Engineering and Construction Specifications
Division 17 - Instrumentation
Title: Instrumentation Electrical Installation
Revision: 5
SECTION INDEX
Document #: CS17002
Revision Date: 10/01/2015
Page: 1 of 21
Effective Date: 11/04/2015
SHEET NO.
PART 1 - GENERAL.................................................................................................................... 2
1.01
CODES AND STANDARDS..................................................................................... 2
1.02
SCOPE ........................................................................................................................ 2
1.03
DRAWINGS ................................................................................................................ 3
PART 2 - PRODUCTS................................................................................................................. 3
2.01
GENERAL ................................................................................................................... 3
2.02
ANALOG SIGNAL CABLE........................................................................................ 4
2.03
FOUNDATION FIELDBUS CABLE......................................................................... 5
2.04
AS-INTERFACE CABLE........................................................................................... 5
2.05
PROFIBUS CABLE.................................................................................................... 5
2.06
DEVICENET ............................................................................................................... 6
2.07
ETHERNET................................................................................................................. 6
2.08
FIBER OPTIC CABLE............................................................................................... 7
2.09
POWER AND DISCRETE SIGNAL WIRING ........................................................ 7
PART 3 - EXECUTION.............................................................................................................. 13
3.01
GENERAL ................................................................................................................. 13
3.02
INSTRUMENT WIRING .......................................................................................... 14
3.03
BUS NETWORKS.................................................................................................... 15
3.04
PANELS AND JUNCTION BOXES....................................................................... 17
3.05
CONDUIT .................................................................................................................. 17
3.06
INTRINSICALLY SAFE WIRING........................................................................... 18
3.07
FIBER OPTIC CABLE............................................................................................. 18
3.08
TESTING AND CALIBRATION.............................................................................. 19
Engineering and Construction Specifications
Division 17 - Instrumentation
Title: Instrumentation Electrical Installation
Revision: 5
Document #: CS17002
Revision Date: 10/01/2015
Page: 2 of 21
Effective Date: 11/04/2015
PART 1 - GENERAL
1.01
1.02
CODES AND STANDARDS
A.
National Electric Code (NEC) and National Fire Protection Association (NFPA)
standards
B.
Instrument Society of America (ISA) Standard RP 12.6
C.
American National Standards Institute (ANSI) / API RP 551 – Process
Measurement Instrumentation
D.
ANSI / API RP 554 Pt 1 – Process Control Systems Functions and Functional
Specification Development
E.
ANSI / API RP 554 Pt 2 – Process Control Systems – Process Control System
Design
F.
ANSI / API RP 554 Pt 3 – Process Control Systems – Project Execution and
Process Control System Ownership
G.
Site Standard Instrument Installation Detail Drawings SD-00-####
H.
Site Engineering and Construction Specifications
1.
CS16111 – Conduits
2.
CS17001 - Instrumentation Mechanical Installation
SCOPE
A.
This specification covers the following work.
1.
2.
Provision of cabling and/or wiring necessary to wire the following items:
a.
Instruments
b.
DCS Equipment
c.
Control Panels
d.
Junction Boxes
Provision of raceways, fittings and supports.
Engineering and Construction Specifications
Division 17 - Instrumentation
Title: Instrumentation Electrical Installation
Revision: 5
1.03
Document #: CS17002
Revision Date: 10/01/2015
Page: 3 of 21
Effective Date: 11/04/2015
DRAWINGS
A.
Perform all work in compliance with the mechanical, instrument, and electrical
drawings provided by vendors and the Work Sponsor (the person responsible for
completing the requested work). The instrumentation application is shown on the
Piping and Instrument Diagrams (P&ID's) in standard ISA format. Each item is
listed in the instrument index as provided by the Work Sponsor and is further
identified by an Instrument Specification Sheet and a Wiring Diagram.
B.
Installation is to be completed as shown on the Site Standard Instrument
Installation Detail Drawings furnished for each type of field mounted device. The
instrument location and routing plans show the desired location of the instrument
hardware and junction boxes. If field conditions make indicated arrangements
impossible or impractical, the Contractor is to submit a written request for
deviation to the Work Sponsor with sketches or drawings, if required for
clarification, and proceed only after receiving written approval by the Work
Sponsor. The Installer (Contractor or BASF Technician) shall verify actual
conditions in the field and is to supply measurements necessary for the proper
installation of his work.
PART 2 - PRODUCTS
2.01
GENERAL
A.
Refer to Division 16, Electrical Specifications for more details on Basic Materials
and Methods.
B.
Single conductors shall be copper cable of concentric, Class B stranded, annealed
copper.
C.
