PDVSA

ENGINEERING DESIGN MANUAL

VOLUME 9II ENGINEERING SPECIFICATION

PDVSA N

TITLE

K334

INSTRUMENTATION ELECTRICAL REQUIREMENTS

1 0
REV.

JUN.02 AUG.94
DATE

GENERAL REVISION FOR APPROVAL

DESCRIPTION DATE

24 38

N.L. L.T.

Y.K. E.J.
APPD. DATE

R.R. A.N.
APPD.

PAG. REV.

APPD.BY Youhad Kerbaje

JUN.02 APPD.BY Ral Rivero

JUN.02

E PDVSA, 1983

ESPECIALISTAS

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Index
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 1.2 2.0 2.2 2.3 Purpose (Modify) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Petrleos de Venezuela PDVSA (Addition) . . . . . . . . . . . . . . . . . . . . . . . . . Industries Codes and Standards (Modify) . . . . . . . . . . . . . . . . . . . . . . . . . . Government Regulation (Modify) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2
2 2

2 REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2
2 3 4

3 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ENVIRONMENTAL CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . 6 INSTRUMENT SIGNAL COMPATIBILITY . . . . . . . . . . . . . . . . . . . . . . 7 WIRE AND CABLE SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1 7.2 7.3 7.4 7.5 8.1 8.2 9.1 9.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Segregation / Separation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cable Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conduit Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Milliamp Signals Typically 4 20 mA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Branch Circuits Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 5 7 7 8
8 8 10 11 12

8 TERMINATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13
13 13

9 INSTRUMENT POWER SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13
13 14

10 GROUNDING AND SURGE PROTECTION (MODIFY) . . . . . . . . . . . 11 INTRINSICALLY SAFE INSTRUMENT SYSTEMS . . . . . . . . . . . . . . 12 NONINCENDIVE SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 CONTROL PANEL AND CABINET WIRING . . . . . . . . . . . . . . . . . . . . 14 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 DATA LINKS AND FIELDBUSES (MODIFY) . . . . . . . . . . . . . . . . . . . . 16 QUALITY ASSURANCE / QUALITY CONTROL (ADDITION) . . . . .

14 15 16 16 16 16 17

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INTRODUCTION
1.1 Purpose (Modify)
The purpose of this document is to provide criteria for the design, specification, installation and commissioning of electrical systems for instrumentation. Guidelines of PDVSA K300, Instrumentation Introduction shall also be explicitly followed. Since PDVSA has decided to adopt the Process Industries Practices (PIP) document PCCEL001 Instrumentation Electrical Requirements as an integral part of the Engineering Design Manual (MID), the requirements in this document are additions or modifications to PCCEL001. The section/paragraph numbers and the associated headings used in this document correspond to the ones used in PCCEL001. The previous version of this document was titled Instrumentation and Thermocouple Extension Cables The present version includes and extends the scope of the previous version.

1.2

Scope
(Modify) This Document provides criteria for equipment and accessory selection, design, and installation of electrical supply, grounding and wiring to support process measurement and control systems. Electrical requirements for telecommunication systems are not within the scope of this Practice.

REFERENCES
(Modify) Applicable requirements in the latest editions of the PDVSA documents listed below shall be considered as an integral part of this Practice. Other industry codes and standards listed below shall be used as reference unless otherwise indicated within this document.

2.0

Petrleos de Venezuela PDVSA (Addition)

IRC02 IRC03 IRI01 IRI02 EM2411/01 K300 K301 Diseo de Edificios de Control Revestimiento Contra Incendio Sistemas de Deteccin y Alarma de Incendio Sistemas de Deteccin de Gases Txicos / Inflamables Cajas y Accesorios para Instalaciones Elctricas de uso en Lugares (Clasificados) Peligrosos Instrumentation Introduction Pressure Instrumentation

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K302 K303 K304 K307 K308 K309 K329 K330 K331 K336 K361 K362 N201 N241 N252 N253 N261 N262 SIS01 SIS13 90619.1.055 90619.1.081 90619.1.086 90619.1.101 90620.1.118 90620.1.124 90622.1.001

Flow Instrumentation Level Instrumentation Temperature Measurement Criteria Electronic and Pneumatic Instrumentation Distributed Control Systems SCADA Systems Instrument Junction Boxes Specification Control Panels and Consoles Instrument Power Supply Safety Instrumented Systems Control Rooms Control Networks Obras Elctricas Instalacin de Conductores y Cables en Tuberas y Bandejas. General Specification for Electrical Engineering Design. Technical Specifications for Uninterruptible Power Systems. 600 V Power and Control Tray Cable and Metal Clad Cable (PIP ELSWC03). 300 V Instrumentation Tray Cable (PIP ELSWC05). Gerencia de Seguridad de los Procesos (GSP) Lineamientos Corporativos. Normativa Legal en Seguridad, Higiene y Ambiente (SHA) Equipo UPS. Lista de cables y Tuberas Conduit. Requerimientos para Sistemas de Bandejas. Seleccin e Instalacin de Equipos Elctricos y Electrnicos en Lugares Clasificados. Safety Instrumented System Guidelines Instrumentation Electrical Requirements Guidelines Guas de Seguridad en Diseo.

