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
prepared from the technica
technicall requireme
requirements
nts in the existing
existing standards
standards of major 
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
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
 professiona
 professionall before applying
applying or acting
acting on any material
material contained
contained in or suggested
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

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
Page 1 of 20  
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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 PIP PCCEL001
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

Process Industry Practices Page 3 of 20  

PIP PCCEL001
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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 PIP PCCEL001
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.

Process Industry Practices Page 9 of 20  

PIP PCCEL001
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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PIP PCCEL001
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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