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1、DOC-WKI-000090DKI GENERAL WIRING PRACTICESWORK INSTRUCTIONDKI GENERAL WIRING PRACTICES1. ScopeThis work instruction shall be applied in the Diamond Key International Workshops Electrical wiring on skids or associated is required. All wiring to be performed by qualified experienced wiring personnel u

2、sing appropriate tools for stripping insulation, cutting, soldering and attaching mechanical crimp type terminals with the correct dies and tools as advised by the terminal manufacturer.Foremost electrical installations are to be performed to latest issue of wiring rules AS/NZS 3000 as well as IEC d

3、irectives2. General installation:2.1. When removing insulation from the conductor, wire strands shall not be nicked or damaged. Proper stripping tools shall be used to avoid such damage.2.2. Wire and cable ties shall be snug but shall not be so tight as to cause indentation and cold flow damage to t

4、he insulation.2.3. Cable ties shall be tensioned and trimmed using cable tie manufacturers tooling.(Use of side cutters for trimming, is not permitted)2.4. All wiring within Exe, Exi or similar enclosures to be terminated.2.5. Where possible, adhesive installed mounting bases should not be used for

5、ties or cable support unless affixed with a mechanical fastener.2.6. Wire and cable dress shall allow sufficient slack for removal and reapplication of the wire terminations, at least twice without excess tension.2.7. All wire and cable, including that in ducts and conduit, shall be handled to be fr

6、ee from kinks and insulation abrasions.2.8. Wire installation shall not be subject to accumulation of water, oil or other foreign matter.2.9. Instrument cables are to be free of Orange drain wires.2.10. Cable to be laid out neatly and undue crossing of cables is to be avoided (refer Appendix 3).2.11

7、. All wire shall be protected against any contact with any surface other than that designed specifically to support or protect the wire.2.12. Protective edging, Grommets and similar materials shall be applied wherever any possibility exists for a wire to contact a sharp edge.2.13. A drip loop shall

8、be provided in each wire or cable where water could otherwise run along the wire or cable to the point where it enters a box or enclosure.2.14. Wire/cables forming part of the wiring system shall be bent in a manner that will not cause damage or place undue stress on their sheathing or insulation.2.

9、14.1.1. Where manufacturers information on recommended bend radii is not available, the following radii may be considered suitable2.14.1.2. Unarmoured sheathed cables 6 times the cable diameter2.14.1.3. Armoured sheathed cables 12 times the cable diameter2.14.1.4. (Change of direction AS/NZS 3000 3.

10、9.7.)2.15. Wire jumpers on devices shall be run within the loom, so as to not be misplaced on device replacement.3. Cable Colors and type:Where possible the DKI standards for cable colors are to be strictly followed 3.1. Power cables 110v 240v Orange3.2. Instrument cables 0v 24vBlack3.3. IS cables -

11、Blue3.4. Flexible cables and cords shall be 0.6/1kV or 450/750V rated, heavy duty, with multiple stranded tinned copper conductors of 1.5sqmm minimum cross section and with a tinned copper braided screen. 3.5. Insulation materials may be either PVC, EPR or NBR 3.6. Screens shall be included in all Z

12、one 1 cables , with the exception of short lengths (not > 600mm) of instrument cables 3.7. Wire and cable type used shall be as stated on DKI drawings, alternatives shall be submitted for DKI approved.3.8. Cables used for the transmission of signals from temperature, pressure, speed, flow, weight

13、, level and similar signals , or any 4-20mA, 0-20mA, 24VDC or similar extra low voltage signal shall comprise twisted screened pairs.3.9. Wire and cable sizes to be as stated or agreed by DKI cable block diagram and cable schedule, alternatives shall be submitted for DKI approved.4. Wire Colors insi

14、de of Exe, Exd boxes and junction boxes shall be:240v Active· Red· White· Brown240v Neutral· Black· Light Blue240v Earth· Yellow / greenAll earth bonding· Yellow / green+24vdc · Grey24 OV· Brown+12vdc· Orange12 OV· Blue4.1. In extreme cases wher

15、e use of different cores color is unavoidable, then heatshrink sleeving applied to the cores is required.5. Wire segregation:-5.1. Segregation of wiring with differing voltage rated Insulation i.e. Dekoron 110vac and Power/control 0.6/1kv is a mandatory requirement.5.2. The minimum separation distan

