointed by

the Operator to exercise the functions entrusted to him
under the Purchase Agreement and notified by the
Operator to the Vendor.

`Vendor' - shall mean a supplier or manufacturer of

equipment/materials subject to this specification.

`Contractor' - shall mean a company awarded a construction contract

by AOO. Such contract may include the purchase of
equipment/materials required to complete their contract.
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2.2 Service Conditions

The Vendor is to supply packages to one of two distinctly, different locations,

ie::

- the Libyan coastal

- the Libyan desert.

The ambient temperatures and conditions for each site are as follows:

(a) coastal - maximum ambient temperature - 110oF (43oC)

- minimum ambient temperature - 32oF (0oC)

- maximum relative humidity - up to 100%

- maximum wind speed (design) - 90 mph

(b) desert - maximum ambient temperature - 122oF (50oC)

- minimum ambient temperature - 32oF (0oC)
- maximum relative humidity - < 30%
- maximum wind speed (design) - 90 mph

Both areas are hostile environments. Instrumentation shall be suitably

constructed and designed for continuous operation in their respective
environments, ie:

(a) high humidity, salt air conditions of the coast

(b) dry, dusty conditions of the Libyan desert.

2.3 List of Reference Codes and Standards

Note: This is a list of codes, standards and other documents referred to in this
document. A reference in this document to those documents invokes the latest
published issue or amendment unless otherwise stated.

BS 5308-1 - Instrumentation Cables for XLPE insulated cables

BS 5308-2 - Instrumentation Cables for PVC insulated cables

BS 6746 - PVC Insulated Cables for Electricity Supply

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IP code part 15- Code of Practice for the Selection, Installation and
Maintenance of Electrical Apparatus for use in
Potentially Explosive Atmospheres .

EIC Spec CCI P/4- Specification for Colour Coding of Instrument Signal
Cables

IEC 60079 - Electrical Apparatus in Explosive Atmospheres.

IEC 60331 - Test on Electric and Fibre Optic Cables under Fire
Conditions, Fire Resistance.

IEC 60332 - Test on Electric and Fibre Optic Cables under Fire
Conditions, Flame Retardant.

IEC 60754 - Test on Gases Evolved During Combustion of Materials

from Cables, Halogen Acid Gas Free Cable.

IEC 61034 - Measurement of Smoke Density of Cables Burning

under defined conditions, Low Smoke Cables.

IEC 601000 - Electromagnetic Compatibility (EMC Requirements)

IEC 60529 - Degrees of Protection Provided by Enclosures (Ingress

Protection – IP Ratings)
IEC 60811 - Common Test Methods for Electrical Cables.

Operators Document

02/54/029 - Instrument Earthing Philosophy

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3.0 INSTRUMENT CABLES

3.1 Cable Construction

3.1.1 Instrument signal cables for field installation should be constructed in

accordance with BS 5308 and as detailed in the Operators Document
No. 02/54/198 - Instrument Cable Specification.

3.1.2 Conductors shall be sized to provide a loop resistance within that

required for the application. The minimum conductor size shall be
1.5 mm2 (7/0.5 mm2) for stranded cables.

3.1.3 On special applications in aggressive environments which require

materials other than PVC or XLPE for insulation and PVC for sheathing,
the materials used for insulation and sheathing shall be subject to
approval by the Operator.

3.1.4 Flame retardant cables shall be used for emergency shutdown circuits.

3.1.5 Fire resistant cables shall be used for fire and gas monitoring circuits.

3.1.6 All field cables shall be protected by Steel Wire Armour (SWA).

3.1.7 Colour coding of insulation and sheathing for instrument cables shall be
in accordance with EIC Specification CCI P/4. Any other colour coding
shall be subject to approval by the Operator.
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3.2 Cable Selection
3.2.1 General
Only signals of the same category shall be contained in the same multi-
core cable. Multi-core cables shall be selected to include a minimum of
20% spare cores.

3.2.2 Analogue Signals and Alarms

3.2.2.1 Individual circuit cables shall consist of a twisted pair with

tape screen. A multi-pair cable shall have only a collective
overall screen.

3.2.3 Low Level Signals

3.2.3.1 Individual circuit cables shall consist of a twisted pair with

tape screen. A multi-pair cable shall have individual pair
screens.

3.2.4 Resistance Thermometers

3.2.4.1 4-wire cables shall consist of two twisted pairs of

conductors, laid in quad formation around a central dummy
and have an overall screen.

3.2.4.2 3-wire cables shall be uniformly twisted together and have

an overall screen.

3.2.4.3 Multi-circuit cables shall have individual quad or triple

screens.

3.2.5 Thermocouples

3.2.5.1 Individual cables shall consist of a twisted pair with tape

screen. A multi-pair cable shall have individual pair screens.

