December 1999

Process Industry Practices

Process Control

PIP PCCEL001
Instrumentation Electrical Requirements
 PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES

In an effort to minimize the cost of process industry facilities, this Practice has
been prepared from the technical requirements in the existing standards of major
industrial users, contractors, or standards organizations. By harmonizing these technical
requirements into a single set of Practices, administrative, application, and engineering
costs to both the purchaser and the manufacturer should be reduced. While this Practice
is expected to incorporate the majority of requirements of most users, individual
applications may involve requirements that will be appended to and take precedence over
this Practice. Determinations concerning fitness for purpose and particular matters or
application of the Practice to particular project or engineering situations should not be
made solely on information contained in these materials. The use of trade names from
time to time should not be viewed as an expression of preference but rather recognized as
normal usage in the trade. Other brands having the same specifications are equally
correct and may be substituted for those named. All Practices or guidelines are intended
to be consistent with applicable laws and regulations including OSHA requirements. To
the extent these Practices or guidelines should conflict with OSHA or other applicable
laws or regulations, such laws or regulations must be followed. Consult an appropriate
professional before applying or acting on any material contained in or suggested by the
Practice.

© Process Industry Practices (PIP), Construction Industry Institute, The

University of Texas at Austin, 3208 Red River Street, Suite 300, Austin,
Texas 78705. PIP member companies and subscribers may copy this Practice
for their internal use.

Not printed with State funds


Process Industry Practices
Process Control
PIP PCCEL001
Instrumentation Electrical Requirements
Table of Contents
1. Introduction ..................................2
1.1 Purpose ............................................2
1.2 Scope ...............................................2
2. References....................................2
2.1 Process Industry Practices ................2
2.2 Industry Codes and Standards ..........2
2.3 Government Regulations ..................4
3. Definitions.....................................4
4. General..........................................5
5. Environmental ..............................6
6. Instrument Signal
Compatibility ...............................6
7. Wire and Cable Systems..............7
7.1 General.............................................7
7.2 Instrument Wiring .............................7
7.3 Segregation/Separation
Requirements .................................11
7.4 Cable Tray ......................................11
7.5 Conduit Systems.............................11
7.6 Junction Boxes ...............................12
Process Industry Practices
December 1999
8. Terminations .............................. 15
8.1 General .......................................... 15
8.2 Milliamp Signals - Typically 4 to
20 mA ............................................ 15
8.3 Voltage Signals - 100 mV or
Greater........................................... 15
8.4 Voltage Signals - Less than
100 mV........................................... 16
8.5 Thermocouple Signals.................... 16
9. Instrument Power Systems ....... 16
9.1 General .......................................... 16
9.2 Branch Circuits Design ................... 17
10. Grounding ................................. 18
11. Intrinsically Safe Instrument
Systems..................................... 19
12. Non-Incendive Systems ........... 19
13. Control Panel and Cabinet
Wiring ........................................ 20
14. Installation................................. 20
Figure 1:
Typical Instrument Systems
Power/Grounding Requirements
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PIP PCCEL001
Instrumentation Electrical Requirements December 1999

1. Introduction

1.1 Purpose
The purpose of this Practice is to provide electrical requirements for process
measurement and control systems.

1.2 Scope
This Practice provides the requirements for the equipment selection, system design,
and installation of electrical supply and wiring to support process measurement and
control systems.

2. References

Applicable requirements in the latest edition (or the edition indicated) of the following industry
codes, standards, and references shall be considered an integral part of this Practice. Short
titles will be used herein when appropriate.

2.1 Process Industry Practices (PIP)

– PIP ELSWC03 - 600 Volt Power and Control Cable
– PIP ELSWC03D - Data Sheet for 600 Volt Power and Control Cable
– PIP ELSWC05 - 300 Volt Instrumentation Tray Cable
– PIP ELSWC05D - Data Sheet for 300 Volt Instrumentation Tray Cable
– PIP PCCGN001 - General Instrument Design Checklist
– PIP PCCGN002 - General Instrument Installation Criteria
– PIP PCESS001 - Safety Systems Guidelines
– PIP PCIEF000 - Instrumentation Fabrication Details
– PIP PCIEL000 - Instrumentation Electrical Details
– PIP PCSCB001 - Control Building Considerations Specification
– PIP PCSEL003 - Instrument Junction Boxes Specifications

2.2 Industry Codes and Standards

• American Petroleum Institute (API)
– API RP500 - Recommended Practice for Classification of Locations for
Electrical Installations at Petroleum Facilities Classified as Class 1,
Division 1 and Division 2
– API RP505 - Recommended Practice for the Classification of Locations for
Electrical Installations at Petroleum Facilities Classified as Class 1, Zone 0,
Zone 1, and Zone 2
– API RP552 - Transmission Systems
– API RP554 - Process Instrumentation and Control

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December 1999 Instrumentation Electrical Requirements

• Institute of Electrical and Electronic Engineers (IEEE)

