Conduit Design &

Installation
(Guide and idea for better Conduit
design)
 Factors to Consider in Designing Conduit

► Conduit sizing (Filling Factor)

► Conduit Bends
► Pullbox sizing
► Instrument / Equipment Connection Point
► Use of Flexible conduit
► Hazardous area Installation
 Description Symbol Picture Purpose

Use for Protection of

Rigid Steel Conduit
cable

Protection for cable

(Usually use for
connection to
Flexible conduit instruments, panel, motor,
etc., especially when
located where vibration
exist

To connect flexible
Box connector No plan for symbol conduit in a box, plate,
etc.
 Connection between flexible
Combination coupling No Plan for symbol  
and rigid steel conduit.

Use to reduce amount of

small size conduit (reduce
cost).
Pull box For pulling of cable
especially when the route of
conduit is very long, to
prevent cable from damage.

No Plan for symbol Connection between two

Coupling  
rigid steel conduit
 To insulate / protect cables
Insulated bushing No plan for symbol  
during cable pulling

To hold or lock a conduit,

Lock nut No plan for symbol
box connector, etc.

Used when conduits are

bend many times. The
Universal elbow No plan for symbol   purpose is same as pull
box, but universal elbow is
use for one route only.
 Usually a 90° bend use
No plan for to connect big size of
Normal bend  
symbol conduit that is hard or
impossible to bend.
Fitting to be used if the
No plan for size of two connecting
Adapter  
symbol materials are not same
or not fitted.

Fitting especially use on

No plan for Hazardous area (To
Sealing fitting
symbol prevent fire, explosion,
etc.)

Use to tighten or hold

cables terminated in a
No plan for steel, box, etc. Usually
Cable gland
symbol used when cables are
not inside a flexible or
rigid steel conduit

Housing where driver or

proximitor is located.
Proximitor
Proximitors are usually
housing
used for supervisory
instruments.
1. Conduit Sizing

► Cable Size (Considering Over-all outside diameter)

► Total no. of cables to entry (1 pc, 2 pcs., etc.)
► Available conduit size to be used (Considering Inside Diameter)
► Space filling Factor
 * Fill Factor of Conduit Computation.

Area of cable x No. of cable

Fill factor  x 100
%
Area of conduit
Where:
(Overall diameter of cable ) 2
Area of cable  x PI
4
( Internal dia. of conduit) 2
Area of conduit  x PI
4

* Fill factor should be less than 40% (Fill factor < 40%)
Note: If fill factor requirement is not attain adjust the conduit to next bigger size and re-do the
computation until the fill-factor requirement is attain.
-40% fill factor can be used for conduits having multiple cables of small size only (Because you have
to consider the stress and twisting of cable)

Note:

• For 1 cable, fill factor must be less than or equal to 53%

• For 2 cables, fill factor must be less than or equal to 31%
• For 3 or more cables, fill factor must be less than or equal to 40%
Explanation why less than or equal 31% is
necessary for 2 cables installation
2. Conduit Bends

► The number of curves for conduit shall not exceed the equivalent of 3
elbows of 90°, or suitable pull box will be used.
3. Pullbox Sizing

ITEM
DESCRIPTION SIZE SPECIFICATION
No.
1. PULL BOX (WATER PROOF TYPE) 1-1 W100 x H100 x D100

  1-2 W200 x H200 x D150

       
Hot Dip Galvanized
       
       
       
       
  TOTAL      
 Factors to Consider for Pullbox sizing

► Quantity or total number of conduit

► Size of each conduit
► Spacing for each conduit
► How to fix or install conduit penetrated inside pullbox
 Necessary to consider fittings specially locknut, box connector, etc.
 Tools for tightening (Usually monkey wrench).
4. Instrument / Equipment Connection Point

► If specification of Instruments / Equipments are already available, you

can checked electrical connection.
► This can make sure that your conduit sizing is correct.
► Adapter will not be necessary, if Conduit and instrument / equipment
electrical connection is matching (same size).
 Example of Electrical Connection Point
PRESSURE TRANSMITTER
Thermocouple
5. Use of Flexible Conduit
► Flexible conduit length should be about 0.5~1.5 meters. If the length
would be longer then consider using a conduit pipe from terminal box
and then add flexible conduit as shown in figure below.
 Drawing Design Sample

OLD NEW
6. Hazardous Area Installation

► Boiler Area (around Pulverizer Area)

► Inside of Conveyor Galleries
► H2 & CO2 Storage House
► H2 System Instruments

You can refer to “Hazardous Area Classification” drawing per project, to

determine which areas are classified as Hazardous.
Drawing Design Sample