Installation and Construction Standard: IPS-C-IN-190
Installation and Construction Standard: IPS-C-IN-190
Installation and Construction Standard: IPS-C-IN-190
FOR
TRANSMISSION SYSTEMS
ORIGINAL EDITION
JAN. 1996
This Standard is the property of Iranian Ministry of Petroleum. All rights are reserved to the owner.
Neither whole nor any part of this document may be disclosed to any third party, reproduced, stored in
any retrieval system or transmitted in any form or by any means without the prior written consent of the
Iranian Ministry of Petroleum.
Jan. 1996 IPS-C-IN-190
1. SCOPE ............................................................................................................................................ 2
2. REFERENCES ................................................................................................................................ 2
3. UNITS.............................................................................................................................................. 2
4. GENERAL ....................................................................................................................................... 2
5. INSTALLATION OF TRANSMISSION AND CONTROL TUBING................................................. 3
6. ELECTRIC SIGNAL WIRING AND CABLES................................................................................. 4
6.1 General..................................................................................................................................... 4
6.2 Cable Specifications ............................................................................................................... 5
6.3 Sharing of Multicore Cables .................................................................................................. 6
6.4 Segregation in Trenches ........................................................................................................ 8
6.5 Segregation in Trunking or Cable Trays............................................................................... 8
6.6 Segregation in Terminal Boxes ............................................................................................. 8
6.7 Construction of Terminal Boxes ........................................................................................... 8
6.8 Accommodation of Individual Signal Lines ......................................................................... 9
6.9 Screening of Signal Cables.................................................................................................. 10
6.10 Use of Quad Cables ............................................................................................................ 10
6.11 Numbering and Identification ............................................................................................ 11
6.12 Pulling into Conduits .......................................................................................................... 11
6.13 Installation of Insulated Wire and Cables......................................................................... 12
6.14 Separation of Cables .......................................................................................................... 12
6.15 Terminations........................................................................................................................ 12
6.16 Installing Cable Trays ......................................................................................................... 14
6.17 Wire Testing......................................................................................................................... 16
7. TRENCHES, TRUNKING AND CONDUITS................................................................................. 16
8. FIELD INSPECTION AND TESTS................................................................................................ 18
FIGURES:
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Jan. 1996 IPS-C-IN-190
1. SCOPE
This Standard explains the general rules and basic instructions for the installation of pneumatic
lines, electrical signal wires and cables. It is intended to be used in oil, gas and petrochemical
industries.
2. REFERENCES
Throughout this Standard the following dated and undated standards/codes are referred to. These
referenced documents shall, to the extent specified herein, form a part of this standard. For dated
references, the edition cited applies. The applicability of changes in dated references that occur
after the cited date shall be mutually agreed upon by the Company and the Vendor. For undated
references, the latest edition of the referenced documents (including any supplements and
amendments) applies.
3. UNITS
This Standard is based on International System of Units (SI), except where otherwise is specified.
4. GENERAL
4.1 This Standard covers the requirements for signal lines for process instrumentation.
4.2 In the context of this Standard, signal lines convey:
a) Pneumatic signals from pneumatic transmitters to their receiving instruments, and from
pneumatic controllers to the relevant final control element;
b) Electric signals, analogue or digital (including RTDS and e.m.f.s from thermocouples)
from transmitters to their receiving instruments and from controllers, safeguarding systems
etc. to solenoid valves, motor starters and other final control elements.
4.3 As detailed further in the following paragraphs, most of the signal lines may be laid together in
common trenches or trunking for instrument signal lines, with a general exception for cables
carrying signals which could cause interference on other signal lines.
4.4 Each plant-mounted instrument shall have individual signal lines, which shall be connected as
soon as feasible to a multicore cable.
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All multicore cables shall be installed in uninterrupted lengths unless the distance to be covered is
more than can be reasonably supplied on one reel. Terminal boxes for connecting individual signal
lines to multicore cables shall be easily accessible.
4.5 At the moment of plant commissioning, approximately 20% of the signal lines in the installed
multicore cables shall still be available as spares for modifications, unless otherwise specified.
4.6 Above ground, multicore cables and most of the individual lines shall be laid on trays or in
trunking.