– IEEE 518 - IEEE Guide for the Installation of Electrical Equipment to
Minimize Electrical Noise Inputs to Controllers from External Sources
– IEEE 1100 - Recommended Practice for Powering and Grounding Sensitive
Electronic Equipment, The Emerald Book
• ISA
– ISA RP12.1 - Definitions and Information Pertaining to Electrical Instruments
in Hazardous (Classified) Locations
– ISA RP12.6 - Wiring Practices for Hazardous (Classified) Locations
Instrumentation Part 1: Intrinsic Safety
– ISA RP60.8 - Electrical Guide for Control Centers
– ISA S12.1 - Definitions and Information Pertaining to Electrical Instruments
in Hazardous (Classified) Locations
– ISA S12.6 - Installation of Intrinsic Safe Systems for Hazardous (Classified)
Locations
– ISA S12.10 - Area Classification in Hazardous (Classified) Dust Locations
– ISA S12.12 - Nonincendive Electrical Equipment for Use in Class I and II
Division 2 and Class III Divisions 1 and 2 Hazardous (Classified) Locations
– ISA S50.1 - Compatibility of Analog Signals for Electronic Industrial Process
Instruments
– ISA S84.01 - Application of Safety Instrumented Systems for the Process
Industries
– ISA Comprehensive Dictionary of Measurement and Control
• National Electric Manufacturers Association (NEMA)
– NEMA 250 - Enclosures for Electrical Equipment (1000 Volts Maximum)
– NEMA ICS6 - Enclosures for Industrial Control and Systems
– NEMA VE2 - Metal Cable Tray Installation Guidelines
• National Fire Protection Association (NFPA)
– NFPA 70 - National Electrical Code (NEC)
– NFPA 496 - Purged and Pressurized Enclosures for Electrical Equipment
– NFPA 497 - Recommended Practice for the Classification of Flammable
Liquids, Gases, or Vapors and of Hazardous (Classified) Locations for
Electrical Installations in Chemical Process Areas
– NFPA 499 - Recommended Practice for the Classification of Combustible
Dusts and of Hazardous (Classified) Locations for Electrical Installations in
Chemical Process Areas

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PIP PCCEL001
Instrumentation Electrical Requirements December 1999

2.3 Government Regulations

Federal Standards and Instructions of the Occupational Safety and Health
Administration, including any requirements by state or local agencies with jurisdiction,
shall apply.
• United States Department of Labor, Occupational Safety and Health
Administration (OSHA)
– OSHA 29 CFR 1910 - Occupational Safety and Health Standards

3. Definitions

AC Safety Ground: The grounding system required by NEC Article 250 to provide protection
for personnel and electrical equipment. The Instrument Ground Bus is connected to the Safety
Ground per the NEC requirements.

Control Room: The location where direct operation of the unit or plant is performed and where
operations personnel are in constant attendance

Field Instrument Enclosure: The term used in the generic sense to indicate a cabinet or
building that houses instruments and/or wiring termination external to Instrument Rooms or
Control Buildings

Field Junction Box (JB): See Junction Box

Field-Powered Devices: Instruments located in the field that are powered from sources other
than the Basic Process Control System (BPCS) and/or Safety Instrumented System (SIS).
These are sometimes referred to as 4-wire devices.

Interface Box or Marshalling Cabinet: See Junction Box

Instrument Rooms: The term used in the generic sense for a walk-in type structure, including
rack rooms, remote instrument enclosures, or any completely enclosed structure that houses
control equipment

Instrument Ground Bus (IGB): Grounding system connected to a high-quality earth ground,
independent from the AC Safety Ground, for all instrumentation signals. The IGB is tied to the
AC Safety Ground at only one point, near a high-quality earth ground, per NEC and Figure 1
of this Practice. The IGB is isolated from all other grounds.

Junction Box (JB): A protective enclosure around connections between electric wires or cables
(ISA Comprehensive Dictionary). The junction box may be a Field Junction Box, usually
referred to as JB, or it may be within a control building or instrument enclosure, where it is
referred to as an Interface Box (IB). The IB is sometimes called a Marshalling Cabinet or
Termination Cabinet.

Owner: Principal end user

Uninterruptible Power Supply (UPS): A power supply system that provides uninterrupted
power to the connected equipment for a specified period of time, even during failure of the

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December 1999 Instrumentation Electrical Requirements

primary power source. The UPS is typically a rectifier with batteries and an inverter system to
provide alternating current (AC). A UPS is often used to provide reliable power to the
instrumentation power distribution system. (Refer to NEC Article 645-11.)

4. General

4.1 All process measurement and control equipment shall be suitable for the electrical area
classification in which they are installed.
4.2 All techniques used to comply with area classification requirements shall comply with
NEC Chapter 5 or the authority having jurisdiction.
4.3 Equipment and enclosures that require purging to comply with area class requirements
shall be purged in accordance with NFPA 496. Use of purging to reduce area
classification shall require Owner’s approval. For environmental purges, see Section
5.4.
4.4 Instruments shall not be installed in Zone 0, Zone 1, or Division 1 areas unless
approved by Owner.
4.5 Instrument electrical equipment shall be rated for continuous energized duty.
4.6 Instrument cabinets or panels that contain more than one power source shall have a
caution sign identifying the separate power sources.
4.7 Redundant instruments shall be supplied from separate circuits and from separate
branches where practical for each instrument. Separate I/O cards should be
considered.
4.8 Indicator lights (non-annunciator lights used to visually communicate messages) on
control panels shall be uniformly color-coded within each operating unit and,
preferably, across each site. A recommended color code for panel indicating lights is:
4.8.1 Green - Normal state, operating, usually energized
4.8.2 Red - Abnormal state, out of service, usually de-energized, or potentially
dangerous
Comment: This convention is opposite to electrical power indicating light
convention and is not allowed on UL- (Underwriters Laboratories,
Inc.) labeled devices.
4.9 Each device of 50 V (AC or DC) or greater shall have its own individual lockable
disconnect switch with appropriate labeling. Either local or remote lockout is
permissible.
4.10 All electrical equipment including instrumentation shall be designed and installed in
accordance with NEC and OSHA 1910 Subpart S.
4.11 Any box, including junction boxes, containing voltages higher than 50 V (AC or DC)
shall have a caution sign on the outside of the box.
4.12 Voltages over 120 VAC in instrument enclosures require Owner’s approval.