With the exception of those listed under 2.02 through 2.07, cable insulation shall
be manufactured according to both the National Electrical Manufacturer’s
Association (NEMA) and the Insulated Cable Engineers Association (ICEA)
standards for 600 volts at 100% insulation level suited for a minimum of 90 C for
normal operation, 130 C for emergency overload operation, and 250 C for shortcircuit operation as per ICEA Pub. No. S-66-524 and NEMA Pub. No. WC7-1971.
D.
Cables shall be suitable for installation in conduits, ducts, or other raceways in wet
or dry areas. THHN – 90 C dry and damp locations; THWN – 75 C dry and wet
locations, and XHHW – 90 C dry and damp locations – 75 C wet locations; TFFN –
90 C dry and damp locations only used for 16 gauge control wiring.
E.
All wire and cables exposed to 480Vac wiring shall have an insulation rating of
600V.
Engineering and Construction Specifications
Division 17 - Instrumentation
Title: Instrumentation Electrical Installation
Revision: 5
2.02
Document #: CS17002
Revision Date: 10/01/2015
Page: 4 of 21
Effective Date: 11/04/2015
F.
All cables installed in cable tray shall be Tray Cable (TC) or Power Limited Tray
Cable (PLTC) cables and shall be suitable for installation in a Class I, Division 2
area classification.
G.
Instrumentation cable shall comply with all applicable standards (latest revisions)
of the Underwriter’s Laboratories (UL), National Electrical Code (NEC) of the
National Fire Protection Association (NFPA), NEMA, Canadian Standards
Association (CSA) and Insulated Cable Engineers Association (ICEA).
H.
Manufacturers shall be Belden or approved equal.
ANALOG SIGNAL CABLE
A.
All 4-20 mA signals are to be twisted shielded pairs, stranded, copper conductors,
tinned with red and black conductors. Red shall be positive and black negative.
100 percent coverage aluminum foil-polyester tape shield (static and magnetic
shielding) shall be used. Jacket shall be polyvinyl chloride or equivalent with
thickness as required by cable size. Insulation shall be 80 C-rated polyvinyl
chloride; 300VAC minimum; 600VAC where required by NEC 725.26. The cable
used shall be:
1.
AWG #22 Belden 9322 (300V, PLTC rated) or equivalent for cable tray.
2.
AWG #22 Belden 9462 (300V rated) or equivalent for conduit.
3.
AWG #18 Belden 9341 (600V, TC rated) or equivalent for wire run in cable
tray or conduit to 480Vac Motor or Heater Controller.
B.
Frequency, millivolt, and pulse type signals shall also use this cable.
C.
All RTD or 3-wire signals are to be twisted shielded triads, stranded, copper
conductors, tinned with red, white and black conductors. 100 percent coverage
aluminum foil-polyester tape shield (static and magnetic shielding) shall be used.
Jacket shall be polyvinyl chloride or equivalent with thickness as required by cable
size. Insulation shall be 80 C-rated polyvinyl chloride; 300VAC minimum; 600VAC
where required by NEC 725.26. The cable used shall be:
D.
1.
AWG #18 Belden 1036A (300V, PLTC rated) or equivalent for cable tray.
2.
AWG #18 Belden 8770 (300V rated) or equivalent for conduit.
Multi-pair cables shall have individually twisted and shielded pairs with an overall
shield and stranded copper conductors. Gauge size shall follow listing above. 100
percent coverage aluminum foil-polyester tape shield (static and magnetic
shielding) shall be used. Jacket shall be polyvinyl chloride or equivalent with
thickness as required by cable size.
Engineering and Construction Specifications
Division 17 - Instrumentation
Title: Instrumentation Electrical Installation
Revision: 5
Document #: CS17002
Revision Date: 10/01/2015
Page: 5 of 21
Effective Date: 11/04/2015
E.
Multi triad cables shall have individually twisted and shielded triads with black,
white, and red conductors, overall shield and # 18 stranded copper conductors.
100 percent coverage aluminum foil-polyester tape shield (static and magnetic
shielding) shall be used. Jacket shall be polyvinyl chloride or equivalent with
thickness as required by cable size.
F.
Standard thermocouple extension cable shall be #20, shielded, PLTC, 300V, solid
conductors, rated for 105°C with PVC insulated conductors and a PVC jacket. In
applications where the thermocouple cable is exposed to temperatures exceeding
105°C, provide a high temperature extension cable rated for 200°C with FEP
insulated conductors and a FEP jacket. Provide Belden cables as specified below
or Site approved equal:
Belden Cable Types:
Type
(+)
E
Purple
J
White
K
Yellow
T
Blue
*This cable is 2/C #16
2.03
200°C
83955
83950
83952
83954
All Foundation Fieldbus cables shall be #18 AWG, shielded, PLTC, 300V, 80 C
minimum, orange PVC cable with orange and blue conductors. Use orange for
positive and blue for negative. 100 percent coverage aluminum foil-polyester tape
shield (static and magnetic shielding) shall be used. Use Belden #3076F or equal
cable.