2.2

Industries Codes and Standards (Modify)

S International Electrotechnical Commission (Add) IEC 60331 Tests for Electrical Cables under Fire Conditions Circuit Integrity (Modify) IEEE 1100, 1999 or later Recommended Practice for Powering and Grounding Electronic Equipment, The Emerald Book

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(Add) IEEE 383 Standard for Type Test of Class IE Electric Cables, Field Splices and Connections for Nuclear Power Generating Stations. S The Instrumentation, Systems and Automation Society ISA (Modify) ISA S12.01.01, 1999 Definitions and Information Pertaining to Electrical Apparatus in Hazardous (Classified) Locations. (Add) ISA S12.16.011998 Electrical Apparatus for Use in Class I, Zone 1 Hazardous (Classified) Locations. Type of Protection Increased Safety

2.3

Government Regulation (Modify)

Venezuelan government laws, decrees, regulations and instructions pertaining to Safety, Health and Environment shall apply. For a list of applicable regulations, refer to PDVSA SIS13 Normativa Legal en Seguridad, Higiene y Ambiente.

DEFINITIONS
(Modify) AC Safety Ground: The grounding system required by NEC Article 250 to provide protection for personnel and electrical equipment. The Signal Reference System is connected to the Safety Ground per the NEC requirements and IEEE 1100, 1999 recommendations. See also Equipment Grounding Conductor. (Add) Electrical/Instrumentation Interface Box or Panel: An interface box or cabinet (see Junction Box), which houses the equipment and accessories necessary to physically separate the instrumentation system signal wiring from the electrical control system signal wiring corresponding to signals for monitoring and control of electrical equipment. (Add) Equipment Grounding Conductor (EGC): The conductor(s) used to connect the noncurrentcarrying parts of conduits, raceways and equipment enclosures to the AC Safety Ground. The EGC insulation cover is green colored. (Add) Fieldbus: A digital, twoway, multidrop communication link among intelligent measurement and control devices. It serves as a Local Area Network (LAN) for advanced process control, remote input/output and high speed factory automation applications. (Add) Ground Grid: A system of interconnected bare conductors arranged in a pattern over a specified area on, or buried below, the surface of the earth. Normally, it is bonded to ground rods driven around and within the perimeter to increase its grounding capabilities and provide convenient connection points for grounding devices. The primary purpose of the ground grid is to provide safety for workmen by limiting potential differences within its perimeter to safe levels in case of high currents that could flow if the circuit being worked on became energized for any reason, or if an adjacent energized circuit faulted. Metallic surface mats and gratings are sometimes utilized for this same purpose. It is sometimes also

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referred to as the Plant Grid. Note: This term should not be used when referring to a signal reference structure, which is defined below. (Add) Intrinsic Safety: Approved method of protection in hazardous (classified) areas based on the principle of energy limitation. An intrinsically safe circuit restricts the electrical energy available in the hazardous (classified) area such that any sparks or hot surfaces that may occur during normal operation or as a result of electrical faults are too weak to cause ignition of the gases or vapors that may be present. Intrinsically safe circuits may be installed in all classified locations. (Delete) Instrument Ground Bus (IGB): The Instrument Ground Bus, or single point ground is not an acceptable grounding method. See Signal Reference Structure (Add) Nonincendive: Approved method of protection in hazardous (classified) locations based on the principle of energy limitation. A nonincendive circuit restricts the electrical energy available in the hazardous (classified) area such that any sparks or hot surfaces that may occur during normal operation are too weak to cause ignition of the gases or vapors that may be present. Nonincendive circuits do not maintain their certified protection during electrical faults. Therefore, they are certified to be installed only in Class I and II, Division 2 and Class III, Divisions 1 and 2 hazardous locations.. (Add) Plant Grid: see Ground Grid. (Add) Signal Reference Structure (SRS): A system of conductive paths among interconnected equipment that reduces noise induced voltages to levels that minimize improper operation. Common configurations include Signal Reference Grids (SRG), and Signal Reference Planes (SRP). As per IEEE 1100, 1999. (Add) Signal Reference Ground Grid (SRGG or SRG): A possible realization of the SRS implemented by means of a crosshatching of bonded flat ground conductors where the size of the crosshatchings is chosen to approximate the behaviour of an ideal SRP in the frequencies of interest (typically from DC to tens of MegaHertz). (Add) Surge Protection Device (SPD): A device that is intended to limit transient over voltages and divert surge currents to ground. It contains at least one nonlinear component. (Add) Uninterruptible Battery System (UBS) A power supply for DC loads, where the load is permanently supplied from the batteries. A UBS is typically a rectifier with batteries to provide direct current (DC) to instrumentation loads

GENERAL
4.1
(Add) The method of protection to be used, i.e., intrinsic safety, explosionproof, nonincendive, etc., shall be defined in specific project design guidelines.

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4.2

(Modify): All techniques used to comply with electrical area classification requirements shall comply with PDVSA 90619.1.101. Protection techniques are those listed in NEC article 5004: S S S S S S Explosion Proof, for areas Class I, Divisions 1 and 2. Dust ignition proof, for areas Class II, Divisions 1 and 2 Dust tight, for areas Class II, Division 2 and Class II, Divisions 1 and 2. Intrinsic Safety, for all classes and divisions Nonincendive for areas Class I and II, Div 2 and Class III, divisions 1 and 2. Other protection techniques: oil immersion, hermetically sealed, purged and pressurized, etc. require Owner approval.

