Today’s manufacturing and processing operations are largely measured & controlled by electronic circuitry. Instrumentation cables monitor process parameters such as pressure, flow rate, and temperature and transmit low voltage signals to the instrumentation or process control room. To ensure accuracy and greater control, interconnecting cables have to be reliable and durable. Instrumentation cables are widely classified depending upon the application.

Manufactured to BS 5308, . These cables are used in diverse applications within industrial process manufacturing plant for control, communication, data (analog/digital) and voice transmission signals, industrial signaling and process control circuit required typically in process industries, oil, gas & petrochemical industry, fertilizers, cement, steel etc. For Instrumentation cables screening plays a vital role; the Al-Mylar screen of the Instrumentation cables, designed and manufactured by Hadron Power Cables, captures the external noise pickups. Also, the ATC drain wire earths the noise pickups which would otherwise cause interference in the low level signals passed between the measuring end and display units.

These cables are designed with a minimum overlap of 25% of the shield that ensures 100% coverage even when the cable is flexed. The carefully produced stranded copper conductors used in the cable maintain high system accuracy and sensitivity. Maximum rejection of electromagnetic noise is achieved by twisting the insulated conductors. Twisting causes the noise to be cancelled in adjacent sections of the wire. Instrumentation cables are generally designed & manufactured based on BS EN 50288 (formerly BS 5308), EIL 6-52-46 and generally as per IS 1554-1, IS 7098-1, IEC 60502-1.

Instrumentation Cable manufactured by Hadron Power are are suitable for operation at voltages up to and including 300V r.m.s core to earth and 500V r.m.s core to core.

PURPOSE

The purpose of this specification is to define the minimum requirements of design and manufacture of instrument cables and related accessories.

 

SCOPE

 The scope of work shall include design, manufacture, testing and supply of instrument cables and related accessories. The inspection requirements shall be as per the inspection plan.

 

CONSTRUCTION

CONDUCTOR

Instrumentation cables are manufactured with Electrolytic Copper (Plain or Tinned) conductor in form of Solid (class 1), Stranded Circular (class 2) or Flexible (class 5) as per IS 8130, IEC 60228 & BS EN 60228.

 

INSULATION

Based on rated conductor & electrical characteristics insulation materials such as PVC (70o C), HR PVC (85o C), XLPE (90o C) or Polyethylene (70o C) are offered.

 

INDIVIDUAL SCREEN

Twisted Pair or Triad are individually shielded with Aluminum-Mylar tape along with ATC Drain wire in continuous contact with Aluminum side of the tape. Shielding of Copper tape can also be provided to meet specific requirements.

 

PAIR/TRIAD IDENTIFICATION

Pair or Triad identification can be done by numbered polyester tape applied over each pair / triad or by number printing on core of each pair / triad or by different color coding.

 

OVERALL SCREEN

Multipair / Multitriad are laid up together and are shielded with Aluminum-Mylar tape along with ATC Drain wire in continuous contact with Aluminum side of the tape. Shielding of Copper tape can also be provided to meet specific requirements.

 

INNERSHEATH

Extruded PVC / LSZH inner sheath is applied as a protection over the laid up pairs / triads.

 

ARMOUR

Galvanized steel wire or strip are applied spirally over inner sheath as a mechanical protection for cable.

 

OUTERSHEATH

Extruded sheath is provided depending on the application requirements such as temperature, flame retardancy (FR), reduced smoke & acid gas emission (FRLS), Halogen free (LSZH / ZHFR).

 

Products-Instrumentation Cable

  1. OVERALL SCREENED INSTRUMENT CABLE – PE /PVC
  2. INDIVIDUAL & OVERALL INSTRUMENT CABLE – PE/PVC
  3. OVERALL SCREENED INSTRUMENT CABLE – PE/PE/SWA/PVC
  4. INDIVIDUAL & OVERALL INSTRUMENT CABLE- PE/PE/SWA/PVC

 

PARAMETERS UNIT CONDUCTOR AREA
0.50 mm2 0.75 mm2 1.00 mm2 1.50 mm2 2.50 mm2
Maximum D.C. Resistance of plain copper conductor at 20o C Ω/km 39.7 26.5 18.5 12.30 7.56
Maximum D.C. Resistance of Tinned copper conductor at 20o C Ω/km 40.5 27.0 18.9 12.50 7.70
Maximum D.C. Resistance of 0.5mm2 ATC Drain wire at 20o C Ω/km 30 30 30 30 30
Maximum mutual capacitance core to core (PVC insulated) nF/km 250 250 250 250 250
Maximum mutual capacitance core to core (PE, XLPE insulated) nF/km 115 115 115 115 115
L/R ratio maximum  μH/ohm 25 25 30 40 70
Electrostatic Noise Rejection Ratio as per IEEE Vol3 (minimum) dB 76 76 76 76 76
Minimum Insulation Thickness  mm 0.50 0.50 0.50 0.50 0.50
Minimum Insulation Resistance at 27o C (PVC insulated) at 500V MΩ/km 10 10 10 10 10
Minimum Insulation Resistance at 27o C (XLPE, PE insulated) at 500V MΩ/km 100 100 100 100 100
High Voltage test  kV 1.0 kV for 1 Minute