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4.13 Field instruments directly connected to flammable or explosive process fluids shall be
designed with multiple barriers to prevent entry of vapors into the cable/conduit
system. If the additional seal is required, a drain, vent, or other device is required so
that the failure of the primary seal is obvious. Refer to NEC Article 501-5(f)(3).
Comment: The use of a sealing fitting with a drain, provided that the drain is on
the instrument side, will satisfy the above-mentioned NEC requirement.
4.14 Minimum Design Capacity Allowance shall be provided as follows:
4.14.1 Design capacity allowance is the capacity available at the completion of
design.
4.14.2 Control building cabinets and consoles shall be designed to accommodate a
minimum of 20% additional equipment.
4.14.3 Field junction boxes and field cables shall be designed and installed to
accommodate a minimum of 20% additional field devices.
4.14.4 Field wire raceways, exclusive of conduits, shall be designed for a minimum
of 20% future additions.
4.14.5 Cable tray from the process area into the control room and instrument
buildings shall be sized for a minimum of 40% future additions.
4.14.6 Power panels shall have at least 20% spare circuit breakers or fuses installed
at design completion (refer to Section 9.2.5).
4.15 Input and output circuits of controllers that are not current limited shall be protected
by fuses.

5. Environmental Considerations

5.1 All instrument equipment shall be enclosed in environmentally appropriate housings.

5.2 NEMA 12 rated enclosures shall be used as a minimum for dry, indoor locations. For
indoor areas that contain oil or dust, NEMA 13 is the minimum rating (refer to NEMA
ICS6 and NEMA 250).
5.3 NEMA 4 shall be the minimum outdoor rating for enclosures, and NEMA 4X shall be
used in wet locations or where corrosion is an issue. Explosion-proof and dust-
ignition-proof enclosures shall be rated for the environment in which they are installed.
If NEMA 7 enclosures are required outdoors, dual-rated enclosures (NEMA 7 and
NEMA 4 or 4X) shall be used (refer to NEMA ICS6 and NEMA 250). See Section 4.3
on the use of purging for reduction of the electrical area classification.
5.4 With the Owner’s approval, enclosure purging for environmental purposes shall be
considered where the ambient atmosphere contains corrosive contaminates or where
other severe conditions exist. Use of purge media other than instrument air shall
require specific Owner’s approval.

6. Instrument Signal Compatibility

6.1 All analog transmitted instrumentation signals shall be a current signal having a range

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December 1999 Instrumentation Electrical Requirements

of 4 mA to 20 mA DC in accordance with ISA S50.1. Other analog signals for existing

instrumentation systems may be allowed with Owner’s approval.
6.2 Digital communications between smart transmitters and control systems shall adhere
to vendor recommendations.
6.3 Power supply voltage shall nominally be 24 VDC.

7. Wire and Cable Systems

7.1 General
The installation of all wiring and cables, including low-voltage instrument cables, shall
comply with NEC requirements for the type of cable or wiring being used and the
location in which it is being installed.
7.1.1 The routing for cables from field areas to the control room and instrument
room in new plant areas is in overhead cable trays. Cable trays should not be
routed in fire hazardous areas (e.g., over pumps, under process air fans, etc.).
7.1.2 For fire protection of instrument cables, refer to PIP PCCGN002 or to
Owner-supplied procedure.
7.1.3 Cables that are laid directly under raised floors shall be specifically approved
for this method of installation by NEC Article 354. AC power wiring (120
VAC and higher) routed in the raised floor space shall utilize conduit, metal-
enclosed raceway, metal clad cable, or cable tray, with adequate separation
from the signal wiring.
7.1.4 The use of the area under a raised floor for an HVAC plenum shall require
Owner’s approval. The wiring shall be installed in accordance with NEC
Article 300-222. Any wiring in the HVAC plenum shall be “Plenum Rated”
and non-toxic, unless installed in an enclosed conduit system.
7.1.5 For Safety Instrumented Systems (SIS) wiring, refer to ISA S84.01 and
PIP PCESS001.
7.1.6 If the room is classified as an information technology equipment room, it shall
meet all the requirements of NEC Article 645.
Comment: Process control electronic equipment alone does not require the
room to be classified as a computer/data-processing room.

7.2 Instrument Wiring

All cables for general instrument use, both single pair and multiple wire, shall meet the
requirements of PIP ELSWC03 and PIP ELSWC05. All instrument wiring shall be
listed for the specific application for which it is being used.
7.2.1 Wiring
7.2.1.1 Each wire within a field cable, including spares entering a JB or
interface cabinet (marshalling panel), shall be terminated.