AS-INTERFACE CABLE
A.
2.05
105°C
1101A*
3111A
3112A
3113A
FOUNDATION FIELDBUS CABLE
A.
2.04
(-)
Red
Red
Red
Red
All AS-I cables shall be #16 AWG, unshielded, PLTC, 300V, 80 C minimum rated
yellow PVC cable with brown and blue conductors. Use brown for positive and
blue for negative. Use Turck model 254 or equal cable.
PROFIBUS CABLE
A.
All Profibus DP cables shall be #22, shielded, 600V, PLTC, 75 C minimum violet
PVC cable with red and green solid copper conductors. Use green for signal A
and red for signal B. 100 percent coverage aluminum foil-polyester tape shield
(static and magnetic shielding) plus a tinned copper braid shield (65% coverage)
shall be used. Use Belden model 3079A or equal cable.
Engineering and Construction Specifications
Division 17 - Instrumentation
Title: Instrumentation Electrical Installation
Revision: 5
2.06
2.07
Document #: CS17002
Revision Date: 10/01/2015
Page: 6 of 21
Effective Date: 11/04/2015
DEVICENET
A.
Devicenet trunk and drop cables used for motor control shall be Class I thick
cable, 2 pair, shielded, 600V, TC, with a gray PVC jacket. One pair shall be used
for power and shall be #16, shielded with red and black conductors. Red shall be
positive and black negative. The data pair shall be #18, shielded with white and
blue conductors. White shall be CAN-H and blue CAN-L. Use Belden model
#7896A or Site approved equal.
B.
Devicenet trunk cables used for field networks shall be Class 2 thick cable, 2 pair,
shielded, 300V, TC, with a yellow CPE jacket. One pair shall be used for power
and shall be #15, shielded with red and black conductors. Red shall be positive
and black negative. The data pair shall be #18, shielded with white and blue
conductors. White shall be CAN-H and blue CAN-L. Use Belden model #3082A
or Site approved equal.
C.
Devicenet drop cables used for field networks shall be Class 2 thin cable, 2 pair,
shielded, 300V, TC, with a gray PVC jacket. One pair shall be used for power and
shall be #22, shielded with red and black conductors. Red shall be positive and
black negative. The data pair shall be #24, shielded with white and blue
conductors. White shall be CAN-H and blue CAN-L. Use Belden model #3085A
or Site approved equal.
ETHERNET
A.
Use Commscope model 5ES4 or Site approved equal four pair, twisted, shielded
cable for the Cat 5e cables on the Delta V network. Use a light blue and black
color jacket for the primary and secondary networks respectively.
B.
Use multi-mode 62.5/125 micron fiber-optic cable for the fiber runs on the Delta V
network. Install six fiber cables in all main runs between Delta V cabinet locations.
C.
Use RJ45 plastic or metal enclosed connectors for the Delta V connections per the
following.
1.
Controller to Switch – Straight through with metal enclosed grounded
connectors on both ends.
2.
Workstation to Switch – Straight through with a metal enclosed grounded
connector on the switch and isolated, plastic enclosed connector on the
workstation.
3.
Switch to Switch – Can use cross-over cable but stay with straight through
cable for standardization because auto sensing ports on switch correct for
this issue. Use a metal enclosed grounded connector on the fiber/CAT5
switch and an isolated, plastic enclosed connector on the CAT5 only switch.
Engineering and Construction Specifications
Division 17 - Instrumentation
Title: Instrumentation Electrical Installation
Revision: 5
4.
2.08
Page: 7 of 21
Effective Date: 11/04/2015
Wall Plates – Metal enclosed grounded female connector and metal
enclosed grounded male connector plugged in to wall plate; other end of
cable plastic or metal depending on device to which it connects (see above).
FIBER OPTIC CABLE
A.
Fiber optic SMA/SMA NIR 600 um patchcord
1.
2.
3.
2.09
Document #: CS17002
Revision Date: 10/01/2015
FiberTech Optica Ultra low OH fiber: part # AS600/660IRPIT or equivalent
a.
Pure silica core: 600 um +/- 2%
b.
Fluorine doped silica clad: 660 um +/- 2%
c.
Polyimide coating: 690 um +/- 3%
d.
Nylon jacket: 1000 um +/- 5%
e.
Numerical aperture: 0.22 +/- 0.02
f.
Operating wavelength: 350 to 2400 um
g.
Temperature resistance: -40 C to + 150 C
h.
Attenuation @ 1385 nm: < 12.55 dB/km
i.
OH content @ 1385 nm: < 0.2 ppm
Terminations:
a.
Standard SMA-905 connector on both ends reinforced with metal
sleeve
b.