16、ce between such cables or their related equipment shall not be less than the distances given in the following table: Circuit rating (kVA) Unshielded power cables (mm) Shielded power cables (mm) <1 300 25 >1 <2 450 50 >2 <5 600 150 >5 1500 300 Separation between Power and Signal/Dat

17、a Cables5.3. Intrinsically Safe cables may only run together with non I.S. cables provided that either the Intrinsically Safe cables or the non-I.S. cables are armoured.5.4. Where a non-armoured intrinsically safe cable is installed with non armoured power and control cables, a segregation distance

18、of 50mm minimum must be strictly observed throughout the complete cable run, and within any switchboard, junction box and the like.6. Wire Marking:-6.1. All wires regardless of location shall be plainly and suitably identified with DKI approved, wire markers on both ends of the conductor, as per DKI

19、 wiring diagrams. 6.2. Each end of the wire shall have the same identifying marker e.g. RTD+1, OUT#46 AC, ESS-A, and etc (Refer Appendix 1). Do not label the cable cores according to cable colour nor according to the terminal that the wire is connected to.6.3. Labeling on both ends of a cable/core m

20、ust be identical. If possible, it should be consistent throughout the circuit.6.4. In addition to numbering, all cables carrying Intrinsically Safe circuits shall be identified by a 200mm length of BLUE heat shrink material at each termination (i.e. at every cable glanding point).7. Pulling Compound

21、:-7.1. Pulling Compound, if used, shall be non-conductive or non-odorous. 8. Conduit-Rigid:-8.1. Conduit shall be Steel Galvanised and conform to AS/NZS 2053.7 in conjunction with AS/NZS 2053.1 or IEC directives8.2. Conduit bends shall have suitable bend radii for the number of wires being carried.8

22、.3. Conduit shall have no more than 40% fill ratio for new installations.8.4. Conduit Elbows and Tees shall be Steel and of the inspection type.8.5. Conduit entries after cutting and thread forming shall not have any burrs or sharp edges inside or outside, with all filings removed before installatio

23、n.8.6. Conduit entry/exits into Enclosures or junction points are to have Nylon or brass bushes.8.7. Conduit shall not be welded to any structures.9. Conduit Sealing Fittings: 9.1. Conduit sealing fittings (stuffing boxes) must to comply to AS or IEC standards9.2. In principle sealing is not to be d

24、one until after the FAT9.3. Manufactures sealing compound is only to be used9.4. Sealing must be done in accordance with the manufactures instructions9.5. For vertical sealing a physical barrier such as silicon must be laid at the lower point of the conduit seal to ensure the compound cannot pass /

25、drip past the sealing area.9.6. For horizontal sealing a physical barrier such as silicon must be laid at both end points of the conduit seal to ensure the compound cannot pass / drip past the sealing area.9.7. All wires passing through the conduit seal must have all outer insulation and any plastic

26、 wrapping removed. Ensure that the removal of the insulation is visible/traceable even after sealing has been done (for inspection purposes).9.8. All wires are to be straightened and not twisted together when passing through the sealing area.9.9. Sealing compound is to be mixed as per the manufactur

27、ers instructions,9.10. Pouring of the compound must ensure that the sealing fitting is completely filled to the required level and must not cover the Plug bung thread.9.11. Sealing fitting plugs / bungs are not to be installed until the sealing compound has hardened to ensure the plug / bung is not

28、in contact with the compound. 10. Conduit- Flexible:-10.1. Flexible conduit shall be of a DKI approved type such as Sealsafe .10.2. Equivalent types may be presented to DKI for approval)10.3. Conduit and fittings shall be rated to IP66 when entering/exiting enclosures or termination junction boxes.1

29、0.4. When a Flexible conduit has IS cable inside both ends of the conduit must be sleeved in blue color.11. Cable Glands:-11.1. Glands are to suit the Hazardous application. And conform to IEC or AS standards11.2. Glands are to be of correct size for the cables used.11.3. All Glands entering an Exd

30、box must be Barrier type11.4. All glands entering an Exe box must be rated Exe type minimum.11.5. Glands to be tightened to manufacturers recommendations.11.6. Barrier Glands to have the correct epoxy resin applied, to manufacturers instructions.11.7. Glands to have nylon washers fitted to Enclosure