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Instrumentation Electrical Requirements December 1999

7.2.1.2 Splitting multiple conductor cables among multiple devices/boxes in

the field is not permitted.
7.2.1.3 Protection against back electromotive force (EMF) shall be
provided for inductive loads such as relays, solenoids, etc. This may
be accomplished within the equipment card or by one of the
methods below:
a. For DC loads, a diode may be installed electrically across the
coil.
b. For AC inductive loads, a metal oxide varistor (MOV) may
be installed across the coil.
7.2.1.4 Lightning protective devices shall be used when any of the
following conditions exist (see API RP552, Section 16 and NEC,
Article 280):
a. Electronic systems are located in large, open areas, such as
tank farms.
b. Instrument wire and cable runs exceed 1500 feet.
c. Instrument cables run aerially on poles.
7.2.1.5 Each pair or triad shall be permanently tagged and identified at both
ends. Wire markers, tubular heat shrink, or other permanently
affixed markers shall be used to ensure permanence of the marking.
Machine printing is preferred for clarity.
7.2.1.6 In general, cables shall meet the design criteria listed below and
shall be selected in accordance with Table 1.
a. Single Pair Instrument Signal Cable with an Overall Shield
(SPISCO)
Application: This type covers the minimum requirements for
single circuit cable for analog (e.g., 4 - 20 mA DC, 1 - 5 VDC,
0 - 100 mVDC) or low-voltage (50 volts DC or less), discrete
signals for instrumentation and control signal transmission.
Type: The pairs shall be 2 copper conductors, minimum 16
AWG, with an overall shield.
b. Single Pair Thermocouple Extension Cable with an Overall
Shield (SPTECO)
Application: This type covers the minimum requirements for
single pair cable made up of individually shielded, thermocouple
extension wires twisted into pairs.
Type: Each pair shall be 2 solid alloy, thermocouple extension
wires per ISA MC96.1 with an overall shield. The individual
wires and outer jackets shall be color coded per
ANSI/ISA MC96.1.

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December 1999 Instrumentation Electrical Requirements

c. Single Triad Instrument Signal Cable with an Overall Shield

(STISCO)
Application: This type covers the minimum requirements for
single circuit cable where three wires are required (e.g., RTDs
and vibration) for instrumentation and control signal
transmission.
Type: The triads shall be 3 copper conductors, minimum
16 AWG, with an overall shield.
d. Multi-Pair Instrument Signal Cable with an Overall Shield
(MPISCO)
Application: This type covers the minimum requirements for
multiple circuit cable for high-level analog (e.g.,
4 - 20 mA DC, 1 - 5 VDC) or low-voltage digital (50 volts DC
or less) signals used for instrumentation and control signal
transmission. This type of cable is not to be used for signals
below 100 millivolts.
Type: The cable shall be 12 or 24 pairs with an overall shield.
Each pair shall be 2 copper conductors, minimum 20 AWG.
e. Multi-Pair Thermocouple Extension Cable, Individually Shielded
with Overall Shield (MPTECI)
Application: This type covers the minimum requirements for
multiple pair cable made up of individually shielded,
thermocouple extension wires twisted into pairs.
Type: The cable shall be 12 or 24 pairs with 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. Conductors shall be minimum 20 AWG. The individual
wires and outer jackets shall be color coded per ANSI/ISA
MC96.1.
f. Multi-Pair Instrument Signal Cable Individually Shielded Pairs
with Overall Shield (MPISCI)
Application: This type covers the minimum requirements for
multiple individually shielded, circuit cable for low-level analog
(e.g., 0 - 100 mVDC). With Owner’s approval, it may be used
for high-level analog (e.g., 4 - 20 mA DC, 1 - 5 VDC) or for
low-voltage digital (50 volts DC or less) signals used for
instrumentation and control signal transmission.
Type: The cable shall be 12 or 24 pairs with an overall shield.
Each pair shall be 2 copper conductors, minimum 20 AWG,
with an individual shield insulated from other pair’s shields.

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Instrumentation Electrical Requirements December 1999

g. Multi Triad Instrument Signal Cable with an Overall Shield

(MTISCO)
Application: This type covers the minimum requirements for
triads (three wire) multiple circuit cable for high-level analog
(e.g., 4 - 20 mA DC, 1 - 5 VDC) or low-voltage digital
(50 volts DC or less) signals used for instrumentation and
control signal transmission. This type of cable is not to be used
for signals below 100 Millivolts.
Type: The cable shall be 12 or 24 pairs with an overall shield.
Each pair shall be 2 copper conductors, minimum 20 AWG.
h. Multi-Triad Instrument Signal Cable Individually Shielded
Triads with Overall Shield (MTISCI)
Application: This type covers the minimum requirements for
multiple individually shielded circuit cable for low-level analog
(e.g., 0 - 100 mVDC). With Owner’s approval, it may be used
for high-level analog (e.g., 4 - 20 mA DC, 1 - 5 VDC) or for
low-voltage digital (50 volts DC or less) signals used for
instrumentation and control signal transmission.
Type: The cable shall be 12 or 24 triads with an overall shield.
Each triad shall be 2 copper conductors minimum 20 AWG,
with an individual shield insulated from other pair’s shields.
7.2.2 Circuit Impedance
7.2.2.1 Wire resistance of single device, 4 - 20 mA instrument loops can
usually be neglected for one-way distances less than 1000 feet.
Where multiple devices are used in applications where the one-way
loop distance is over 1000 feet and are wired in series in a
4 - 20 mA loop, the total circuit impedance shall be evaluated for
proper operation.
7.2.2.2 120 VAC wiring to solenoid valves, relays, and other electro-
mechanical devices shall be sized to have a voltage drop of less than
5% from the voltage source transformer to the control device at the
rated holding current.
7.2.2.3 For long runs where wiring distributed capacitance is in parallel
with the control device, designer shall perform calculations to
ensure correct operability of each circuit.
Comment: AC input as discussed above may not de-energize
due to the distributed capacitance effect. The use of
rectifiers and DC relays should be considered.