Sleeve dimension: 40 mm long x 7 mm OD
c.
The stainless steel sleeve is installed in order to release the pressure
over the connector during the pulling process.
Sheathing: Black PVC-furcation tube, 3.8 mm OD
POWER AND DISCRETE SIGNAL WIRING
A.
Use individual conductors in conduit.
B.
Wire size #14 to #10 shall be stranded type THHN/THWN.
Engineering and Construction Specifications
Division 17 - Instrumentation
Title: Instrumentation Electrical Installation
Revision: 5
Document #: CS17002
Revision Date: 10/01/2015
Page: 8 of 21
Effective Date: 11/04/2015
C.
Wire size #18 and #16 shall be stranded type TFFN.
D.
Single conductors shall conform to the following color code (for striped wires,
several pieces of tape at both ends colored the same color as the stripe can be
used to replace the stripes):
1.
12 and 24VDC bussed field power from DCS cabinet to field instruments
where polarity is an issue:
Blue = Positive (+)
Blue with White Stripe = Negative (-)
2.
120VAC bussed field power from DCS cabinet to field instruments:
Black = Line (L)
White = Neutral (N)
3.
24VDC discrete signals circuits:
Input:
Blue = Line Fused Supply
Blue with Black Stripe = Switched Hot from Device
Output:
Blue = Output to Device
Blue with White Stripe = Return
4.
120VAC discrete signal circuits:
Input:
Red = Line Fused Supply
Red with Black Stripe = Switched Return
Output:
Red = Output to Device
White = Neutral
Engineering and Construction Specifications
Division 17 - Instrumentation
Title: Instrumentation Electrical Installation
Revision: 5
Document #: CS17002
Revision Date: 10/01/2015
Page: 9 of 21
Effective Date: 11/04/2015
5.
Discrete Valve Control Wiring, On-Off and 3-way, 120VAC (preferred):
Red = switched hot to solenoid
White = neutral to solenoid
Black = hot to confirm switches
Yellow = confirm close, 3-way position A, cam farthest from the valve
Orange = confirm open, 3-way position B, cam nearest to the valve
6.
Discrete Valve Control Wiring, On-Off and 3-way, 24VDC:
Blue = Output to solenoid
Blue with White Stripe = Return from solenoid
Black = hot to confirm switches
Yellow = confirm close, 3-way position A, cam farthest from the valve
Orange = confirm open, 3-way position B, cam nearest to the valve
7.
Motor Control
Three Wire Control
Red = hot to stop button
Black = terminal 2 of holding coil
Blue = terminal 3 of holding coil
Green = switch casing ground*
Two Wire Control
Red = hot to switch
Blue = return from switch
Green = switch casing ground*
* Not required if phase conductors and control wires are in the same conduit
and the switch casing ground is wired to the motor ground.
DCS Motor Control IO Wiring
Black = 1 to DCS stop (HS) (1 is short for MCC terminal 1)
Red = DCS stop (HS) to 1A
Black with red stripe = 2 to DCS start (HR)
Blue = DCS start (HR) to 3
Yellow = 4 (or auxiliary contact terminal) to DCS run confirm (HI)
White = DCS run confirm (HI) to X2*
* When using As-i control the run feedback is a dry contact wired to the As-i
module. In this case use an orange wire not a white wire connected to X2.
E.
Cables installed in cable tray shall conform to the following specifications:
1.
DC Power
2/C #16 AWG, unshielded, stranded, copper conductors, tinned with red and
black conductors, PLTC, 300V, 80 C grey PVC jacket. Use red for positive
and black for negative. Use Belden 9410 or equal.
Engineering and Construction Specifications
Division 17 - Instrumentation
Title: Instrumentation Electrical Installation
Revision: 5
2.
Document #: CS17002
Revision Date: 10/01/2015
Page: 10 of 21
Effective Date: 11/04/2015
DC 2-wire Devices
2/C #22 AWG, unshielded, stranded, copper conductors, tinned with red and
black conductors, PLTC, 300V, 80 C chrome PVC jacket. Use red for
positive and black for negative. Use Belden 9407 or equal.
3.
12 or 24Vdc Powered Discrete Devices
3/C #22 AWG, unshielded, stranded, copper conductors, tinned with red,
black and white conductors, PLTC, 300V, 80 C chrome PVC jacket. Use red
for positive, black for negative and white for signal. Use Belden 9491 or
equal.
4.
120Vac Powered Devices
3/C #16 AWG, unshielded stranded, copper conductors, tinned with black,
white and red conductors, PLTC, 300V, 80 C chrome PVC jacket. Use black
for hot, white for neutral and tape the red wire green for ground. Use Belden
9494 or equal.
Note: If device is not protected by a 10 amp or less fuse, then use Belden
9495 for #14 wire if protected by a 15 amp breaker.