3.2.5.2 Conductor material shall be as follows:

For type J thermocouple - iron/copper-nickel
(constantan)
For type K thermocouple - nickel-chromium/nickel-
aluminium
For type R thermocouple - platinum-13%
rhodium/platinum
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3.2.6 Emergency Shut-down Fire Circuits

3.2.6.1 Twisted pair cables shall be used for this service. Where
volt drop is excessive for the apparatus connected, non-
twisted pair cable to BS 6346 (except as noted in this
document) may be used.

3.2.6.2 All conductors forming part of fire detection circuits shall be

contained in separate multi-core cables reserved solely for
those circuits.

3.2.7 Digital Signals

3.2.7.1 Twisted pair cables shall be used for this service. Where
volt drop is excessive for the apparatus connected, non-
twisted pair cable to BS 6346 (except as noted in this
document) may be used.

3.2.8 Data Transmission

3.2.8.1 Individual twisted pair cables used for data transmission

shall be screened. Multi-pair cables carrying audio and data
transmission shall have individual pair screens to avoid
crosstalk. System design shall be subject to approval by the
Operator.

3.2.8.2 Extended frequency circuits shall be carried on twisted pairs

in a multi-core cable with individual screens.

3.2.8.3 Co-axial signal cable shall comply with the general

requirements of instrument cables. Signal levels on
adjacent cables in the same frequency band shall be similar
to minimise crosstalk.

3.2.8.4 Double screening shall be provided where additional

protection from noise is necessary for long co-axial cables.
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3.2.9 Intrinsically Safe Circuits

3.2.9.1 Intrinsically Safe (IS) circuits shall be grouped into

categories as listed above. However, all conductors forming
part of Intrinsically Safe (IS) circuits shall be contained in
separate multi-core cables reserved solely for those circuits.

3.2.9.2 Cable outer sheath shall be coloured blue.

3.2.10 Fire and Gas Monitoring Circuits

3.2.10.1 Twisted pair cables shall be used for this service except
when connections to field devices require three conductors
where twisted triple cables shall be selected.

Where volt drop is excessive for the apparatus connected,

non-twisted pair cable to BS 6346 (except as noted in this
document) may be used.

4.0 EARTHING AND BONDING SYSTEMS

4.1 For details of earthing and bonding systems refer to the ‘Operators Document’
02/54/029– Instrument Earthing Philosophy.
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5.0 MARSHALLING AND JUNCTION BOXES

5.1 Separate marshalling and junction boxes shall be used for fire and gas
monitoring, emergency shutdown and Intrinsically Safe (IS) circuits.

5.2 All instrument junction boxes and their terminals shall conform to the standard
IEC 60079 increased safety.

5.3 Junction boxes shall be manufactured from minimum 14 SWG galvanised

sheet steel, with a hinged lockable door, secured with a captive screw in each
corner.

5.4 Marshalling and junction boxes shall be sized for the termination of 40 single
pair overall screened cables into 2 x 20 multi-pair cables in two banks. They
shall permit termination of all cores and screens, including spares, without the
need for more than one core per terminal. In addition, a minimum of 20%
spare terminals shall be provided.

5.5 Cable entries shall not be at the top of boxes unless installed in a fully weather
protected environment. Removable gland plates shall be provided as
necessary.

5.6 The degree of protection of marshalling and junction boxes shall be a minimum
of IP 65 as defined in IEC 60529, unless installed in a fully weather protected
environment.

5.7 The box shall be complete with both external lugs for mounting and a brass
stud for connection to dirty/plant earthing system.

5.8 Terminals shall be `clamp-type' tin plated, sized for a 2.5 mm2 sized cable. The
terminal insulation housing shall be manufactured from polyamide suitable for
carrying `strip' marker circuit. IS terminals shall be blue, non-IS terminals shall
be Manufacturer's standard colour.

5.9 Identification labels when installed shall be capable of being read from LEFT to
RIGHT.

5.10 Terminal rows shall be further identified with the Vendor's proprietary `row'
marking system. Left `hand' vertical row identified as TB 1 followed by
multi-paired cable number. Right-hand row as TB 2 followed by the
subsequent multi-paired cable number.
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5.11 Connection of multi-paired overall screen cable to single pair overall screen
cable shall be by means of the junction box Vendor's proprietary `comb bridge'
conductor.

5.12 Terminals shall be installed into the box using the Manufacturer's proprietary
mounting rail.

5.13 The junction box shall be identified with a laminated Traffolyte nameplate sized
3 x 6 inches in ¼-inch high engraved characters as follows:

1st line - junction box number

2nd line - type of protection

3rd line - type of circuit

4th line - voltage (when applicable).

5.14 Nameplate colours:

Fire and safety - red/white/red

Intrinsically safe - blue/white/blue

All other services - black/white/black.

5.15 Voltages above 24 volts AC or DC shall be stated.

5.16 Nameplates shall be secured to junction box by the Vendor's supplied fixings.

6.0 CABLE TRAY AND RACKING

6.1 Cable tray and racking shall be constructed of heavy duty, hot dipped
galvanised steel. End cuts shall be sealed immediately after cutting.

6.2 Trays or racking shall be suitably sized to allow for future additional cabling,
typically 40%.