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7.2.2.4 DC wiring to solenoid valves, relays, and other electromechanical

devices should be sized to have a voltage drop of less than 10%.
Comment: Voltage drop calculations are not required for low-
wattage (1.4 watts) DC solenoid valves that use
multiple conductor cables, 20 AWG twisted pairs,
and have lengths less than 700 feet. For distances
over 700 feet, the use of higher voltage devices or
larger wire size should be considered.
7.2.2.5 When low-energy devices such as pilot-operated solenoids, pilot
lights, etc., are driven by an electronic amplifier, the “off position”
leakage current must be low enough to allow the load to be “turned-
off” when de-energized.

7.3 Segregation/Separation Requirements

7.3.1 Instrument wiring shall be segregated according to wiring class and circuit
type in accordance with Table 1 and separation distances in accordance with
Table 2.
7.3.2 Generally, each circuit type shall be run in a separate tray/conduit, except as
noted in Table 2.
7.3.3 Intrinsically safe systems and fire detection systems shall be segregated from
other wiring and shall have dedicated junction boxes and marshalling panels.
7.3.4 If different circuit types have to be terminated in the same junction box, each
circuit type shall enter the junction box in a separate cable or conduit and shall
be terminated on terminal strips that are physically separated according to
circuit type. Plastic or metal barriers that are labeled with the circuit type or
power level shall have separate terminal strips.

7.4 Cable Tray

7.4.1 Cable tray systems shall be utilized to route multi-pair and multi-wire cables
from field junction boxes or remote I/O enclosures to instrument buildings (see
NEMA VE2).
7.4.2 Cable tray systems shall be grounded in accordance with
NEC Table 318-7(b)(2).
7.4.3 Cable tray fill shall be based on NEC Tables 318-9, 318-9(c), and 318-10.

7.5 Conduit Systems

7.5.1 Instruments installed in NEC Class I, Division 2, or Division 1 with Owner’s
approval that by design rely on a single compression seal diaphragm or tube,
shall require an additional seal that meets the conditions of the process fluid.
(See 4.13).
7.5.2 Terminations of the conduit shall be in accordance with PIP PCIEL000.

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7.5.2.1 Field instruments shall be wired from the field junction box to the
field instrument by a dedicated, individual cable. Single pair cables
in conduit or trays shall be the preferred wiring method.
7.5.2.2 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.
7.5.2.3 Conduit wiring capacity shall be sized in accordance with NEC.
Comment: When performing this sizing calculation, care must
be taken to allow for the reduced area of the
conduit fitting.
7.5.2.4 In highly corrosive environments, aluminum, PVC, or PVC-coated
conduit may be used where approved by Owner. When PVC is
used, the use of a grounding wire and additional supports are
required in accordance with NEC Article 347.
7.5.2.5 Fiber and data highways shall meet equipment and cable vendor’s
installation requirements and NEC Article 770.
7.5.2.6 Redundant data highways 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 data highway routings shall be approved by
Owner.

7.6 Junction Boxes

Field junction boxes shall meet the requirements of PIP PCSEL000.