5.
120Vac Discrete Devices
2/C #16 AWG, unshielded stranded, copper conductors, tinned with red and
black conductors, PLTC, 300V, 80 C chrome PVC jacket. Use black for hot
and red for neutral or input. Use Belden 9410 or equal.
6.
120Vac Powered Switches
4/C #16 AWG, unshielded stranded, copper conductors, tinned with black,
red, blue and orange conductors, TC, 600V, 75 C black PVC jacket. Use
black for hot, red for signal, tape the orange wire white for neutral and tape
the blue wire green for ground. Use Belden 27338A or equal.
Engineering and Construction Specifications
Division 17 - Instrumentation
Title: Instrumentation Electrical Installation
Revision: 5
7.
Document #: CS17002
Revision Date: 10/01/2015
Page: 11 of 21
Effective Date: 11/04/2015
Discrete Valve Control Wiring, On-Off and 3-way, 120VAC
6/C #18 AWG, unshielded stranded, copper conductors, tinned with black,
red, blue, orange, yellow and brown conductors, TC, 600V, 75 C black PVC
jacket. Use Belden 27600A or equal with the following color code.
Red = switched hot to solenoid
Brown (Taped Green) = Ground
Blue (Taped White) = neutral to solenoid(s)
Black = hot to confirm switches
Yellow = confirm close, 3-way position A, cam farthest from the valve
Orange = confirm open, 3-way position B, cam nearest to the valve
8.
Discrete Valve Control Wiring, On-Off and 3-way, 24VDC:
6/C #18 AWG, unshielded stranded, copper conductors, tinned with black,
red, blue, orange, yellow and brown conductors, TC, 600V, 75 C black PVC
jacket. Use Belden 27600A or equal with the following color code.
Red = switched hot to solenoid
Brown (Taped Green) = Ground
Blue = negative to solenoid(s)
Black = hot to confirm switches
Yellow = confirm close, 3-way position A, cam farthest from the valve
Orange = confirm open, 3-way position B, cam nearest to the valve
9.
Discrete Valve Control Wiring, On-Off and 3-way, Dual Solenoid, 120VAC
7/C #18 AWG, unshielded stranded, copper conductors, tinned with black,
red, blue, orange, yellow, brown and red/black conductors, TC, 600V, 75 C
black PVC jacket. Use Belden 27327A or equal with the following color
code.
Red = switched hot to solenoid #1
Red with Black Stripe = switched hot to solenoid #2
Brown (Taped Green) = Ground
Blue (Taped White) = neutral to solenoid(s)
Black = hot to confirm switches
Yellow = confirm close, 3-way position A, cam farthest from the valve
Orange = confirm open, 3-way position B, cam nearest to the valve
Engineering and Construction Specifications
Division 17 - Instrumentation
Title: Instrumentation Electrical Installation
Revision: 5
10.
Document #: CS17002
Revision Date: 10/01/2015
Page: 12 of 21
Effective Date: 11/04/2015
Discrete Valve Control Wiring, On-Off and 3-way, Dual Solenoid, 24VDC:
7/C #18 AWG, unshielded stranded, copper conductors, tinned with black,
red, blue, orange, yellow, brown and red/black conductors, TC, 600V, 75 C
black PVC jacket. Use Belden 27327A or equal with the following color
code.
Red = switched hot to solenoid #1
Red with Black Stripe = switched hot to solenoid #2
Brown (Taped Green) = Ground
Blue = negative to solenoid(s)
Black = hot to confirm switches
Yellow = confirm close, 3-way position A, cam farthest from the valve
Orange = confirm open, 3-way position B, cam nearest to the valve
11.
120Vac Motor Control – 3-wire
4/C #18 AWG, unshielded stranded, copper conductors, tinned with black,
red, blue and orange conductors, TC, 600V, 75 C black PVC jacket. Use
Belden 27326A or equal with the following color code.
Red = hot to stop button
Black = terminal 2 of holding coil
Blue = terminal 3 of holding coil
Orange (Taped Green) = switch casing ground
12.
120Vac Motor Control – 2-wire
3/C #18 AWG, unshielded stranded, copper conductors, tinned with black,
red and blue conductors, TC, 600V, 75 C black PVC jacket. Use Belden
27334A or equal with the following color code.
Red = hot to switch
Blue = return from switch
Black (Taped Green) = switch casing ground
Engineering and Construction Specifications
Division 17 - Instrumentation
Title: Instrumentation Electrical Installation
Revision: 5
13.
Document #: CS17002
Revision Date: 10/01/2015
Page: 13 of 21
Effective Date: 11/04/2015
DCS Motor Control
7/C #18 AWG, unshielded stranded, copper conductors, tinned with black,
red, blue, orange, yellow, brown and red/black conductors, TC, 600V, 75 C
black PVC jacket. Use Belden 27600A or equal with the following color
code.