4.7 To reduce risks of damage to the signal lines they shall be laid underground wherever possible
in trenches which shall penetrate as far as possible into the processing units.
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p) The service of the tubes shall be so arranged that in the processing area the length of
individual tubing is as short as possible.
q) In the trunking, when it is desired to be used instead of trays, the individual tubes shall
be connected to the multicore cables by means of straight couplings. These individual tubes
shall continue in the trunking as far as possible, pass through trunk wall, and reach the
instrument by being clamped to the instrument air supply piping, refer Figs. 2, 3 & 4 on
pages 22, 23 and 24. For this purpose the instrument air supply piping system shall be
installed underneath the trunking.
r) Where tubing has to be connected to equipment without air supply (e.g. control valves not
having a booster or positioner) the tubing shall be clamped around 15 mm (half-inch)
dummy piping which is firmly attached to process piping, or stand pipe.
s) Pneumatic tubing shall never be clamped to process piping.
6.1 General
a) Extreme care is to be used in the handling of electronic instruments to assure that dirt
and oils from the hands do not come in contact with the various resistors, terminals and
other components.
b) Cables on reels and wire in coils shall be protected from damage by construction
activities.
c) Conductors shall be carefully handled during installation to avoid damage of any kind.
They shall be unreeled or uncoiled slowly in order to prevent damage to the insulation or
sheath due to sudden bending. Repeated bending shall be avoided., sharp kinks shall be
avoided in unreeling, uncoiling and pulling.
d) Every possible precaution shall be taken to ensure that the measurement signals are not
subjected to electrical interference. (refer to Table No. 2 on page 18).
This is of special importance when digital indicators, data loggers and/or computers are
applied.
e) The above point requirements are based on the use of cables with signal wires twisted in
pairs or quadruples (quads) with full screening.
f) Special signal cables such as coaxial cables for pH electrodes shall be installed in
accordance with the manufacturers instructions.
g) All electric signal lines shall be installed and terminated as indicated on the drawings.
h) All external services between cables and cable glands in the plant shall be sealed with
proper sealing compound.
i) At low temperature most plastics are so brittle that they may crack when bending the
cable, and therefore no cables shall be installed during freezing weather.
j) Mineral insulated, copper covered, PVC sheathed wires shall be used wherever practical.
Whenever MICC cables are used sufficient spare lengths of cable shall be provided at the
gland termination points to allow rejoining when required.
k) All thermocouple wires in conduits and multicore cables run to control rooms shall
terminate in appropriate junction boxes with leads carried in wireways to the panel.
l) Water tight junction boxes shall be used for outdoor services. Gasketed sheet metal
junction boxes shall be used inside control rooms.
m) When conduits are sealed at both ends, appropriate vents shall be provided between
the seals.
n) Where electrical or electronic instruments are used, these shall be of a type which can
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Note:
Cables having conductors of 0.8 mm diameter (cross section area approx. 0.5 mm2) have a
maximum current rating of 1 ampere per core. The fuse rating for these cables shall not
exceed 4 amperes.
6.2.8 In an intrinsically safe circuit, the total capacitance of the cables and either:
a) The total inductance of the cables, or
b) The L/R ratio of any of the cables shall not exceed the value stated on the certificate of
intrinsic safety, or in the case of no value being stated as in following para.
6.2.9 The following values are typical for 28 volt barriers, but may only be used in
preliminary work, or as in foregoing para.
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6.2.10 When specifying the size of signal transmission cable the maximum loop impedance in to
which the transmitter is specified to operate shall be taken in to consideration.
6.2.11 When an intrinsically safe circuit is protected by barriers the circuit connected to terminals 3
and 4 (external circuit connected to the barrier) shall be adequately insulated from earth in the
danger area.
6.2.12 Cables for intrinsically safe circuits shall have a blue outer sheath exclusively.
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1
Analogue low level ( mV) e.g. thermocouples, radiation
pyrometers, I.B.P., F.B.P., F.P. analyzers
2 Analogue medium level ( 1V) e.g. resistance thermometer
elements, strain gages, oxygen analysers, gas chromatographs
3 Analogue high level ( 10V, mA) e.g. electronic instrumentation
Loops
4 Digital low level (pulse train) e.g. turbine meters, P.D. meters
5 Digital high level (pulse train) e.g. tank-gauging systems
Note:
I.B.P. = Initial boiling point analyzer.