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Table 1
Wire and Cable Requirements for Instrument Circuits
(For control panel wiring, see PIP PCSCP001. For 300 volt instrument tray cable, see PIP ELSWC02.
For 600 volt power and control cable, see PIP ELSWC03.)
A. NEC Class 1 Circuits (Notes 1 and 3)
Instrument Class Circuit Example Conduit Wiring Tray Cable
A. 120 VAC or Less Switches, Solenoids, Relays 600 V THWN, Insulated, 600 V TC, Insulated
14 AWG Minimum
B. NEC Article 727 Circuits, Conduits, and Cable Tray Installations (Notes 1 and 11)
B1. Instrument Circuit Example Single Pairs or Triads Multiple Pair or Triad Cable
Circuit Class and
Type
B2. 24 VDC or Less 4 - 20 mA DC RTDs, Weigh 300 V Shielded Twisted Pairs or 300 V ITC PVC Insulated
(Notes 4 and 8) Cells, Solenoids, Alarms, Triads Twisted Pairs or Triads, Overall
Switches, Relays, CABLE TYPES: Shield
Secondary Motor Control, SPISCO, STISCO CABLE TYPES:
Digital Process Transmitter MPISCO, MTISCO
(Notes 2, 3, 5, 9, and 10)
(Notes 2, 3, 4, 9, and 10)
B3. Frequency or Speed, Vibration, Turbine 300 V Shielded Twisted Pairs or Individually Shielded Pairs Tray
Pulse Train Digital Meter Triads Cable or Triads
Communication CABLE TYPES: CABLE TYPES:
(Note 6) SPISCO, STISCO MPISCO, MTISCO
(Notes 2, 3, 9, and 10) (Notes 2, 3, 5, 9, and 10)
B4. Thermocouple Thermocouples 300 V ITC, 16 AWG, Individually 300 V ITC, 20 AWG, Individually
Measurement Shielded Twisted Pair Shielded Twisted Pairs, Overall
(Note 8) CABLE TYPES: Shield
SPTECO CABLE TYPES:
(Notes 2, 3, 9, and 10) MPTECO
(Notes 2, 3, 9, and 10)
C. Data Highways and Other High-Speed Circuits
Data Highways EIA-422A Data Highways/ Follow Cable and System Follow Cable and System
(Notes 7 and 10) High-Speed Communication Manufacturer’s Manufacturer’s
Recommendation Recommendation
Notes:
1. Type A circuits shall be separated from all other types of instrument circuits by either conduit tray dividers or separate trays.
2. 20 AWG minimum wire size for multi-pair cable; 16 AWG minimum wire size for single pair cable. A larger wire size shall be used if
required by the calculations.
3. Wire sizes listed in the table and notes are minimum requirements. Actual wire size shall be based on load current and voltage drop
requirements. The use of parallel wires to meet the current requirements is not allowed.
4. Higher DC levels require Owner’s approval.
5. Type ITC cable shall not be installed on either non-power-limited circuits or powered-limited circuits operating at more than 150 volts
or more than 5 amperes.
6. Vibration signals shall be run in galvanized steel conduit, flexible conduit, or armored cables from the probe to the local transducer.
7. Maximum separation between redundant highways shall be obtained within the operating plant. The use of a single cable tray for
primary and redundant highways is not acceptable.
8. Type B1 and B3 circuits may be routed in the same conduits and trays.
9. For a description of the six-letter designators, see Section 6.2.1.7 and refer to the listings in
PIP ELSWC05 and PIP ELSWC05D.
10. Differences in the manufacturer-recommended cable and these requirements shall be resolved with the Owner.
11. Physical barriers are also required to separate intrinsically safe wiring from other wiring.

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Instrumentation Electrical Requirements December 1999

Table 2
Segregation and Minimum Spacing Requirements for Parallel Runs
(For wiring level definitions, see Note 1. For units of measurement in inches, see Note 3.)
Steel-Conduit-to-Steel-Conduit Spacing
Wiring Levels 1 2 3 4 5
1 0 1 3 12 12
2 1 0 3 9 12
3 3 3 0 0 0
4 12 9 0 0 0
5 12 12 0 0 0
Tray-to-Tray Spacing or Tray-to-Conduit Spacing
Wiring Levels 1 2 3 4 5
1 0 1 6 26 26
2 1 0 6 18 26
3 6 6 0 6 12
4 26 18 6 0 0
5 26 26 12 0 0
Notes:
1. Wiring Levels:
Level 1 - High Noise Susceptibility Application
1. 4 - 20 mA, 24 VDC instrument signals, other analog < 50 VDC and digital process transmitters
2. Discrete, 24 VDC instrument signals
3. +/- 50 VDC and common buses feeding analog instrument signals
4. +/- 24 VDC and common buses feeding digital instrument signals
5. Thermocouple and RTD circuits
6. Telephone circuits
Level 2 - Medium Noise Susceptibility Application
1. Light and switching circuits 24 VDC or less
2. Analog signals > 50 VDC < 28 VAC ripple
Level 3 - Low Noise Susceptibility Application
1. 120/240 VAC feeders < 20 amps
2. Light and switching circuits 24 VDC or greater
3. 120/240 VDC relay, contactor and circuit breaker coils < 20 amps
4. Analog signals > 50 VDC < 28 VAC ripple
Level 4 - Medium Power Application
1. Primaries and secondary of transformers > 5 KVA
2. AC and DC buses 0 - 800 volts with currents > 20 amps
Level 5 - High Power Application
1. AC and DC buses > 1 kW or currents > 800 amps, or both
2. This table is based on IEEE 518.
3. This table does not apply to the use of non-metallic conduit.
4. Cable tray spacing is defined as the minimum distance (in inches) between the top of one tray and the bottom of the tray above or
between the sides of adjacent trays. This spacing also applies to the distance between trays and power equipment less than 100
KVA.
Conduit spacing is defined as the minimum distance (in inches) between the outside surfaces of conduits. This spacing also
applies to the distance between conduits and power equipment less than 100 KVA.
5. When unlike signal levels must cross, in trays they shall cross at 90-degree angles. Where it is not possible to maintain spacing,
a grounded metal barrier should be placed between unlike levels at the crossover point.
6. Levels 3 and 4 may be run in a common tray if separated by a barrier.
7. When separate trays are impractical, Levels 1 and 2 may be combined in a common tray, provided a grounded metal barrier
separates the levels.
8. Trays for all levels were based on metal, solidly grounded, with good ground continuity.
9. Only cables having the same voltage class (Table 1) may be run together.
10. Trays and conduits containing Levels 1 and 2 shall not be routed parallel to high-power equipment enclosures of 100 KVA and
larger at a spacing of less than 5 feet for trays and 2-1/2 feet for conduit.
11. Where the spacing listed in Table 2 is difficult to maintain, parallel runs should be minimized and in no case be run parallel to
each other for a distance greater than 5 feet.