4.3

(Modify) Equipment and enclosures that require purging to comply with area class requirements shall be purged in accordance with NFPA 496 and following the recommendations of ISA RP12.4. Use of purging to reduce area classification shall require PDVSA approval. For environmental purges, see Section 5.4. (Modify) Instruments shall not be installed in Zone 0, Zone 1, or Division 1 areas unless approved by PDVSA. See PDVSA 90619.1.101 for area classification and equipment selection guidelines. (Modify) All electrical equipment including instrumentation shall be designed and installed in accordance with NEC, OSHA 1910 Subpart S and IEEE 1100, 1999 (Modify) Control building cabinets and consoles shall be designed so that at design completion there are a minimum of 20% installed and connected spare I/Os as well as space to accommodate a minimum of 20% additional equipment. This installed spare capacity and additional space shall be proportionately distributed among the different types of I/O and processor modules. For control building cabinet and console fabrication requirements, refer to PDVSA K330. (Modify).Cable tray from the process area into the control room and instrument buildings shall be sized as per NEC 318 including a minimum of 20% future additions. (Add) Percent occupancy for conduits shall be as per NEC Chapter 9, Table 1. (Modify) Individual signal input/output circuits that are not current limited shall be protected by fuses.

4.4

4.10

4.14.2

4.14.5

4.14.7 4.15

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4.16

(Add) Individual signal input/output circuits shall be connected to field in marshalling panel terminal boards with terminal strips or stacked snapin singletiered terminal blocks with captive screws or pressure type connectors. Terminal blocks may be either standard type or disconnecting type, depending on specific project requirements. If par. 4.15 applies, disconnecting terminals shall be of the fused type. Wiring terminations shall be adequate to guarantee electrical continuity in the presence of shock and vibration. (Add) Control room cabinets, consoles and field junction boxes of Safety Instrumented Systems shall be dedicated to SIS circuits. For additional requirements, refer to PDVSA K336 and PDVSA 90620.1.118. (Add) Signal input/output circuits shall be segregated by signal type: Discrete, analog, pulse, etc. and by energy level: mV, 24 VDC, 125 VAC, 125 VDC, etc. Inside control or equipment rooms, either dedicated cabinets or clearly marked and separated terminal boards within cabinets shall be used. Field junction boxes shall be dedicated to only one type of signal. Exceptions require PDVSA approval.

4.17

4.18

4.19

(Add) Instrumentation signals dedicated to the remote control and monitoring of electrical equipment shall not be directly connected to the motor control cells. They will be routed to an interface box or panel located in the motor control center. The function of this panel is to convert the low power level (24 VDC or logic) of instrumentation signals to the required power levels of electrical control (either 125 VDC or 120 VAC). This will be effected either through the use of interposing relays or electrooptic isolators for individually wired signals, or through the use of remote I/O modules dedicated to the control of electrical equipment. The interface equipment between electrical system SCADA and instrumentation system shall also be installed inside the electrical/instrumentation interface panel. See appendix A for a more detailed specification of the E/I interface panel.

ENVIRONMENTAL CONSIDERATIONS
5.3 5.4
(Add) Specific corrosive agents shall be specified. (Add) Purging for environmental purposes shall be effected through a standard instrument air supply setup: root valve, filter regulator (set at 0.2 to 0.4 bar 2.5 to 5 psi), and needle valve.

6
6.2

INSTRUMENT SIGNAL COMPATIBILITY

(Add) Digital communications between smart transmitters and control systems shall adhere to PDVSA K362 requirements and vendor recommendations.

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6.3 6.4 6.5

(Add) Other voltage levels shall require PDVSA approval. (Add) pulse train signals for specialty flow meters shall be applied in cases where uncertainty of measurement is an important issue. (Add) ONOFF signals from field sensors and actuators shall be 24 VDC. 120 VAC or 120 VDC for solenoid valves, relays and other electromechanical devices may be used only after PDVSA approval.

WIRE AND CABLE SYSTEMS

7.1
7.1.1

General
(Modify) The routing of cables from field junction boxes to the control room and instrument room in new plant areas may be in overhead cable trays, overhead conduits, directly buried armored cable or buried cables inside conduits. Specific method used shall be according to existing plant standards. Cables run aerially on poles shall require PDVSA approval. Cable routes should avoid fire hazardous areas (e.g. over pumps, under process air fans, etc.). Distances of cable routing to fire hazardous areas shall follow PDVSA N201, Sections 15 and 16. Underground routing shall be considered as per recommendations of PDVSA IRP01, Table 3. (Modify) For fire protection of instrument cable, refer to PDVSA IRC03, Section 7.8, or to PDVSA supplied procedure. (Add) Intrinsic safety wiring routed inside control rooms shall utilize dedicated conduits or enclosed metallic cable trays in order to guarantee segregation with other electrical circuits. (Modify) For Safety Instrumented Systems refer to PDVSA K336 and the design guidelines in PDVSA 90620.1.118. (Add) Entrance of cables to control room or field instrument rooms may be either through underground trenches or specially designed wall penetration cable or conduit frames. Design shall comply with watertightness, gas tightness, fire resistance, blast resistance, area classification and EMC requirements established in PDVSA IRC02 and specific project requirements.

7.1.2 7.1.3

7.1.5 7.1.7

7.2

Instrument Wiring
(Modify) All cables for general instrument use, both single pair and multiple wire, shall meet the requirements of PDVSA N261 and N262. All instrument wiring shall be listed for the specific application for which it is being used.

7.2.1 7.2.1.5

Wiring (Add) Spare circuits shall also be tagged and identified as such at both ends.