F.B.P. = Final boiling point analyzer.
F.P. = Flash point analyzer.
= Denotes: in the ranges
Remarks:
1) For thermocouple signals, the signal lines shall consist of pairs of dissimilar materials, to
match the e.m.f. characteristic.
Typical examples:
2) Signals with higher power levels than specified in Table 1, shall be accommodated in
separate cables and laid in the trench, such as electric cables, power and illumination, and
the electric power cables for instrumentation installed in the processing area.
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6.7.2 The above construction details are also applicable to terminal boxes for:
a) intrinsically safe circuits in Div. 1 areas
b) non-intrinsically safe circuits in Div. 1 areas
Non-intrinsically safe circuits in Div. 1 areas shall be accommodated in flame-proof terminal boxes.
6.7.3 For safe areas in the plant, terminal boxes identical in construction to those described for
Division 2 areas shall be specified for standardization reasons.
6.7.4 For use in control center with basements, much larger terminal-boxes may be required, they
shall be designed to suit the application.
6.7.5 The number of terminals in each box shall be sufficient to terminate all signal wire (including
spares) and to interconnect the cable screens.
6.7.6 For terminal boxes in the plant, adaptor plates for glands, trays or trunking shall preferably
only be applied in the bottom of the terminal box. This is mandatory when sheet steel covers are
applied to protect plastic terminal boxes.
6.7.7 For terminal boxes in the control center with basement, the glands shall preferably be in the
bottom of the box.
6.7.8 Underground junction boxes are not permitted.
6.7.9 Terminals for intrinsically safe circuits should be enclosed by a cover suitably marked and
distinctively colored (e.g. "intrinsically safe circuits" on a light blue background).
6.7.10 Plugs and sockets for intrinsically safe circuits shall be separate and non-interchangeable
except when it can be established that no hazard can arise from an interchange.
6.7.11 Sufficient length of cable shall be provided for termination to be remade if necessary.
6.7.12 When ever a termination is made to a measuring element which has to be withdrawn (e.g.
thermocouple) sufficient length of lead shall be allowed for the element to be withdrawn with out
electrical disconnection. The minimum additional length for this purpose shall be 600 mm.
6.7.13 Cables associated only with data processing apparatus shall be brought direct to the
apparatus input cabinet.
Double terminal, removable link-type connectors shall be used for this duty cables concerned also
with process control shall be taken first into the control room signals required by the apparatus from
process instrumentation shall then be fed from the process control panel to the input cabinet.
6.7.14 Where plastic tubing is used underground and copper tubing is used above ground, a sheet
steel terminal box shall be provided at the riser point to accommodate the bulkhead couplings
necessary for the transition from copper tubing to plastic tubing.
Note:
Where cubicle panels are installed at grade level the underground cables shall terminate on
bulkhead connectors inside the cubicle.
In cases where the distance between control room and processing area requires field-
mounted blind controllers, special weather-proof cubicles shall be designed. The upper part
of these cubicles shall accommodate the controllers, the lower part shall serve as a
termination point for the underground cables.
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6.8.2 Armoured signal cables shall be installed similar to the cables for power and lighting and have
a cable loop near the instrument.
6.8.3 Electric signal cables shall be connected to field-mounted instruments such as transmitters,
valve positioners, etc., by means of armoured cable and proper terminal box.
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c) For signals requiring 4 wires, e.g., for resistance thermometer elements in a constant
current circuit, the current carrying wires shall occupy one pair of diametrically opposed
wires, the measuring signal shall occupy the other pair.
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d) Ends of conduit shall be inspected to assure that no raw edges are present which would
damage cable insulations during pulling.
e) Particular care shall be applied when pulling shielded cables to assure that pulling forces
do not separate or otherwise damage the cable shield.
6.15 Terminations
6.15.1 Exposed sheathed wiring shall be installed in a neat and workman-like manner, straight and
true as far as possible. Where installed in groups, the cables shall be parallel in so far as
practicable.
