CABLE BLOCK DIAGRAM

GENERAL GUIDELINES

PROJECT:

CLIENT:

LOCATION:

CONSULTANT:
ISSUED FOR
C1 22-Sep-23 COMMENTS AND NK SS/UK JW
APPROVAL

REV. DATE REVISION DESCRIPTION PRPD. BY CHK. BY APPR. BY

DOCUMENT ISSUED FOR DOCUMENT NO. PROJECT NO.

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In-house Review Design

Issued to Vendor Construction

Client Comments Client Approval

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TABLE OF CONTENTS

1. PURPOSE.........................................................................................................................................3

2. SCOPE..............................................................................................................................................3

3. ABBREVIATIONS...............................................................................................................................3

4. INPUTS & REFERENCES......................................................................................................................3

5. JUNCTION BOX.................................................................................................................................4

5.1 JUNCTION BOX TAGGING....................................................................................................................4

5.2 JUNCTION BOX LOADING/GROUPING............................................................................................4

5.3 TYPES OF JUNCTION BOX..............................................................................................................4

6. CABLE..............................................................................................................................................5

6.1 CABLE TYPES/SPECIFICATIONS.......................................................................................................5

7. CREATION OF CABLE BLOCK DIARAM.................................................................................................6

8. PARALLEL COORDINATION – CBD and Termination Diagram / Cable List..............................................7

9. PACKAGE – CBD and Termination Diagram / Cable List.......................................................................8

10. SMART – CBD...............................................................................................................................9

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1. PURPOSE
The Purpose of this document is to provide to Instrument Engineers/Designers general guideline for
development of cable block diagram.

2. SCOPE
The guideline covers defining the field instruments cables, type of junction box, I/Os and Control
system types which are part of ICSS system.

Also, to note the documents listed under reference section 4 are input documents for executing
cable block diagram activity.

3. ABBREVIATIONS
AI: Analog Input
AO: Analog Output
DI: Digital Input
DO: Digital Output
CP: Control Panel
CS tag: Control System tag
ESD: Emergency Shutdown System
FGS: Fire and Gas System
ICSS: Integrated Control and Safety System
IP: Ingress Protection
JB: Junction Box
LCP: Local Control Panel (Outdoor Panel)
PCS: Process Control System
PSS: Process Safety System
SIF: Safety Instrumented Function
SPI: Smart Plant Instrumentation

Note: I/O’s related to SIF Loop shall be allocated to PSS system.

4. INPUTS & REFERENCES

S.No Document Title
1 Topsides P&IDs
2 Instrument Index/LIST

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3 Instrument Layouts
4 Sublocation List
5 GTS – APPENDIX A Instrument Junction Box PESDINPF550016
Details
6 TOPSIDES PCS/PSS I/O List
7 TOPSIDES ESD/FGS I/O List
8 Mechanical Package Vendor Drawings
9 Electrical Cable Specification PECEELPF447001
10 Electrical and Instrumentation Cables PECEELPF999001
selection and rationalization Technical
Guidelines

5. JUNCTION BOX

5.1 JUNCTION BOX TAGGING

JBs shall be tagged as per project specific tagging procedure.

5.2 JUNCTION BOX LOADING/GROUPING

Group the signals that are geographically located closer and assign to a junction box. While grouping
tag numbers to junction boxes the following rules should be followed

Separate junction boxes should be considered for signals going to different systems like
- Process Control System (PCS)
- Process Safety System (PSS)
- Emergency shutdown system (ESD) & Fire & Gas monitoring system (FGS)

Further, separate junction boxes should be considered as below:

- JBAs: Dedicated JB for AI & AO signals (inputs and outputs). Separate JB should be considered
for 3 wire instruments.
- JBDs: Dedicated JB for DI & DO Signals (Inputs & Outputs)
- JBEs: Dedicated JB for Power (for externally powered instruments)

Separate junction boxes should be considered for intrinsic safe signals (JBAI/JBDI).

5.3 TYPES OF JUNCTION BOX

- TYPICAL-1 (24 Terminals)
- TYPICAL-2 (36 Terminals)
- TYPICAL-3 (76 Terminals)

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6. CABLE

6.1 CABLE TYPES/SPECIFICATIONS

Each type of cable for both electrical and instrumentation circuits shall be designated by the
following type references as per GTS PECEELPF447001(Electrical Cable Specification)

Following cable types are considered for instrumentation.

- Cable Type P (Externally powered Instruments Low Voltage, Flame retardant)

o Used for PCS/PSS System

- Cable Type R (Field Instrument Collective Screen, Flame Retardant)

o Used for PCS/PSS System

- Cable Type S (Field Instrument Individual Screen, Flame Retardant)

o Used for PCS/PSS System

- Cable Type PF (P + Fire Resistance)

o Used for FGS/ESD System

- Cable Type RF (R + Fire Resistance)

o Used for FGS/ESD System

- Cable Type SF (S + Fire Resistance)

o Used for FGS/ESD System

- Cable Type RFB (RF + Intrinsic safe)

o Used for PCS/PSS/FGS/ESD

- Cable Type SB (S + Intrinsic safe)

o Used for PCS/PSS

- Flame retardant cables are designed to resist the spread of fire into a new area.

- Fire resistant cables are designed to maintain circuit integrity and continue to work for a
specified period under defined conditions.

- Intrinsically safe cables are usually colored blue to identify the potential risk of the electric
circuit and the need for special consideration. The cables are often protected by tough
sheathing materials such as polyurethane to prevent any mechanical damage which could
compromise electrical safety.