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December 1999 Instrumentation Electrical Requirements

8. Terminations

8.1 General
8.1.1 All field instruments wiring shall be landed on terminal strips in field junction
boxes. See NEC Article 110-14. Devices with attached pigtails may be spliced
in conduit fittings with Owner’s approval. See
NEC Article 370-16.
8.1.2 Individual circuit wires shall not be spliced.
8.1.3 Connections to terminal strips shall be limited to two wires per screw. If the
wires are solid or ferruled, then only one wire shall be connected per screw.
8.1.4 When terminating lugs are used on stranded wire, they shall be of the locking
type and limited to their design capability (i.e., two wires maximum per lug).
8.1.5 Terminal shall be tightened to the torque required by manufacturer.
8.1.6 All wires (including spares and shield drain wires) of each cable shall be
landed on both ends in continuous order on terminals, dressed out neatly, and
labeled.
8.1.7 Overall cable shield drain wires and individual pair shields shall be grounded
to the IGB in the instrument building in which the cables terminate. Grounded
thermocouples shall be installed per
Section 8.5 with shield wire grounded in thermocouple head.
8.1.8 All wire pairs, triads, and cables (including spares) used to connect instrument
components and systems shall have uniform identification labels on each wire
and cable at each point of termination.

8.2 Milliamp Signals - Typically 4 - 20 mA

8.2.1 Each signal pair shield shall be connected to the IGB and shall be isolated
from ground elsewhere.
8.2.2 Signal (power) isolation shall be required for all devices powered from sources
other than the Basic Process Control System (BPCS) and SIS that are located
in the instrument building.
8.2.3 The black wire shall be positive at the power source and the white wire shall
be negative.
8.2.4 Individual drain wires shall be isolated from ground at the field device and
where exposed in conduit or cable seal fittings by use of electrical tape or heat
shrink tubing.

8.3 Voltage Signals - 100 mV or Greater

The cabling for these measurement signals, sometimes called high-level signals, shall
meet the same requirements as mA signals. (See Section 8.2.)

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Instrumentation Electrical Requirements December 1999

8.4 Voltage Signals - Less than 100 mV

These measurement signals, sometimes called low-level signals, shall meet the same
requirements as thermocouples. (See Section 8.5.)

8.5 Thermocouple Signals

8.5.1 Thermocouple extension wire shall be used between the thermocouple and the
transmitter, multiplexer, or other monitoring device.
8.5.2 Thermocouple extension wire shall be the same type of material as the
thermocouple. Specifically designed extension wire may be used instead of
exotic materials with Owner’s approval.
8.5.3 The number of thermocouple extension cable junctions shall be minimized.
8.5.4 For grounded thermocouples, individual shield wires shall be grounded only at
the thermocouple connection in the head.
Comment: Shielding of thermocouple signals is extremely important to
prevent noise.
8.5.5 If the ambient temperature is above 190º F (in rotating equipment or near
furnaces), thermocouple wires shall have high-temperature insulation such as
extended polytetra-fluorethylene.

9. Instrument Power Systems

9.1 General
9.1.1 Control system instrument power requirements generally shall be 120 VAC
and/or 24 VDC. Use of other voltages requires Owner’s approval.
9.1.2 AC power for instrument systems and supervisory control computers shall be
supplied from UPS. The UPS shall be supplied from both a primary and a
secondary power source.
9.1.3 For a typical power distribution system for the BPCS and SIS that requires a
UPS, see Figure 1.
9.1.4 Alarms shall be installed in the control room to indicate:
a. The loss of the secondary source
b. A transfer to the secondary source
c. UPS trouble
d. UPS on batteries
e. Low-battery alarm
9.1.5 A dedicated isolation instrument power transformer shall be provided for UPS
bypass power.
9.1.6 The instrument power system shall be separate and distinct from non-critical
circuits such as heating and lighting.

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December 1999 Instrumentation Electrical Requirements

9.1.7 Operating time capability (power from batteries of UPS) required after the
total outage of AC supply power shall be set by the Owner considering unit
response time and needs of units served.
Comment: A minimum of 30 minutes is a typical time for instrument
systems power backup. Where additional time is required,
consideration should be given to a backup generator as a
secondary source for UPS.
9.1.8 Provisions for testing the UPS with process running shall be provided.

9.2 Branch Circuits Design

9.2.1 Circuit breakers or fuses shall be used to safeguard principal branches from
subordinate branch faults. Each instrument supply shall be protected by an
individual fuse or a current-limiting device.
9.2.2 Circuit protective devices shall be coordinated to ensure that the device nearest
the overload or fault will open first, minimizing the possibility of initiating a
UPS transfer and isolating the fault from the rest of the system. Circuits and
loops shall be protected in related process systems.
Comment: UPS power distribution panels usually require either fast-acting
electronic circuit breakers or fuses to allow circuit protective
device coordination.
9.2.3 Power connections to redundant control system components and modules (e.g.,
DC power supplies, BPCS control modules, etc.) shall be taken from separate
branch circuits and separate supplies (minimum of different breakers or
distribution panels) to reduce common mode failures.
Three-phase UPS output is desirable and allows redundant components to be
connected to separate phases, minimizing the impact of voltage depression on
faulted phases before clearing.
9.2.4 Fast-acting single pole breakers or fuses shall be used for the 120 VAC,
single-phase 2-wire circuits. Each circuit shall have an individual, unswitched
neutral wire. Where only one single-phase inverter is supplied, fuses may be
required to clear faults in adequate time to prevent loss of power supplies
during a fault.

