电气接线标准.docx
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电气接线标准
WORKINSTRUCTION
DKIGENERALWIRINGPRACTICES
1.Scope
ThisworkinstructionshallbeappliedintheDiamondKeyInternationalWorkshopsElectricalwiringonskidsorassociatedisrequired.
Allwiringtobeperformedbyqualifiedexperiencedwiringpersonnelusingappropriatetoolsforstrippinginsulation,cutting,solderingandattachingmechanicalcrimptypeterminalswiththecorrectdiesandtoolsasadvisedbytheterminalmanufacturer.
ForemostelectricalinstallationsaretobeperformedtolatestissueofwiringrulesAS/NZS3000aswellasIECdirectives
2.Generalinstallation:
2.1.Whenremovinginsulationfromtheconductor,wirestrandsshallnotbenickedordamaged.Properstrippingtoolsshallbeusedtoavoidsuchdamage.
2.2.Wireandcabletiesshallbesnugbutshallnotbesotightastocauseindentationandcoldflowdamagetotheinsulation.
2.3.Cabletiesshallbetensionedandtrimmedusingcabletiemanufacturerstooling.
（Useofsidecuttersfortrimming,isnotpermitted）
2.4.AllwiringwithinExe,Exiorsimilarenclosurestobeterminated.
2.5.Wherepossible,adhesiveinstalledmountingbasesshouldnotbeusedfortiesorcablesupportunlessaffixedwithamechanicalfastener.
2.6.Wireandcabledressshallallowsufficientslackforremovalandreapplicationofthewireterminations,atleasttwicewithoutexcesstension.
2.7.Allwireandcable,includingthatinductsandconduit,shallbehandledtobefreefromkinksandinsulationabrasions.
2.8.Wireinstallationshallnotbesubjecttoaccumulationofwater,oilorotherforeignmatter.
2.9.InstrumentcablesaretobefreeofOrangedrainwires.
2.10.Cabletobelaidoutneatlyandunduecrossingofcablesistobeavoided（referAppendix3）.
2.11.Allwireshallbeprotectedagainstanycontactwithanysurfaceotherthanthatdesignedspecificallytosupportorprotectthewire.
2.12.Protectiveedging,Grommetsandsimilarmaterialsshallbeappliedwhereveranypossibilityexistsforawiretocontactasharpedge.
2.13.Adriploopshallbeprovidedineachwireorcablewherewatercouldotherwiserunalongthewireorcabletothepointwhereitentersaboxorenclosure.
2.14.Wire/cablesformingpartofthewiringsystemshallbebentinamannerthatwillnotcausedamageorplaceunduestressontheirsheathingorinsulation.
2.14.1.1.Wheremanufacturer’sinformationonrecommendedbendradiiisnotavailable,thefollowingradiimaybeconsideredsuitable
2.14.1.2.Unarmouredsheathedcables6timesthecablediameter
2.14.1.3.Armouredsheathedcables12timesthecablediameter
2.14.1.4.（ChangeofdirectionAS/NZS30003.9.7.）
2.15.Wirejumpersondevicesshallberunwithintheloom,soastonotbemisplacedondevicereplacement.
3.CableColorsandtype:
WherepossibletheDKIstandardsforcablecolorsaretobestrictlyfollowed
3.1.Powercables–110v–240vOrange
3.2.Instrumentcables–0v–24vBlack
3.3.IScables-Blue
3.4.Flexiblecablesandcordsshallbe0.6/1kVor450/750Vrated,heavyduty,withmultiplestrandedtinnedcopperconductorsof1.5sqmmminimumcrosssectionandwithatinnedcopperbraidedscreen.
3.5.InsulationmaterialsmaybeeitherPVC,EPRorNBR
3.6.ScreensshallbeincludedinallZone1cables,withtheexceptionofshortlengths（not>600mm）ofinstrumentcables
3.7.WireandcabletypeusedshallbeasstatedonDKIdrawings,alternativesshallbesubmittedforDKIapproved.
3.8.Cablesusedforthetransmissionofsignalsfromtemperature,pressure,speed,flow,weight,levelandsimilarsignals,orany4-20mA,0-20mA,24VDCorsimilarextralowvoltagesignalshallcomprisetwistedscreenedpairs.
3.9.WireandcablesizestobeasstatedoragreedbyDKIcableblockdiagramandcableschedule,alternativesshallbesubmittedforDKIapproved.
4.WireColorsinsideofExe,Exdboxesandjunctionboxesshallbe:
240vActive
∙Red
∙White
∙Brown
240vNeutral
∙Black
∙LightBlue
240vEarth
∙Yellow/green
Allearthbonding
∙Yellow/green
+24vdc
∙Grey
24OV
∙Brown
+12vdc
∙Orange
12OV
∙Blue
4.1.Inextremecaseswhereuseofdifferentcorescolorisunavoidable,thenheatshrinksleevingappliedtothecoresisrequired.
5.Wiresegregation:
-
5.1.SegregationofwiringwithdifferingvoltageratedInsulationi.e.Dekoron110vacandPower/control0.6/1kvisamandatoryrequirement..
5.2.Theminimumseparationdistancebetweensuchcablesortheirrelatedequipmentshallnotbelessthanthedistancesgiveninthefollowingtable:
Circuitrating
（kVA）
Unshielded
powercables
（mm）
Shielded
powercables
（mm）
<1
300
25
>1<2
450
50
>2<5
600
150
>5
1500
300
SeparationbetweenPowerandSignal/DataCables
5.3.IntrinsicallySafecablesmayonlyruntogetherwithnonI.S.cablesprovidedthateithertheIntrinsicallySafecablesorthenon-I.S.cablesarearmoured.