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7.2.1.6

In general, cables shall meet the design criteria listed below and shall be selected in accordance with Table 1. a. c. d. Single Pair Instrument Signal Cable with an Overall Shield (SPISCO) (Add) May also be used on some process fieldbus network wiring. Single Triad Instrument Signal Cable with an Overall Shield (STISCO) (Add) May also be used on some process fieldbus network wiring. MultiPair Instrument Signal Cable with an Overall Shield (MPISCO) (Add) May also be used on some process fieldbus network wiring with distance constrains. Type: (modify) The cable shall be multipair with individually twisted pairs and an overall shield. Each pair shall be 2 copper conductors, where wire gauge shall be selected based on voltage drop vs. distance calculations, with a minimum of 20 AWG (note 3 of Table 1). e. MultiPair Thermocouple Extension Cable, Individually Shielded with Overall Shield (MPTECI) Type: (Modify) The cable shall be multipair with individually twisted pairs and an overall shield. Each pair shall be 2 solid alloy, thermocouple extension wires per ISA MC96.1 with an individual shield. Each pair shall have an identifying number and shall be insulated from other pair shields. Conductor wire gauge shall be selected based on voltage drop vs. distance calculations, with a minimum of 20 AWG . . The individual wires and outer jackets shall be color coded per ANSI/ISA MC96.1. f. MultiPair Instrument Signal Cable Individually Shielded Pairs with Overall Shield (MPISCI) Application: (Modify) If required by Plant specifications, it shall be used also for highlevel analog (e.g., 4 20 mA DC, 1 5 VDC) or for lowvoltage digital (50 volts DC or less) signals used for instrumentation and control signal transmission. (Add) May also be used on some process fieldbus networks wiring. Type: (modify) The cable shall be multipair with individually twisted pairs and an overall shield. Each pair shall be 2 copper conductors with an individual shield insulated from other pairs shields. Conductor wire gauge shall be selected based on voltage drop vs. distance calculations, with a minimum of 20 AWG (note 3 of Table 1). g. Multi Triad Instrument Signal Cable with an Overall Shield (MTISCO) Type: (modify) the cable shall be individually twisted triads with an overall shield. Each triad shall be 3 copper conductors. Wire gauge shall be selected

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based on voltage drop vs. distance calculations, with a minimum of 20 AWG (note 3 of Table 1). h. MultiTriad Instrument Signal Cable Individually Shielded Triads with Overall Shield (MTISCI) (Add) May also be used on some process fieldbus networks wiring. Type: (modify) The cable shall be individually twisted triads with an overall shield. Each triad shall be 3 copper conductors with an individual shield insulated from other triads shields. Conductor wire gauge shall be selected based on voltage drop vs. distance calculations, with a minimum of 20 AWG (note 3 of Table 1). 7.2.1.7 (Add) All of the above cables described in 7.2.1.6 may be specified with metallic armour, for direct burial and/or installation in open (ladder type) cable trays in lieu of conduits or enclosed cable trays. For direct burial armor shall be continuous welded impervious corrugated aluminum. See PDVSA N261 and PDVSA N262. (Add) For intrinsic safety wiring, outer protective jacket shall be light blue in color. (Add) For intrinsic safety and nonincendive wiring, vendor shall certify the following electrical parameters: resistance, capacitance and inductance per unit length, and L/R ratio. (Add) For critical applications where fire resistant cables are specified, certification in compliance with IEC 60331 circuit integrity tests and IEEE 383 flame tests is required. (Add) For downhole applications, specially designed cables with longitudinal traction force protection shall be used. (Add) For burner or pilot igniter, flame rod detector wiring and other applications exposed to high temperature, specially designed cable with fireproof outer protective jacket shall be used. Circuit Impedance (Modify second paragraph) Where multiple devices are wired in series in a 4 20 mA loop, total circuit impedance shall be evaluated for proper operation. (Add) For process fieldbus networks, appropriate circuit impedance and voltage drop calculation shall be done for each particular fieldbus network requirement. 7.2.2.4 7.2.2.6 (Add) Comment: special applications may require more stringent voltage drop allowances, i.e., loading arm electrohydraulic systems. (Add) For intrinsically safe and nonincendive circuits, distributed parameters capacitance per unit length, inductance per unit length and L/R ratio are required

7.2.1.8 7.2.1.9

7.2.1.10

7.2.1.11 7.2.1.12

7.2.2 7.2.2.1

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for the calculations to ensure safety of the installation, as indicated in Chapters 11 and 12.

7.3
7.3.3

Segregation / Separation Requirements

(Add) Intrinsically safe systems and fire detection systems shall be segregated from other wiring and shall have dedicated junction boxes, cable trays / conduits and marshalling panels. (Add) Comment: Intrinsically safe circuits located inside non intrinsically safe cabinets must be clearly segregated and isolated by physical means such as grounded metal barriers. PDVSA approval is required.

7.3.5

(Add new paragraph) For Protective Systems (SIS, Fire and Gas), additional requirements are: a. b. All wiring between initiating contacts and individual protective systems shall be isolated from ground. Protective systems shall use dedicated junction boxes or barriers within junction boxes of the BPCS to clearly segregate wiring of the protective system. All wiring shall be clearly separated on a system by system basis. Where multiple sensors (voting) are used, sensor signals may be segregated to isolate failures. A ground fault detector system shall be provided for each protective system that will identify a faulted circuit while the system is in the normal operation. The detector shall identify the specific protection system or circuit causing a faulted condition. Electronic fault finding devices or power transfer switching to an additional isolated power supply are acceptable methods to satisfy this requirement.

c.

d.

7.4
7.4.1

Cable Tray
(Modify) Cable tray systems may be utilized to route multipair and multiwire cables from field junction boxes or remote I/O enclosures to instrument buildings (see NEMA VE2). (Add) Cable tray systems shall be grounded in accordance with NEC Table 3187(b) (2) and following requirements of Chapter 10, Grounding. (Add) Cable rails may be utilized to route individual signals to field instruments. (Add) Cable tray systems may be utilized to route instrument power supply cables powering instruments or equipment.