31、 externals.11.8. Glands to have Shrouds fitted, unless requested by the customer not to.Cable gland types shall be selected as follows: Cable type Enclosure Gland Type Manufacturers PVC/PVC/SWA/PVC XLPE/PVC/SWA/PVC Exe Compression glands certified Exe and fitted with a sealing gasket · Crouse-H

32、inds type TWAE · CMP E1FW seriesPVC/PVC/SWA/PVC XLPE/PVC/SWA/PVC Exd See AS/NZS 60079.14 Figure 2 Compression gland certified Exd and fitted with sealing gasket · CMP E1FW seriesBarrier type gland certified Exd · Crouse-Hinds type TWAB · CMP PX2K seriesPVC or EPR Screened Flexibl

33、eExe or Exd· CMP E1FX seriesPVC/PVC XLPE/PVC Intrinsically Safe circuits General industrial glands. · Crouse-Hinds TUA · CMP A2 series PVC/PVC/SWA/PVC XLPE/PVC/SWA/PVC Intrinsically Safe circuits General industrial glands for armoured cables. · Crouse-Hinds TWA · CMP CW seri

34、es PVC/PVC/SWA/PVC XLPE/PVC/SWA/PVC Switchboards in Non Hazardous Areas Compression glands designed for armoured cables · Crouse-Hinds type TWA · CMP CW series 12. Cable ladders/Trays:-12.1. All Cable Trays shall be EzyStrut/ Unistrut perforated tray or approved equivalent.12.2. All Ladder

35、 Trays shall be Burndy LT series or approved equivalent.12.3. All Cable Ladder shall be NEMA 16A or approved equivalent.12.4. To be free of kinks sharp edges and burrs12.5. Cable entering through the sides must have Grommet protection13. Plastic Duct:-13.1. To be of an approved DKI slotted finger ty

36、pe.13.2. Duct covers to be fitted, after completion of wiring.13.3. No sharp fasteners to be present on the inside to damage wiring.13.4. Duct with blue I.S. wiring inside requires a blue label with white lettering, stating “IS CIRCUIT”14. Cable Connectors:- D15,D25 etc14.1. Unused connector contact

37、 positions shall be sealed with either connector contacts or plastic sealing plugs designed for that purpose.14.2. Adjacent connectors wherever possible are to have different insert or different insert orientations to prevent erroneous connections.14.3. Wherever possible, connectors are to have mech

38、anical crimp contacts.14.4. Whenever connectors such as Cannon D with solder pot connections are used, the wire is to have clear Heat-shrink tubing applied to joint, for strain relieving.15. Splices:-15.1. Slicing/Joiners of conductors shall be avoided and under no circumstances will splicing of con

39、ductors in conduit be permitted. 16. Enclosures:-16.1. Enclosures shall be of a DKI approved range with an IP65 or better rating.16.2. Enclosures for External use are to be metallic type unless approved otherwise.16.3. All wire bundles within an Enclosure shall be supported and free from the Enclosu

40、re structure, metal edges, bolt heads etc.16.4. Enclosures shall have their mounting brackets/holes external wherever possible.16.5. Enclosures & equipment to be earthed using fitted earth studs for prevention against static, as shown on DKI Static Earthling wiring diagram.16.6. Enclosures shall

41、 have earth connections between door and main chassis.16.7. All enclosure covers to have gaskets using approved material.16.8. Enclosures with IS circuits inside, are to have a label mounted on the front door stating “INTRINSICALLY SAFE CIRCUITS ONLY” when only IS or “INTRINSICALLY SAFE CIRCUITS INS

42、IDE” when a mixture of circuits.16.9. Label to be white lettering upon a blue background16.10. Enclosure drilling/machining swarf is to be thoroughly removed along with any burrs or sharp edges prior to installation.16.11. All spare gland holes to be blanked off with suitable zone Stopping plugs.17.

43、 Solder:-17.1. A non-corrosive solder shall be used.17.2. An automatic temperature controlled solder station shall be used.18. Terminal Blocks:-18.1. Terminal blocks shall be of the molded unit type Tension clamp or clamping yoke screw on agreed projects and be DKI approved. In the case where different model of terminals has to be used other than what had specified in the drawings, please acquire for sign-off on