Cable

Selection Guide for Process Instrumentation

Cable selection for process instrumentation has been complicated by the variety of instruments now in use in process
plants, their increased sensitivity to electrical interference and the drive for more exact information regarding the
process parameters.
In selecting a cable for a particular application a number of factors have to be considered, some of which are discussed
below.

• Type of instrument to be installed v Route measurement cables away from AC
• Length of cable run fields or vica-versa; signal and power
• Degree of electrical interference present in the cables or wires should not be in the same
area where the cable is installed conduit, tray or junction box.
• Environmental conditions v Eliminate the source of interference.
v Install measurement cables in suitably
Instrument Type earthed steel conduits or covered trays.

The type of instrument normally dictates the type of
Cable circuit to be employed. For example a thermocouple • Electrical (capacitive) coupling
v Screen each twisted pair/triad.
probe would require a thermocouple (pairs) extension
cable, the type of which is dictated by the probe type.
Similarly a Resistance Temperature Device (RTD) would • Direct coupling
require a triad configuration. v use a high quality insulation eg XLPE
v reduce risk of moisture ingress into cables
v earth screens at one point only
Length of Cable Run v use one pair/triad per circuit ie; avoid the
The selection of conductor size is largely dependent upon use of “sharing” leads in different circuits.
allowable volt drop within the circuit. In addition other
parameters such as Mutual Capacitance and L/R ratio may
also be of equal importance.
Environmental Conditions Identification
• maximum operating conditions
Electrical Interference • presence of chemicals/moisture
Electrical interference, often termed EMI, is an extremely • abrasion and/or cut through resistance
complex subject and is perhaps the least understood. In • fire retardancy
this section no attempt will be made to provide complete • installation route ie; duct, direct burial, tray
solutions, however guidelines will be given. etc. (See table below.)

Electrical interference is any spurious voltage or current
Direct Burial
arising from external sources that appears in the signal
transmitting circuit. When this voltage becomes too large Outer sheath material must be compatible with soil
and the signal to noise ratio is exceeded, errors occur in conditions.
the measurement/control circuit.
Soil Containment PVC PE
Sources of electrical interference can be categorised into Acids – diluted E E
three fields viz: Acids – Concentrated G G
§ Magnetic coupling from AC fields eg motors, Alcohols – aliphatic G E
power cables. Aldehydes G G
§ Electrical (capacitive) coupling with adjacent Bases/Alkali E E
circuits Esters N G
§ Direct coupling eg; earth current loops involving Hydrocarbons – aliphatic G F
two or more earth points or a common return lead Hydrocarbons – aromatic N N
for more than one circuit. Hydrocarbons – halogenated N N
Ketones – aromatic F N
Methods of minimising interference in transmission Oxidizing Agents - strong G F
circuits are explained below:


§ Magnetic coupling
v Use of twisted pair/triad cores

Standard and Barrier Sheath Cables
Cable Design Packaging
CBI Telecom offers a broad range of cables including All cables are supplied on sturdy non-returnable
Control, Instrument and Thermocouple. These wooden cable drums constructed from timber which
products are available in a number of configurations has been treated with a preservative. Both ends of the
each dependant upon the required application. cable fitted with end caps to prevent moisture ingress
to the cable. The free end of the cable is fastened to a
These cables are reviewed frequently to take drum flange to prevent uncoiling during
advantage of developments in material technology. transportation. Wooden lags are nailed side by side
over the rims of the drum flanges to protect the cable.
Copper conductors are manufactured in three sizes Steel strapping is then applied around the lags to keep
each in a multi-wire bunched configuration to provide them in place.
increased flexibility. Thermocouple extension cable
conductors are manufactured in solid form in two Transport
sizes as per American Wire Gauge (AWG) standard. Drums must be transported in accordance with all the
requirements of SANS 10198 – The selection,
The standard insulation material is cross-linked handling and installation of electric power cables of
polyethylene (XLPE) which provides greater rating not exceeding 33kV.
mechanical strength, more stable high temperature
performance and lower capacitance which is Drums must only be rolled in the direction indicated
specifically important for intrinsic applications. The by the arrow painted on the flange.. Preferably, drums
use of this compound covers virtually all process cable must be moved by forklift or crane using a suitable
requirements and eliminate the use of other materials steel shaft and slings with spreader to prevent
for special applications. damage to the flanges.

The screening method used is aluminium/polyester On no account should drums be laid flat on their
foil tape applied with it’s own bunched tinned copper flanges. Drums shall be secured to the truck with
drain conductor for ease of termination. Each tape is either suitable wooden chocks or slings or chains fed
electrically isolated from the other and are applied through the spindle holes in the drum flanges. Use
with a suitable overlap in order to maintain 100% must be made of a fork lift or crane to offload the
cover once the cable is bent following installation. drums from the truck. Drums should never be rolled
off the truck onto the ground.
Two barrier sheath constructions are available in
cases which moisture/chemical ingress is likely. In Storage
both cases an aluminium co-polymer laminate tape is Always store drums with their flanges in a vertical
folded longitudinally around the bedded cable and position and adjacent drums with their flange(s)
the overlap sealed. A sheath is then extruded over the touching. If drums are stacked on top of one another,
tape providing a good bond. Selection of the sheath make sure that each end drum of the bottom row are
material is dependant upon the area where the cable suitably chocked. The storage surface should be hard
will be installed. In the case where fire retardancy is and well drained. If a length of cable is cut from a
necessary the sheath shall be either black UV drum, the end on the drum should be sealed again
resistant, fire retardant PVC or LSZH otherwise black with an end cap to prevent moisture ingress.
UV resistant PE shall be applied. Fire retardancy of the
PVC or LSZH sheathed cable shall comply with
Installation
IEC60332-3-24 Cat. C and are suitable for overhead
All cables must be installed in accordance with SANS
rack and tray installations.
10198 as far as it is applicable to instrumentation
and/or control cables. Failure to do this will invalidate
CBI Telecom Cables’ product warranty.



 Electrical Characteristics of Instrumentation Cables with XLPE Insulation

Conductor Nominal Mutual Maximum DC Nominal Maximum LR

Area Cable Element Capacitance Resistance Inductance Ratio
(mm²) (nF/km) (Ω/km) (mH/km) (µH/Ω)
Core/core ind & oa 95
screen
Core/ind screen 190
0.5 39.6 0.72 25
Core/core oa screen 60

Core/oa screen 120

Core/core ind & oa 115

screen
Core/ind screen 230
1.0 19.5 0.64 25
Core/core oa screen 75

Core/oa screen 150

Core/core ind & oa 130

screen
Core/ind screen 260
1.5 14.4 0.63 40
Core/core oa screen 80

Core/oa screen 160

Note: Multi pair cables with overall screen > 4 pair, “core/core oa screen“ figures apply.
Multi pair cables with overall screen ≤ 4 pair, “core/core ind & oa screen“ figures will apply.