7.4.2 7.4.4 7.4.5

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7.4.6

(Add) Cable trays shall be either hot dip galvanized steel or aluminum, solid or perforated bottom. Where corrosive atmospheres are present, hot dip galvanized steel with baked epoxy coating may be considered. (Add) Cable trays carrying multicables shall be covered throughout their entire outdoor routes in cases where mechanical or environmental protection are required (corrosion, sunlight, lightning, etc). (Add) Open (ladder type) cable trays shall be used in conjunction with armored cable. (Add new paragraph) Cable tray systems carrying instrument power cables shall be filled as per the requirements of NEC Table 3189

7.4.7

7.4.8 7.4.9

7.5
7.5.0 7.5.2 7.5.2.2

Conduit Systems
(Add) Conduit systems may be utilized to route multipair and multiwire cables from field junction boxes or remote I/O enclosures to instrument buildings . (Add) PIP PCIEL000 may be used only as a referential document until PDVSA reviews and approves it. (Modify) For explosion proof installations, termination of conduit with flex conduit in Division 2 or approved flex for Division 1 area shall be used to provide isolation of the conduit system from vibration to protect against thermal expansion and for maintenance. The length shall be limited to 24 inches unless otherwise approved by Owner. (Modify) Fiber, digital data networks and process fieldbus networks shall meet equipment and cable vendors installation requirements and NEC Article 770. (Modify) Redundant digital data networks and process fieldbus networks shall have separate routings with maximum practical physical separation to minimize the possibility of a single event causing the simultaneous loss of both wiring systems. Redundant network routings shall be approved by PDVSA. (Modify) Field junction boxes shall meet the requirements of PDVSA K329

7.5.2.5 7.5.2.6

7.6

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TABLA 1. WIRE AND CABLE REQUIREMENTS FOR INSTRUMENT CIRCUITS Heading (Modify) (For control panel wiring, see PDVSA K330, Control Panels and Consoles. For 300 volt instrument tray cable, see PDVSA N262, for 600 Volt power and control cable, see PDVSA N261 Circuit type A (Add): For multicables, AWG 18 minimum may be used. Circuit type B3 (Add) Equipment networks and fieldbus networks. Circuit type C. (Modify) Substitute links for highways. Note 2. (Add) Final wire size shall be based on voltage drop vs. distance calculations Note 8 (Correct) Circuit types are B2 and B3

TERMINATIONS
8.1
8.1.7

General
(Modify) Substitute signal reference grid (SRG) for IGB

8.2
8.2.1

Milliamp Signals Typically 4 20 mA

(Modify) Each signal pair shield shall be connected to the signal reference grid (SRG) and shall be isolated from ground elsewhere, except as specified in section 10, Grounding. (Modify) Wire color coding shall follow facility local practice.

8.2.3

INSTRUMENT POWER SYSTEMS

9.1
9.1.0 9.1.1 9.1.2

General
(Add new paragraph) Instrument Power Supply design shall meet PDVSA K331, N201 and N253. (Modify) Control system instrument power requirements generally shall be 120 VAC and/or 24 VDC. Use of other voltages requires PDVSA approval. (Modify) Power for instrument systems and supervisory control computers shall be supplied from UPS/UBS. The UPS and UBS shall be supplied from both a primary and a secondary power source. (Modify) For typical power distribution system for BPCS, SIS and other instrumentation systems, refer to PDVSA K331 and N201. Note: Figure 1 of PIP document does not comply with IEEE 1100, 1999, and should not be used as a

9.1.3

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reference. For typical acceptable grounding configurations, refer to PDVSA 90620.1.124 or IEEE 1100, 1999. 9.1.9 9.1.10 (Add) UPS system shall be installed in an electrical room inside or adjacent to the Control Building. See PDVSA IRC02. (Add) Separate UPSs and/or UBSs dedicated to Plant SIS, Fire and Gas Detection System and individual equipment SIS shall be included in the design of the Instrumentation System Power Supply.

9.2
9.2.1 9.2.2

Branch Circuits Design

(Add) Circuit breakers shall have individual breakeroff indicating lights. (Add) Electrical Protection Coordination shall comply with PDVSA N201 and PDVSA K331. Comment: (Modify) UPS/UBS power distribution panels shall use fast acting electronic circuit breakers, not fuses

9.2.4

(Modify) Fastacting single pole breakers shall be used for the 120 VAC, singlephase 2wire circuits. Each circuit shall have an individual, unswitched neutral wire. (b) (Delete)

9.2.6

10 GROUNDING AND SURGE PROTECTION (MODIFY)

(Modify whole chapter 10 as follows) 10.1 Grounding of instrumentation systems shall adhere strictly to recommended practices in IEEE 1100, 1999, IEEE Recommended Practice for Powering and Grounding Electronic Equipment. See Appendix B for guidelines on grounding design. For field instruments located in remote areas of high risk of lightning strikes, SPDs may be installed individually at field instrument terminations (positive, negative and shield wires), after a costriskbenefit analysis is performed. For SIS applications and critical control loops, SPDs may be installed individually at field instrument terminations and marshalling cabinet terminations (positive, negative and shield wires), after a costriskbenefit analysis is performed. For intrinsically safe circuits, installation of SPDs shall follow specific SPD manufacturer instructions for I.S. applications. SPDs shall be applied to power distribution panels which support instrumentation equipment, as per IEEE 1100, 1999, 8.4.2.5 and 8.6.