Black = 1 to DCS stop (HS) (1 is short for MCC terminal 1)
Red = DCS stop (HS) to 1A
Brown = 2 to DCS start (HR)
Blue = DCS start (HR) to 3
Yellow = 4 (or auxiliary contact terminal) to DCS run confirm (HI)
Orange (Taped White) = DCS run confirm (HI) to X2*
Red with Black Stripe (Taped Green) = Ground
* When using As-i control the run feedback is a dry contact wired to the As-i
module. In this case use the orange wire color and do not tape it white.
PART 3 - EXECUTION
3.01
GENERAL
A.
Provide supervision and labor that has been qualified by training and experience to
perform the activities.
B.
Ensure the physical mounting of an instrument is complete, prior to terminating
conduit and wiring at the instrument.
C.
Refer to Division 16, Electrical Specifications for installation methods not listed
below.
D.
During construction, wire pulls through conduit should be planned to be completed
by the end of the contiguous working shifts. If a wire pull cannot be completed, the
coiled wire must have an orange tag attached with the following information
completed on the tag:
CONSTRUCTION IN PROGRESS
NAME: _________________
COMPANY NAME: _________________
DATE: __________________
PROJECT/WORK ORDER#: _____________________
THESE WIRES ARE NOT POWERED (INITIALS): ____________
The DATE entry is the first day the wire is left coiled up. Exception 1 below *
applies.
Engineering and Construction Specifications
Division 17 - Instrumentation
Title: Instrumentation Electrical Installation
Revision: 5
Document #: CS17002
Revision Date: 10/01/2015
Page: 14 of 21
Effective Date: 11/04/2015
If the coiled wire cannot be completely placed in conduit within three days, the
coiled wire must be placed in an enclosure connected to the end of the conduit,
with the CONSTRUCTION IN PROGRESS tag attached to the wire.
Wires run to MCC or DCS IO cabinets shall be landed immediately if the electrical
hardware is installed. If not landed before the end of the shift, attach a
CONSTRUCTION IN PROGRESS tag to the wire or bundle of wires. Exception 1
below * applies.
The CONSTRUCTION IN PROGRESS tag (and enclosure) should be removed
only after the wires are landed on both ends. If a different work crew completes a
wire pull, they should coordinate with the crew that left the CONSTRUCTION IN
PROGRESS tag (and enclosure) before completing the wire pull.
No power shall be applied to any wires until the installation of the wire and conduit
is complete.
*Exception 1. If construction is in a building or area that is shut down, these
temporary measures are not required. Once the building or area is started up,
these temporary measures must be implemented.
3.02
INSTRUMENT WIRING
A.
All Site and NEC color codes must be used unless written authorization to deviate
from these codes is obtained from the Work Sponsor.
B.
The use of wire nuts is not permitted for instrument signal wiring. Soldered splices
can be used with the written approval of the Work Sponsor.
C.
Use spade lugs under screwed terminals where pressure plates are not furnished.
D.
Do not run D.C. wiring in common conduit with A.C. wiring.
E.
Ground shields only at one end of the cable, preferably at the signal source.
F.
Cross analog signal circuits at right angles to AC circuits or D.C. inductive circuits.
G.
Label each end of wires and cable. These markers are to have printed wire and
cable numbers as shown on drawings.
H.
Install bus networks per drawings paying particular attention to lengths. Inform
Work Sponsor if cable length is longer than what the drawing specifies. Red-line
the drawings with the installed cable length.
Engineering and Construction Specifications
Division 17 - Instrumentation
Title: Instrumentation Electrical Installation
Revision: 5
I.
3.03
Document #: CS17002
Revision Date: 10/01/2015
Page: 15 of 21
Effective Date: 11/04/2015
Separate raceway systems shall be provided and run for the following types of
instrument wiring.
1.
120 VAC Power and Signals
2.
Analog, 24Vdc Power and Signals, Networks (AS-I, Foundation Fieldbus,
Profibus, etc.)
3.
Low Level (Load Cells, ph sensors, etc.)
4.
Intrinsically Safe Signals
5.
Communication Cables (Ethernet, Serial, RS3 Peerway, etc.)
6.
SIS systems as documented in G-P-EI 201 M
7.
EPA Regulated Systems as documented in Kankakee EHS list 6.01.01, Air
Pollution Control Devices and Responsibilities.
J.
Instrument signals from field devices shall be grouped by type and routed to their
respective destinations. Refer to wiring diagrams and I/O schematics for point-topoint wire terminations and for wire tagging information.
K.