6.15.2 Where stranded wire is used the terminal ends shall be securely twisted to assure that no
frayed ends are present to cause shorting or grounding. Terminal lugs are to be used only where
indicated.
6.15.3 Where any confusion exists as to the identification of wires or terminals it is to be reported
promptly to the Construction Superintendent for clarification; no assumptions are to be made.
6.15.4 The use of field terminal points other than those indicated on the instrument schematic wiring
diagrams is not permitted.
6.15.5 Care shall be taken where field splices are required in hot or neutral leads that the proper hot
or neutral is used. The wiring philosophy, for process reasons, may contain more than one hot and
neutral leg. Use of random "hot" or neutral legs is not permitted.
6.15.6 Above ground wiring systems shall be routed, wherever possible, to provide at least 7.5 m,
horizontal clearance from equipment which is designated as a source of sustained fire.
6.15.7 Above ground wiring systems routed less than 7.5 m from such equipment shall be fire
proofed using a covering of 50 mm of high temperature mineral wool or calcium silicate insulation,
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or equivalent, and a galvanized or stainless steel jacket. Additionally, any junction boxes in such
areas shall be fire proofed.
6.15.8 Where a plug and socket outlet is used as wiring connection to the instrument, the socket
must be labeled with the instrument identification symbol. Plug and socket type shall be such that
the plug cannot be inserted with reverse polarity.
6.15.9 To prevent entrance of water, the cable entry point into a field mounted instrument shall be
from the bottom wherever practicable. Where top entry must be used, conduit shall have a seal and
drain fitting within 450 mm (18 inch.) of the instrument to prevent liquid collection in the conduit from
entering the instrument.
6.15.10 Thermocouple lead wire shall run from the thermocouple to the terminal points indicated on
the drawings. No splicing shall be permitted.
6.15.11 Thermocouples will be permanently tagged with metal-discs, with item numbers stenciled in
securely attached with noncorrosive wire.
6.15.12 Shielded wire and cable shall run directly from point to point as indicated on the drawings.
No splicing shall be permitted.
6.15.13 When extension wire is run next to fired heaters or other heat radiating equipment, every
effort shall be made to keep wire in areas where temperature are not excessive. If this is not
practical, wire with a moisture resistant, high temperature insulation shall be used. As soon as lead
wire is away from a hot area a common junction box shall be provided for splicing into lead wire with
PVC insulated wire which shall be run the remaining distance to instrument.
6.15.14 Where instruments are local or mounted close by on heater panels, and lead wire has to be
run in a heated area that would caused damage to PVC insulation, wire with moisture resistant, high
temperature insulation shall be run continuously from the thermocouple to local instrument.
6.15.15 Where a tower has alternate temperature points and all are not used at a given time a
terminal block enclosed in a weather proof fitting shall be provided so that thermocouple leads can
be changed when necessary.
6.15.16 Initial installation shall include 20% spare thermocouple extension and instrument signal
wires between the junction box on the control board and the principal junction boxes in the area.
6.15.17 All conductors shall be terminated in strict accordance with the manufacturers
recommended methods. Particular care and compliance with manufacturers instructions shall be
utilized in connection with terminating high voltage cables.
6.15.18 Solderless crimp type cable connectors shall be used on insulated cable sizes #10 A.W.G.
(6 mm2) and smaller.
6.15.19 Solderless crimp type spade wire connectors shall be used on low voltage signal wiring (16
A.W.G) 1.5 mm2 and smaller.
6.15.20 Numbered or lettered wire Markers shall be installed on control and instrument leads and
thermocouple cables at all terminal points. Identification shall be in accordance with applicable job
drawings (see 6.11 Numbering and identification).
6.15.21 Manufacturers instructions or recommendations for installing, splicing wire or cable,
splicing materials, wiring accessories or other wiring materials shall be adhered to.
Insulating paint shall be used over the insulation of all taps, splices and terminations exposed to
the weather, if applicable.
6.15.22 Cutting wire or cable to required lengths as it comes off a reel requires a location free from
sharp objects.The jacket and insulation thickness on many instrument cables are much thinner than
on power cables and greater protection against damage is necessary. A paved area is usually ideal
but, if not available, a grassy or sandy area is adequate.