10.2

10.3

10.4 10.5

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11 INTRINSICALLY SAFE INSTRUMENT SYSTEMS

11.1 11.2 (Modify) Intrinsic safety shall be considered for areas classified as Class I and II, Division 1 and 2. (Modify) The design of the Intrinsically Safe System shall adhere strictly to the requirements and follow as closely as possible the recommendations of the following standards: S NFPA 70, National Electrical Code, 1999 Edition, Article 497M, Classification of Gases, Vapors and Dusts for Electrical Equipment in Hazardous (Classified) Locations. S NFPA 70, National Electrical Code, 1999 Edition, Articles 500 to 503, Hazardous (Classified) Locations. S NFPA 70, National Electrical Code 1999 Edition, Article 504, Intrinsically Safe Systems. S Instrument Society of America Standard ISAS12.1, Definitions and Information Pertaining to Electrical Instruments in Hazardous (Classified) Locations. S Instrument Society of America Recommended Practice ANSI/ISA RP12.61995, Installation of Intrinsically Safe Systems for Hazardous (Classified) Locations. S Instrument Society of America Technical Report ISATR12.2 1995, Intrinsically Safe System Assessment Using the Entity Concept. S Instrument Society of America Recommended Practice ISARP12.2.02 1996, Recommendations for the Preparation, Content, and Organization of Intrinsic Safety Control Drawings. Exceptions to the above mentioned standards shall require PDVSA approval. 11.3 (Add) All field instruments and associated apparatus included in an Intrinsically Safe circuit shall be intrinsically safe approved as required for the area classification and surface temperature limits, according to NFPA 70, Articles 497M and 500 to 504. Certification shall be either by FM, UL, or equivalent in country of origin. (Add) Instrument wire and cable to be used in intrinsically safe circuits shall be certified by supplier for its relevant physical and electrical parameters: insulation material, insulation thickness, resistance, capacitance and inductance per meter, and L/R ratio. (Add) All intrinsically safe apparatus, associated apparatus, cables and accessories shall be clearly marked in order to render them easily identifiable, as per NEC 50480. Unless otherwise specified, outer protective jacket of intrinsically safe cables shall be of light blue color.

11.4

11.5

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11.6

(Add) The intrinsically safe system design shall be guaranteed by EPC contractor. An engineering document, titled Intrinsically Safe System Document of Compliance , shall be emitted for review and approval by Owner. See Appendix C for a description of the contents of this engineering certificate of compliance. (Add) Intrinsically safe circuits for SIS applications shall use barriers certified for safety applications, and require PDVSA approval .

11.7

12 NONINCENDIVE SYSTEMS
12.1 12.3 12.4 (Modify) In general, nonincendive systems shall not be used. They may be used for special applications after PDVSA approval. (Add) Nonincendive systems shall be applied only for Class I and II, Div. 2 and Class III, Divs. 1 and 2 hazardous (classified) areas. (Add) All field Instruments and associated apparatus included in a nonincendive circuit shall be approved as required for the area classification and surface temperature limits, according to NFPA 70, Articles 497M and 500 to 504. Certification shall be either by FM, UL, or equivalent in country of origin. (Add) Instrument wire and cable to be used in nonincendive circuits shall be certified by supplier for its relevant physical and electrical parameters: insulation material, insulation thickness, resistance, capacitance and inductance per meter, and L/R ratio. (Add) The nonincendive system design shall be guaranteed by EPC contractor. An engineering document, titled Nonincendive System Document of Compliance , shall be emitted for review and approval by PDVSA. See Appendix C for a description of the contents of this engineering certificate of compliance.

12.5

12.6

13 CONTROL PANEL AND CABINET WIRING

(Modify) All control panels, consoles and equipment cabinets shall comply with the requirements of PDVSA K330

14 INSTALLATION
(Modify) For instrumentation wiring installations, PIP PCIEL000 may be used as a referential document. Installation details shall be approved by PDVSA. All type B circuits shall use Instrument Tray Cable (ITC).

15 DATA LINKS AND FIELDBUSES (MODIFY)

(Modify) Primary and backup data link cables shall follow different routing and preferentially enter buildings and/or enclosures from opposite sides. Fieldbus network installations shall comply with the requirements of PDVSA K362.

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16 QUALITY ASSURANCE / QUALITY CONTROL (ADDITION)

Refer to PDVSA Specification K369, Instrumentation QA/QC.

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APPENDIX A (ADDITION)
REQUIREMENTS FOR ELECTRICAL/INSTRUMENTATION (E/I) INTERFACE PANEL
1. Instrumentation signals (24 VDC, wiring level 1) shall be physically separated from power control signals (120 VAC/125 VDC, wiring level 3) by means of separate raceways (panduits) and separate termination boards. See table 2, page 18 of PIP PCCEL001, tray to tray spacing. Cabinet and components shall be clearly identified, as per PDVSA K330, Control Panels and Consoles Signals in termination boards, isolating relay boards and PLC I/O cards shall be grouped as per electrical equipment. In general, each piece of electrical equipment (e.g. motor) may have some or all of the following monitoring and control signals: S S S S S 4. ON command Off command ON/OFF status LOCAL/REMOTE status Electrical failure indication

2. 3.

Electrical separation of signals shall be effected by means of interposing relays or electrooptic isolators, or by the use of dedicated remote I/O modules with high power level I/Os (120 VAC, 125 VDC and higher), inside the E/I interface panel. The Instrument/Electrical interface panel may also be used to house the digital interface between the BPCS and the electrical supervisory system. For a typical equipment distribution of the Electrical/Instrumentation Interface Panel, see figure A1.