Main conduit runs to an area, a junction box or local panel shall be sized for at
least 15% spare cables or wires, and it is preferred to add all spare wires to main
conduits during initial installation to avoid future risk to operations when pulling
new wire through conduits that contain live instrument wires. If spare wires are not
installed initially, future installation may require new conduit. The project manager
or work sponsor (any party responsible for the installation) will determine if spare
cables or wires are actually installed and, if they are, the required quantity. If
installed these cables and wires shall be labeled at both ends with the location of
the other end followed by SP and the spare number. The cables and wires shall
be long enough at both ends to reach the furthest terminal.
BUS NETWORKS
A.
General
1.
Install bus networks as shown on the drawings.
2.
Do not exceed cable lengths shown on drawings without authorization from
the Work Sponsor.
3.
Do not substitute bus network connectivity components without authorization
from the Work Sponsor.
4.
Locate bus network local junction boxes as shown on the location plans and
as close as possible to the connected devices.
Engineering and Construction Specifications
Division 17 - Instrumentation
Title: Instrumentation Electrical Installation
Revision: 5
5.
B.
C.
D.
E.
Document #: CS17002
Revision Date: 10/01/2015
Page: 16 of 21
Effective Date: 11/04/2015
Do not move devices or add additional devices to a network without
authorization from the Work Sponsor.
Foundation Fieldbus
1.
Foundation Fieldbus networks require a terminator at each end.
2.
If the cable lengths exceed what is shown on the drawing notify the Site Area
Representative. Typically cable lengths are not an issue with this type of
network.
3.
Cut and tape shields at the field devices.
AS-i
1.
Cable lengths are critical with this type of network. If the total cable length
on a given segment exceeds what is shown on the drawing notify the Work
Sponsor.
2.
Each AS-i segment must not exceed more than 100 meters of total cable
length.
3.
When mounting AS-I components in a panel or junction box be aware of the
maximum temperature rating and allow spacing between components for
heat dissipation.
Profibus DP
1.
Profibus networks require a terminator at each end.
2.
All devices on a network must be set for the same baud rate as indicated on
the drawings.
Devicenet
1.
All devices on a network must be set for the same baud rate as indicated on
the drawings.
2.
Use the cable shown on the drawings.
3.
Each Devicenet network requires a terminating resistor at each end.
4.
The maximum drop length must not exceed 20 feet.
Engineering and Construction Specifications
Division 17 - Instrumentation
Title: Instrumentation Electrical Installation
Revision: 5
3.04
3.05
Document #: CS17002
Revision Date: 10/01/2015
Page: 17 of 21
Effective Date: 11/04/2015
5.
If flat cable with insulation displacement connectors is used do not remove a
connector once it is placed on the cable. If the device is moved install a new
connector on the cable at the new location.
6.
Do not re-use insulation displacement connectors.
PANELS AND JUNCTION BOXES
A.
The contractor shall devise and provide stands, brackets, or other supports as
necessary to securely mount panels and junction boxes. Acceptable designs are
available from your Work Sponsor.
B.
Panels must be stored, handled, moved, and installed in an upright position.
C.
Anchor self supporting freestanding enclosed panels in place with anchor bolts.
D.
Conduits to all panels or junction boxes shall be supported independent of the
panel or junction box.
E.
Do not support panels and junction boxes from equipment without prior written
approval of the Work Sponsor.
F.
No panels or junction boxes may protrude into walkways or aisle ways.
G.
Install small wall mounted panels and junction boxes so that their centerlines are
approximately 5’-3” from the floor. The top of the panel or junction box should not
exceed 6’-6”.
H.
Install panels to provide adequate clearance to conform to the requirements of the
National Electric Code.
I.
Clean welded joints between supports and structural steel and paint per Site
Finished Paint specification.
J.
Paint supports per Site Finished Paint specification.
CONDUIT
A.
Wherever a seal-off is to be poured, install an explosion proof union between the
seal off and the device to permit later removal of the device for maintenance.
B.
Use watertight hubs for conduits entering enclosures mounted outside or in wash
down areas.
C.
To prevent water from entering instruments and panels mounted outdoors or in
hose down areas, conduits should run up to device and/or should enter through
Engineering and Construction Specifications
Division 17 - Instrumentation
Title: Instrumentation Electrical Installation
Revision: 5
Document #: CS17002
Revision Date: 10/01/2015
Page: 18 of 21
Effective Date: 11/04/2015
the side or bottom. Install low point combination drains and breather in conduit
runs (Crouse-Hinds ECD18 or equal).
3.06
3.07
D.
Do not support devices and conduit from equipment without prior written approval
of the Work Sponsor.
E.
For instruments requiring removal for testing or calibration, provide a sufficient
length of flexible conduit at the instrument no longer than 30” and within the limits
of the National Electric Code to allow removal of the instrument without the need to
dismantle the conduit system.
F.