Crushed stone, muddy, and shelled areas should be avoided. Where traffic must cross wire as it is
laid on the ground, temporary board ramps should be provided to keep vehicles from damaging the
wire. Additionally these ramps will reduce the tripping hazard to personnel which can result in
serious injury.
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6.15.23 Excess length should be allowed for pulling in. Later this excess length will be discarded,
but the amount must be carefully considered. A reel of wire 1,500 meters long may be used to make
15 No. ninety-meter runs. If 10-meters cutting allowances are used, and included in the 15 one
hundred meters lengths which are cut, the reel will be adequate in length. If more than 10 meters
are allowed, the reel will not be adequate and additional wire will have to be secured.
6.15.24 A cable end preparation should accomplish the following:
a) Terminate jackets and shield material without nicking insulation underneath.
b) If no pair jacket is used, and pairs are individually shielded, then insulating tape or
sleeving should be applied to exposed shielding in order to protect against accidental
grounds and hold any spiral wrapped shielding material in place without unravelling.
c) Ground drain wires should be insulated against accidental grounds.
d) Shields should be stripped back a minimum distance from the ends of the wires. A
maximum of 25 mm is recommended.
e) Tagging should identify cable, pair, and service.
f) All cable ends should be protected against moisture entry prior to connecting the cable to
its permanent terminations.
6.15.25 Stripping insulation from wire should be done without nicking the conductor. Such nicks
result in stress concentration which can cause failure while bending the wire during installation,
repair, or normal vibration. Although this is of greater importance with solid wire than with stranded
wire, it is a matter of concern with stranded wire also. The simplest way of avoiding nicks is to use
commercially available stripping tools of proper design.
6.15.26 Terminal screws should be torqued adequately to get good contact with the wire inserted
under the screw.
6.15.27 On tubular screw terminals and wire smaller than 2 mm2 (14 AWG), it is recommended to
doubling back the wire under the screw to assure good connections.
6.15.28 Proper compression of the terminal screws is necessary to prevent products subject to
corrosion from later causing poor continuity, galvanic, or rectification action.
6.15.29 Spade lugs should be used to terminate wire ends where screw terminals are used,
specially for 1.5 mm2 (16 AWG) and smaller if solid, and for all sizes of stranded wire.
6.15.30 All wires or leads terminated of a connection should have sufficient slack to reduce the
effects of vibration.
6.15.31 In applications where multiple wires are routed from a common cable trunk to equally
spaced terminals, the vibration bends should be uniform in length to prevent stress on any one wire.
6.15.32 Proper cable support is necessary to avoid having cable weight supported from wire
terminations.
6.15.33 Support bars and tiedowns in junction boxes should be incorporated, for the weight support
if applicable.
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6.16.6 Tray fittings, such as branches, reducers, flat elbows, tees and crosses, shall be used for
changes in direction and elevation. The dimensions of tray fittings shall provide ample bending radii
for the cables contained in them at all changes in tray direction.
6.16.7 Tray shall be carefully aligned and leveled plumb and true. Tray sections and fittings shall be
assembled on their supports and joined together, using manufacturers standard connector units,
properly aligned, and secured.
6.16.8 Steel angles, trapeze hangers, channels, bolting and miscellaneous materials required for
the support of trays from the building structure, shall be supplied and installed. Additional supports
as required shall be provided for individual cables where the cables leave trays before reaching
their final terminations.
6.16.9 Where it is necessary to field cut and fit galvanized tray, the sub-contractor shall remove all
rough edges and burrs and touch up bare metal surfaces with primer followed by aluminum paint.
6.16.10 To repair damage to the polyvinyl chloride coating and where it is necessary to field cut and
fit polyvinyl coated tray the sub-contractor shall remove all rough edges and burrs and shall apply
PVC protective coating or epoxy paint in accordance with the tray manufacturers detailed
procedures and recommendations.
6.16.11 Polyvinyl chloride coated trays and fittings shall be furnished with the splice plate or
connection device area not coated, in order to assure metal to metal contact and assure earth
continuity. The splice or connection device and adjacent uncoated area shall be restored in the
same manner as described for field cut and fit procedures.