5. 6.

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FIGURA A1 PANEL DE INTERFAZ INSTRUMENTACIN / ELECTRICIDAD

MDULOS I/O REMOTOS DCS PANDUIT INSTRUMENTACIN (24 VDC) MDULOS I/O REMOTOS PLC INTERFAZ DIGITAL BPCS/SCADA ELECT. CABLES DE BUSES DE DATOS PANDUIT ELECTRICIDAD (125 VAC VDC) RELS DE INTERPOSICIN Y AISLADORES ELECTROPTICOS REGLETA DE CONEXIONADO 24 VDC BUSES DE DATOS PLC Y SCADA SALA DE CONTROL CENTRO DE CONTROL DE MOTORES

REGLETA CONEXIONADO 125 V

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APPENDIX B (ADDITION) GUIDELINES FOR GROUNDING OF ELECTRONIC EQUIPMENT

The following guidelines may be applied in the design of instrumentation grounding systems. The standard of reference is IEEE 1100, 1999, Recommended Practice for Powering and Grounding Electronic Equipment 1. Grounding system consists of four (4) distinct, solidly (e.g.: galvanically) interconnected functional subsystems. They are as follows: a. NEC 250 described fault and personnel protection grounding subsystems, including the earthgrounding conductors (green wires), earth grounding electrodes (generally in the form of a plantwide grounding grid) and related grounding electrode conductors. This subsystem is also called the power system ground or the AC safety ground, and is installed following the guidelines of PDVSA 90619.1.091, Puesta a Tierra yProteccin contra Sobre tensiones. Outside the scope of this specification. Signal reference structure (SRS), consisting either of a signal reference grounding plane (SRGP) or a signal reference grounding grid (SRGG), and installed following the original equipment manufacturers instructions and the recommendations made in chapter 8 of IEEE 1100, 1999. The function of the SRS is to provide an effective high frequency grounding system for protection of electronic equipment against damage or interference caused by power system faults or lighting strikes. Lightning protection subsystem, installed per PDVSA electrical guidelines. This subsystem is outside the scope of this specification. Telecommunications, data transmission and signaling circuit surge protection grounding subsystem, as installed per the original equipment manufacturers instructions, the requirements of the NEC and recommendations made in chapters 8 and 9 of IEEE 1100, 1999. Outside the scope of this specification.

b.

c. d.

2.

SRS shall be installed as per IEEE, 1100, chapter 8.5.4. See below a summary list of recommended practices for installing a Signal Reference Ground Grid, extracted from IEEE 1100, 1999, par. 8.5.4.8 a. Follow the NEC and other related applicable codes and standards for safe grounding. There is no conflict between personal safety grounding and effective higherfrequency grounding for electrical systems and their associated electronic equipment. Select a suitable signal reference grid approach and assure that it is engineered, installed and maintained properly. Permanently and effectively bond the signal reference grid to all accessible building steel and to each metallic path (e.g.: conduits, raceways, cable

b. c.

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trays, pipes and ducts) that cross into the SRG in any plane or within 1.8 m (6 ft) of the SRG. d. If a single point of entry for power, grounding cables and other metallic items into the space exists (e.g.: physical ground window or bulkhead), then singlepoint grounding of the SRG is acceptable. The electronic load equipment installed on the SRG may be multipoint grounded or single point grounded to the SRG, depending on the signal frequency of interest. Bond the signal reference grid to each piece of electronic equipment and to any other electrical or mechanical equipment located on the SRG. Bonding connections to the SRG should be as short as practical with no sharp folds or bends. Flexible flat straps are preferred to the use of round conductors. Where in accordance with manufacturer requirements, more than one bonding conductor for each piece of equipment should be used. These conductors should be connected to opposing corners of the equipment and to the nearest, but separate points on the SRG. These conductors should be short (less than 0.5 m) and of different lengths (at least 20%). Electronic equipment should not be installed nearest to the outer edges of the SRG if practicable. Instead, this equipment should be installed one or more SRG conductor intersections (about 1 m) towards the center of the SRG . . . HVAC equipment and panelboards should be connected to any SRG conductor, or to the outermost SRG conductor. Where feasible, critical equipment should be located and bonded to the SRG greater than 1.8 m (6 ft) away from building steel or other potential lightning current or sideflash paths. All separatedly derived systems serving equipment located on the SRG should have their power grounding point (i.e.: neutraltoground bond) connected to the SRG by a suitable bonding strap, This connection is in addition to the required connection of the grounding electrode conductor to the grounding electrode (AC safety ground). All HVAC equipment, its associated piping, panelboards, switchboards, transformers and similar electrical or mechanical equipment within the protected area should be bonded to the signal reference grid. No special or supplementary grounding connections should be made to remote or dedicated earth grounding points, nor should there be any similar attempt to provide any form of separate earth ground paths to or from the SRG or any equipment installed upon it. All interconnecting communications, data and power cables should lay on or very close to the SRG.

e. f.

g.

h.

i.

j.

k.

l.

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m.

Construction documentation should be complete in all details, including the proper grounding and bonding of HVAC equipment, piping, raceways, and similar items, The engineer preparing the documentation should not expect installers to complete the design.

3.