EPA Regulated Systems should be in accordance with 3.02 Section I. No new
wire shall be pulled through existing conduit going to an EPA regulated system.
G.
Refer to Site specification CS16111 for additional information regarding conduit
materials and NEC code adherence for installation.
H.
Prior to pulling new instrument wires through existing conduit (cannot be done on
conduit going to EPA regulated systems), the integrity of the conduit and contained
wiring should be evaluated. The project engineer or work sponsor should be
consulted if there is risk that pulling new wire could affect the integrity of existing
wire. Condition of the conduit and existing wiring, how full the conduit is and will
be after pulling the new wire, and the length and difficulty of the new pull should be
considered. If the risk is evaluated to be unacceptable, new conduit should be
installed.
INTRINSICALLY SAFE WIRING
A.
Make installation of intrinsically safe wiring in accordance with ISA Recommended
Practice RP12.6 latest edition.
B.
Wireways and conduit carrying intrinsically safe wiring will be color-coded blue at
each end and at intervals not exceeding 6 feet.
C.
Intrinsically safe and non-intrinsically safe wiring will not be run in the same
conduit.
D.
Intrinsically safe and non-intrinsically safe wiring will be at least two inches apart or
separated by a grounded metal barrier within cable tray, wireway or enclosures.
FIBER OPTIC CABLE
A.
Refer to the manufacturer’s literature to obtain the minimum bend radius and
maximum tensile loading before installing fiber optic cable.
Engineering and Construction Specifications
Division 17 - Instrumentation
Title: Instrumentation Electrical Installation
Revision: 5
3.08
Document #: CS17002
Revision Date: 10/01/2015
Page: 19 of 21
Effective Date: 11/04/2015
B.
Conduits should be routed and pull boxes installed to stay within the limits of the
cable.
C.
When pulling the fiber optic cable through conduit, it is important to ensure that a
basket weave type grip of the correct size is used. To install the grip, the cable is
fed through the basket weave portion of the grip, the sheath is removed, and the
Kevlar yarns are separated from the other components of the cable. The
remaining portions are cut back, and the yarns are tied off with a series of half
hitches to the small eye inside of the basket weave. The grip is then covered with
plastic tape from about six inches behind the basket weave to the free end of the
grip so that the lays of tape overlap. The pull can begin after a swivel is attached
between the pull line and the grip. The swivel is important because fiber optic
cable is very light and the stranding of the pull line can induce a twist in the cable if
the two are directly coupled under tension.
D.
If a pull is going to require lubrication, a suitable water based lubricant must be
used.
TESTING AND CALIBRATION
A.
Handle instruments with care to prevent loss of calibration.
B.
Refer to Site Engineering and Construction Specification CS17010 Instrumentation
Checking Procedures for additional information.
C.
Conventional wire and cable required functional testing and operational checks.
D.
1.
Check continuity and terminations.
2.
Check that all shields are only grounded at one location.
3.
Check bus networks for terminating resistors when required.
4.
Verify bus networks are within length and current limitations.
Fiber Optic Cable
1.
Perform end-to-end attenuation testing on each segment of fiber optic cable.
Use wavelengths of 850 and 1300 nanometers for this test.
2.
Perform OTDR (Optical Time Domain Reflectometer) testing on all cables
before and after installation. Also test all splices and connectors. Use a
high resolution OTDR for this testing.
3.
Measure and record each transmitters output and the power levels at each
receiver.
Engineering and Construction Specifications
Division 17 - Instrumentation
Title: Instrumentation Electrical Installation
Revision: 5
4.
Document #: CS17002
Revision Date: 10/01/2015
Page: 20 of 21
Effective Date: 11/04/2015
Document the results of all testing and turn over to the Work sponsor upon
completion.
Engineering and Construction Specifications
Division 17 - Instrumentation
Title: Instrumentation Electrical Installation
Revision: 5
Document #: CS17002
Revision Date: 10/01/2015
Page: 21 of 21
Effective Date: 11/04/2015
Revision History
Revision
Date
Page
Description
0
07/19/10
All
Original
J. Shute
1
02/08/13
All
Updated BASF Header. Reviewed, no changes
made to content.
J. Shute
2
01/30/14
7
Add Fiber Optic Cable section in Part 2
J. Shute
3
04/17/14
7
Add cabling details for wall plates
J. Shute
4
09/22/15
15,18
5
11/04/15 15, 18
EPA Regulated Systems and Clarification of Best
Practices Per NEC Code, Site Area
Representative changed to Work Sponsor
Clarify practices regarding conduit wire pulls and
EPA Regulated Systems
Initiator
R. Arias
R. Arias
Approvals
Prepared By: _____________________________________ Date: __________________
Process Control Engineer
Approved By: _____________________________________ Date: __________________
TES Manager