6.16.12 The polyvinyl chloride coated tray system is to be connected to the grounding system. To
accomplish this, the polyvinyl chloride coating shall be removed on the side channel, a hole shall be
drilled and an earthing connector attached by means of a round head machine screw, lockwasher,
and nuts, the head of the machine screw being on the inside of the tray. The adjacent disturbed
area shall be restored in the same manner as described for field cut and fit procedures.
6.16.13 Long runs of cable shall be fixed to suitable cable trays or otherwise supported throughout
its length. The cable shall be mechanically supported up to the point of entry to the equipment in
which it is being terminated, except that flexible leads may be unsupported for the last 600 mm.
6.16.14 Instrument cables shall be located at a sufficient distance from any hot surface to avoid
damage.
6.16.15 In control rooms runs from the junction boxes terminating multi-core cables to individual
instruments should be in non-metallic troughing with protective covers.
6.16.16 Cable trays and trunking can be made of conducting or non-conducting materials. The latter
is preferred. Metal cable trays should preferably be plastics coated.
6.16.17 For more details refer to Figs. 6 & 7, on pages 26 & 27.
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7.1 Routing
The shortest possible routing shall be selected, taking into account the aspects mentioned below.
7.2 Trenches
7.2.1 The trenches shall be kept away from those for electric cables for power and illumination and
wherever possible shall not run in parallel with them at a distance of less than 0.6 meter.
7.2.2 At crossing of trenches for signal cables with those for electric power cables the separation
between the highest cable in the lowest trench and the lowest cable in the highest trench shall be at
least 0.3 m.
7.2.3 Trenches shall be kept away from buried pipes containing hot fluids and from pipes liable to
temperature rise due to steaming-out.
7.2.4 It is of paramount importance to avoid deterioration of signal lines due to ingress of solvents,
acids, etc., in the trenches. Where possible the trenches shall be kept above ground-water level.
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7.2.5 The signal lines shall be at such a depth that they are not damaged by traffic passing over
them.
7.2.6 Where trenches are made in soft soil, signal lines shall be laid with sufficient slack (especially
at riser points) to prevent stresses.
7.2.7 Signal lines shall be laid on, and be covered with, sand on top of which tiles shall be laid for
mechanical protection.
7.2.8 The location of trenches shall be clearly marked and no excavation shall be allowed without
permission given by instrument department.
7.4.1 Trenches
a) In paved areas between control center and processing areas, trenches may be
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7.4.2 Trunking
a) The trunking shall be firmly supported, wherever possible the supports shall be arranged
in such a way that cables can be laid sideways into the trunking instead of pulling them
through consecutive holes.
b) To prevent stresses on cables, they shall be suitably fixed in the trunking, especially in
vertical trunking.
c) Based on an average cable diameter of approx. 25 mm, the following table gives the
quantity of cables to be accommodated in each standard size of trunking, leaving space for
individual signal lines, possible later extensions, etc.
1 9 12 18 27
QUANTITY OF MULTICORE CABLES
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FIGURES
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Notes:
1) Front of trunking to be kept free to facilitate laying of cables.
2) Multicores to penetrate as far as possible into plant before coming above ground,
consistent with above ground runs being located away from potential fire hazards as much
as possible.
3) Pneumatic multicores and ext. cable to be laid in same trunking as required.
4) details of pneum tubing-refer Fig. 3.
5) Details of t.c. wiring-refer Fig. 4.
6) sufficient headroom required to easily remove channel covers.
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Notes:
1) All dimension in millimeters unless stated otherwise.
2) Dimension "X" to be 500 mm, unless stated otherwise.
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Note:
Length of angle to be increased if two marshalling boxes are installed adjacent to each
other.
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ISOMETRIC VIEW
DETAIL OF RAIN CANOPY FOR MARSHALLING & DISTRIBUTION BOXES
Fig. 10
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PLAN VIEW
DETAIL OF RAIN CANOPY FOR NON WEATHERPROOF LARGE DISTRIBUTION BOXES
Fig. 11
Notes:
1) Rain canopy for distribution box to be constructed similar to rain canopy for marshalling
box given on this drawing.
2) Width of frame to be increased if necessary depending on width of distribution box to give 150 mm
overhang at front of distribution box.
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