5.4.Whereanon-armouredintrinsicallysafecableisinstalledwithnonarmouredpowerandcontrolcables,asegregationdistanceof50mmminimummustbestrictlyobservedthroughoutthecompletecablerun,andwithinanyswitchboard,junctionboxandthelike.
6.WireMarking:
-
6.1.AllwiresregardlessoflocationshallbeplainlyandsuitablyidentifiedwithDKIapproved,wiremarkersonbothendsoftheconductor,asperDKIwiringdiagrams.
6.2.Eachendofthewireshallhavethesameidentifyingmarkere.g.RTD+1,OUT#46AC,ESS-A,andetc（ReferAppendix1）.Donotlabelthecablecoresaccordingtocablecolournoraccordingtotheterminalthatthewireisconnectedto.
6.3.Labelingonbothendsofacable/coremustbeidentical.Ifpossible,itshouldbeconsistentthroughoutthecircuit.
6.4.Inadditiontonumbering,allcablescarryingIntrinsicallySafecircuitsshallbeidentifiedbya200mmlengthofBLUEheatshrinkmaterialateachtermination（i.e.ateverycableglandingpoint）.
7.PullingCompound:
-
7.1.PullingCompound,ifused,shallbenon-conductiveornon-odorous.
8.Conduit-Rigid:
-
8.1.ConduitshallbeSteelGalvanisedandconformtoAS/NZS2053.7inconjunctionwithAS/NZS2053.1orIECdirectives
8.2.Conduitbendsshallhavesuitablebendradiiforthenumberofwiresbeingcarried.
8.3.Conduitshallhavenomorethan40%fillratiofornewinstallations.
8.4.ConduitElbowsandTeesshallbeSteelandoftheinspectiontype.
8.5.Conduitentriesaftercuttingandthreadformingshallnothaveanyburrsorsharpedgesinsideoroutside,withallfilingsremovedbeforeinstallation.
8.6.Conduitentry/exitsintoEnclosuresorjunctionpointsaretohaveNylonorbrassbushes.
8.7.Conduitshallnotbeweldedtoanystructures.
9.ConduitSealingFittings:
9.1.Conduitsealingfittings（stuffingboxes）musttocomplytoASorIECstandards
9.2.InprinciplesealingisnottobedoneuntilaftertheFAT
9.3.Manufacturessealingcompoundisonlytobeused
9.4.Sealingmustbedoneinaccordancewiththemanufacturesinstructions
9.5.Forverticalsealingaphysicalbarriersuchassiliconmustbelaidatthelowerpointoftheconduitsealtoensurethecompoundcannotpass/drippastthesealingarea.
9.6.Forhorizontalsealingaphysicalbarriersuchassiliconmustbelaidatbothendpointsoftheconduitsealtoensurethecompoundcannotpass/drippastthesealingarea.
9.7.Allwirespassingthroughtheconduitsealmusthaveallouterinsulationandanyplasticwrappingremoved.Ensurethattheremovaloftheinsulationisvisible/traceableevenaftersealinghasbeendone（forinspectionpurposes）.
9.8.Allwiresaretobestraightenedandnottwistedtogetherwhenpassingthroughthesealingarea.
9.9.Sealingcompoundistobemixedasperthemanufacturer’sinstructions,
9.10.PouringofthecompoundmustensurethatthesealingfittingiscompletelyfilledtotherequiredlevelandmustnotcoverthePlugbungthread.
9.11.Sealingfittingplugs/bungsarenottobeinstalleduntilthesealingcompoundhashardenedtoensuretheplug/bungisnotincontactwiththecompound.
10.Conduit-Flexible:
-
10.1.FlexibleconduitshallbeofaDKIapprovedtypesuchasSealsafe.
10.2.EquivalenttypesmaybepresentedtoDKIforapproval）
10.3.ConduitandfittingsshallberatedtoIP66whenentering/exitingenclosuresorterminationjunctionboxes.
10.4.WhenaFlexibleconduithasIScableinsidebothendsoftheconduitmustbesleevedinbluecolor.
11.CableGlands:
-
11.1.GlandsaretosuittheHazardousapplication.AndconformtoIECorASstandards
11.2.Glandsaretobeofcorrectsizeforthecablesused.
11.3.AllGlandsenteringanExdboxmustbeBarriertype
11.4.AllglandsenteringanExeboxmustberatedExetypeminimum.
11.5.Glandstobetightenedtomanufacturersrecommendations.
11.6.BarrierGlandstohavethecorrectepoxyresinapplied,tomanufacturer’sinstructions.
11.7.GlandstohavenylonwashersfittedtoEnclosureexternals.
11.8.GlandstohaveShroudsfitted,unlessrequestedbythecustomernotto.
Cableglandtypesshallbeselectedasfollows:
Cabletype
Enclosure
GlandType
Manufacturers
PVC/PVC/SWA/PVC
XLPE/PVC/SWA/PVC
Exe
CompressionglandscertifiedExeandfittedwithasealinggasket
∙Crouse-HindstypeTWAE
∙CMPE1FWseries
PVC/PVC/SWA/PVC
XLPE/PVC/SWA/PVC
Exd
SeeAS/NZS60079.14Figure2
CompressionglandcertifiedExdandfittedwithsealinggasket
∙CMPE1FWseries
BarriertypeglandcertifiedExd
∙Crouse-HindstypeTWAB
∙CMPPX2Kseries
PVCorEPRScreenedFlexible
ExeorExd
∙CMPE1FXseries
PVC/PVC
XLPE/PVC
IntrinsicallySafecircuits
Generalindustrialglands.
∙Crouse-HindsTUA
∙CMPA2series
PVC/PVC/SWA/PVC
XLPE/PVC/SWA
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