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Cable core identification shall be as below:

7. CREATION OF CABLE BLOCK DIARAM

Initially Cable block diagram should be prepared based on the 3D model extraction and
sublocation of the instruments.

Based on the Instrument located in different Modules & levels the Junction box are
selected/located and grouped as mentioned under section 5.2.

The cables have to be selected from the default cables available in SPI (Default Cable
types in SPI will be created by SPI admin based on DLD input during initial phase of the
project). Cable sizes are selected as per GTG PECEELPF999001(Electrical and
Instrumentation Cables selection and rationalization Technical Guidelines) and in
consultation with project DLD.

7.1. Process Flow of CABLE BLOCK DIAGRAM

The Process starts from Filed instruments which are grouped (Single Pair Cables) and
connected to junction box, the cables which are connected from filed instrument to junction
box are selected based on the signal type/system function (PCS/PSS/ESD/FGS) Refer Section
6.1 on selection of cable type/Specification.
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From Junction box, a multipair cable is selected based on how many instruments are
connected and routed to ICSS system (LCP and CP) Refer section 6.1.
We have to make sure that the junction box must have 20% spare for future connections.

Below is the example for the process flow from filed to control panel.

7.2. EXAMPLES:

PCS/PSS – ANALOG SIGNALS (FIELD ------> JB ------>LCP)

SINGLE PAIR CABLES

MULTIPAIR CABLE

LHS RHS

After the Filed Instruments are grouped based on the levels with selected Junction Box. The
single pair instrument PCS cables are connected on the Left-hand Side (LHS), now we need to
select the Multipair cable which should be connected to local control panel. The process of
selecting the multipair cable is based on the total instrument pair cables which are
grouped/Connected to the junction box on the LHS.
Multipair cable will be connected on the RHS of the JB routing to LCP.

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Cable Type used on LHS is 1x2x1.0 R(Collective screen Refer Section 6.1) – which is single pair
cable for PCS analog signals.

Cable Type used on RHS OF JB is 12x2x0.75 S (Individual & Collective screen Refer Section 6.1)
which is multipair pair cable for PCS analog signals connected to Local control panel(LCP).

Note: Similarly way PSS signals are connected to PSS analog JB to LCP.

PCS/PSS – DIGITAL SIGNALS (FIELD ------> JB ------>LCP)

LHS RHS

Where as in Digital JB we can combine DI & DO’s in same JB, from the above picture on the LHS
we can see Limit switches with 2x2x0.75 R is connected and Solenoid power cables 2x2.5 P
cables are connected.

Cable Type used on LHS is 2x2x0.75 R (Collective screen Refer Section 6.1) connected to JB.
JBZS is combination of ZSO & ZSC.

Cable Type used on RHS is 8x2x0.75 R (Collective screen Refer Section 6.1) which is multipair
pair cable for PCS digital signals connected to Local control panel (LCP).

Multipair cable is Selected based on how many signals are connected to the junction box on
the LHS.

Note: Similarly way PSS signals are connected to PSS digital JB to LCP.

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8. PARALLEL COORDINATION – CBD and Termination Diagram / Cable List

In the process of the cable block diagram preparation, we must create cables, Junction
Box and Local Control panels (LCP’s) & Control Panels (CP’s) in SPI based on CBD.

Once the Junction box and Cables are created in SPI, Cables to be terminated to the
respective Junction box and control panels based on the Cable block diagram.

Addition/Deletion/Update of cables if any during each revision must be done in CBD/SPI-

Termination/Cable List judiciously in order to ensure that the cable list being issued to electrical
for procurement is correct and up to date.

- Addition: During addition No existing cable/deleted cable can be re-used while creating a
new cable in SPI.

- Deletion: Cable deleted to be mentioned as “_DEL” at the end of the Cable tag in SPI for
Identifying that it got deleted. The same should be marked in CBD and it has to be updated in
the cable list for next revision parallely.

- Update: In SPI, If any Cable Type/Size has to be changed (For Ex. Cable Type is modified or
instead of 4 pair we need to change to 8 Pair, then the current cable to be deleted and new
cable shall be created and the same has to be updated in CBD and Cable list parallely.

The changes should be marked-up on the CBD with appropriate FONT style (Text and Color)
that means it should be legible.

9. PACKAGE – CBD and Termination Diagram / Cable List

Package CBD is created purely based on the vendor inputs. Once the inputs are provided by
vendor, CBD is created.

While creating the cable block diagram based on the Vendor inputs, If any information is not
available or missing inputs from vendor, A notification/Mail is sent to the respective package
engineer to provide the required information as soon as possible. So that the CBD,
Termination and Cable-list can be updated/revised accordingly.

Once required inputs are available, the same should be marked-up on the CBD with
appropriate FONT style (Text and Color) that means it should be legible.

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Below is the flowchart for Package CBD.

PACKAGE
VENDOR

JUNCTION BOX
CREATION IN
SPI

VENDOR
INPUTS MISSINNG
INFORMATION
OR INPUTS
PENDING

PACKAGE CBD
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PREPARATION
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BASED ON VENDOR
INPUTS/DATA
FINAL
CABLE BLOCK
DIAGRAM
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TERMINATION DIAGRAM CABLE LIST UPDATE

10. SMART – CBD
In Smart CBD, The Junction box and Cables tags numbers are created under some attributes
(Blocks/Macros) in AUTOCAD, this can easily extract the tag numbers, From and to location of the
cables and Cable from CAD.

This procedure makes the error free, and the cable list can be updated without manual entry.
Due to which we can save so much of manhours.

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