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Instrumentation Electrical Requirements December 1999

9.2.5 Design and installation of the neutral wire shall satisfy the following
requirements:
Grounding: The main bonding jumper at the derived source or the first panel
downstream of the derived source establishes the AC neutral
ground point. All circuit neutral wiring shall be insulated.
Color Coding: Neutral wires shall be white except when there is more than
one, in which case, each shall be color coded to satisfy
NEC Article 210.5.
Splicing: Splicing of the neutral wire is prohibited except when necessary
at a field device.
Connection: The neutral wire connected to a device shall always be the one
assigned to the source that serves that device, never one from
some other circuit source.

9.2.6 Assignment of computer circuits shall meet the following requirements:

a. Each computer system or subsystem requiring power shall be on a
separate circuit. The circuit may be wired with type “SO” service cord
(NEC Table 400-4). Computer cabinets and devices shall be wired either
to the computer power panel or connected to a receptacle using a “twist-
lock” plug. UPS receptacles shall be distinguishable from other
receptacles.
b. High-power peripheral devices, such as line printers, shall be on a
separate circuit and shall be connected via a wall- or floor-mounted
receptacle, providing an isolated AC Safety Ground per NEC
Article 250-74, Exception 4.
c. Peripheral devices (e.g., CRTs, gateways, etc.) and other equipment
essential to normal process control shall be assigned to the highest
reliability power available (such as UPS power).
d. Devices that are not essential for normal process control may be assigned
to lower reliability power.
e. No spare wall or floor outlets are to be installed in the computer power
system unless clearly marked as to the service.

10. Grounding

10.1 Grounding electronic systems (e.g., BPCS, SIS, and Programmable Logic Controller
(PLC)) shall follow the criteria below and the manufacturer’s recommendations. Any
deviation shall be reviewed by the manufacturer’s technical representative and
approved by Owner. See Figure 1 (INSTGND001).
10.2 Two grounding systems shall be required in the control room or instrument building:
a. AC Safety Grounding for personnel safety
b. IGB for signal reference

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December 1999 Instrumentation Electrical Requirements

The IGB and AC Safety Grounds shall join electrically at a single point near a high-
quality earth ground (IEEE 1100, API RP 552, and Figure 1).
10.3 All electrical equipment shall be grounded to the AC Safety Ground for personnel
protection to satisfy NEC Article 250.
10.4 The IGB wiring shall be installed to provide a stable voltage reference. The grounding
system(s) should provide ground resistance level(s) consistent with supplier
recommendations and should meet the NEC requirements.
10.5 Ground systems shall be installed to provide a ground system that meets vendor
requirements. Since various suppliers have different grounding requirements, care
must be taken to develop a scheme that meets those requirements, meets the NEC
requirements, has testing capabilities, and has supplier approval. (See IEEE 1100.)
Comment: A removable link may be provided between the AC Safety Ground and
the IGB to allow testing of the IGB.
10.6 All IGB bars, plates, and wire shall be isolated from building AC Safety Ground path
except at the one point specified in Section 10.2 above.
10.7 The following signal and equipment connections shall be made to the IGB:
a. Instrument power supplies (negative leads)
b. BPCS, PLC, SIS, and other control modules (signal common, logic ground,
network ground, etc.)
c. Instrument (individual and overall cable) shields
10.8 Signals originating from instruments powered by sources external to the control
building (e.g., a chromatograph in an analyzer building) often are electrically
referenced to another ground potential. These instruments shall have isolated outputs,
or the output signals shall be electrically isolated when brought into the BPCS, PLC,
SIS, and other control modules.
10.9 Ground loops shall be avoided.
Comment: Ground loops exist when extraneous, unwanted currents flow in a wire
causing an offset in the instrument reading. Care must be taken to
avoid multiple grounds.
Comment: When instrumentation wiring is of the shielded type, shields should be
grounded at only one place.

11. Intrinsically Safe Instrument Systems

11.1 Use of intrinsically safe systems shall require Owner’s approval.

11.2 Refer to NEC Article 500-4(e) and ISA RP12.6 for requirements of intrinsically safe
systems.

12. Non-Incendive Systems

12.1 Use of non-incendive systems shall require Owner’s approval.

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Instrumentation Electrical Requirements December 1999

12.2 All non-incendive wiring shall be installed in accordance with NEC Article 500-4(f)
and ISA RP 12.12.

13. Control Panel and Cabinet Wiring

All control panels, consoles, and equipment cabinets shall be wired in accordance with
PIP PCSCP001.

14. Installation

All instrumentation wiring installations shall be in accordance with installation details in

PIP PCIEL000, unless otherwise approved by Owner. All Type B circuits shall use Instrument
Tray Cable (ITC).

15. Data Highways

Primary and backup data highway cables shall follow different routing and preferentially
enters buildings and/or enclosures from opposite sides.

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