Single point dedicated instrumentation grounding (tree structure) shall be considered only for small installations of analog instrumentation. Instrumentation grounding system shall be firmly bonded to the AC safety ground. Separate grounding electrodes intentionally not bonded to the power system grounding are strictly forbidden. This is usually known as clean ground, signal ground, instrument ground. This type of installation is forbidden by NEC, since it may cause extreme and hazardous voltage conditions to exist between differently grounded metal objects during power system faults and lightning activities. Furthermore, as explained in IEEE 1100, 1999, this type of installation does not effectively protect against EMI. Signal or shield grounding bars shall be solidly bonded to cabinet frames. Cable tray systems shall be part of the SRS, as per IEEE 1100, Sc. 8.4.12 Raceways, external metal cladding of armored cables and metal conduits shall be part of the SRS, as per IEEE 1100, 1999, section 8.4.8. Cable tray systems shall be solidly grounded at entrance to control building. For connections to the SRG, short length (less than 0.5 m) flat grounding straps shall be used.

4.

5. 6. 7. 8. 9.

10. Grounding straps shall be affixed to metal conduits and armored cables by means of grounding bushings, in order to insure a low impedance bond. 11. Metallic junction boxes shall be solidly bonded to plant ground by means of flat grounding straps.

12. Junction box sub panels (back plane) shall be solidly bonded to ground. For nonmetallic junction boxes, a grounding strap bonded to external grounding lug shall be used. 13. UPS System shall be grounded as per IEEE1100, 1999, Sc. 8.5.2. 14. Shields for instrumentation analog, pulse and digital signals shall be grounded at control room cabinet.

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APPENDIX C (ADDITION)
TABLE OF CONTENTS OF THE INTRINSICALLY SAFE DOCUMENT OF COMPLIANCE
(Note: For nonincendive installations, the guidelines below apply as noted) As a minimum, the Intrinsically Safe (or Nonincendive) System Document of Compliance shall be provided with the following sections: 1. 2. Frontispiece , including a box with the history of revisions/approvals. Scope, indicating the scope of the document which is, basically, the show of proof of the correct design, installation and verification of the intrinsically safe and/or nonincendive equipment and circuits designed, procured and installed within the scope of the specific project under consideration. List of Applicable Standards. Including PDVSA K334 and those listed in paragraphs 11.2 and 12.2. General Statement of Compliance. In this section, the EPC contractor shall declare that the instrumentation electrical installation is effectively designed as an intrinsically safe and/or nonincendive system, indicating its compliance with each and all sections of the above mentioned mandatory standards and PDVSA requirements. Where alternatives are allowed, the document shall describe the specific way in which compliance was obtained. Also, the intent and extent of the approved exceptions, if any, shall be described. Calculations: This section shall include the Control Drawing for each distinctive type of intrinsically safe or nonincendive circuit, as defined in Section 50410 of the NEC. The Control Drawing for each type of circuit shall use the greater length (worst case), of interconnecting wire for the calculations proving that the safety parameters are within acceptable range. A list of all instrument loops for which each Control Drawing applies shall be included. For nonincendive circuits, control drawings shall be similar in form to those for intrinsic safety circuits, but calculations shall follow general guidelines as stated in ISA S12.12. Certificates of Approval for Intrinsically Safe and Associated Apparatus: This section shall present the official certificates of approval for each and every intrinsically safe apparatus and associated apparatus installed in the plant, issued by an internationally recognized certifying authority: FM, UL, CSA, BASEEFA, PTB, CESI, etc. The apparatus shall be approved for the specific hazardous area classification where they are to be installed, according to the NFPA 70 Articles 500 to 503 hazardous location classification scheme and the NFPA 497M group and autoignition temperature (AIT) classification. Each certificate shall be accompanied with the corresponding list of instrument tags covered by the certificate.

3. 4.

5.

6.

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7.

Certificates of Approval for Nonincendive and Associated Apparatus: This section shall present the official certificates of approval for each and every nonincendive apparatus and associated apparatus installed in the plant, issued by an internationally recognized certifying authority: FM, UL, CSA, BASEEFA, PTB, CESI, etc. The apparatus shall be approved for the specific hazardous area classification where they are to be installed, according to the NFPA 70 Articles 500 to 503 hazardous location classification scheme and the NFPA 497M group and autoignition temperature (AIT) classification. Each certificate shall be accompanied with the corresponding list of instrument tags covered by the certificate. Cable and Wire Certifications: This section shall include the pertinent cable and wire guaranteed electrical and physical specifications from the suppliers, as well as the results of the program of spotwise inspections of these wires and cables for the pertinent physical and electrical parameters: wire and insulation materials, minimum insulation thickness, electrical insulation test results, electrical parameter test results (capacitance per unit length, inductance per unit length, R/L ratio). Design and Installation Documents/Instructions: This section shall include a reference list of all the specific design standards and specifications, engineering documents and drawings, QA/QC specifications, purchase specifications and installation instructions pertinent to the attainment of a correctly designed and installed intrinsically safe and/or nonincendive system. The list may include, but not be limited to: S S S S Specifications for grounding of intrinsically safe and nonincendive circuits Grounding system diagrams Shield bonding instructions Instructions for identification of intrinsically safe cables, accessories and components S Instructions for correct routing and separation of intrinsically safe wiring and cable trays S Purchase specifications for cabinets and equipment using intrinsically safe or nonincendive components S Construction inspection plans and verification forms, etc.

8.

9.

10. Quality Control of Fabrication. This section shall include a reference list of all equipment or system vendor inspection books where inspection/verification forms testifying to the correct design and installation of intrinsically safe circuits and components are filed. 11. Quality Control of Construction. This section shall include a reference list of all inspection forms filed in the Construction Quality Control Book where correct installation of intrinsically safe equipment and wiring is verified.