Best Practice

SABP-J-902 1 September 2016

Installation Guidelines for Instrumentation Wiring and Terminal Blocks
Document Responsibility: Instrumentation Standards Committee

Contents
1 Purpose ......................................................... 2
2 Scope ............................................................ 2
3 Disclaimer ...................................................... 2
4 Conflicts with Mandatory Standards .............. 2
5 References .................................................... 2
6 Safety Precautions......................................... 3
7 Recommended Tools
and Wiring Preparation ............................ 4
8 Termination Procedure .................................. 7
Revision Summary............................................... 9

Previous Issue: New Next Planned Update: TBD

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Contact: Faihan, Lahdan F (alfaihlf) on +966-13-8801141

©Saudi Aramco 2016. All rights reserved.

Document Responsibility: Instrumentation Standards Committee SABP-J-902
Issue Date: 1 September 2016
Next Planned Update: TBD Installation Guidelines for Instrumentation Wiring and Terminal Blocks

1 Purpose

The purpose of this document is to establish installation guidelines and recommended

procedures for instrumentation wiring and terminal blocks installed at Saudi Aramco
facilities.

2 Scope

The installation guidelines and recommended procedure presented in this practice,

addresses both screw type terminal block and pressure loaded (screw-less) terminal
block. Proper tools and wiring methods are introduced in this document.

3 Disclaimer

This document provides most correct and accurate installation guidelines for
instrumentation wiring and terminal blocks which comply with international industry
practices and vendor recommendations. This document is being provided for the
general guidance and benefit of plant Maintenance and Operations after due diligence,
but it does not take away overall professional and ethical responsibility from the end
user. Plant maintenance and operations are still responsible to make sure electrical
systems for instrumentation installed at their plants is fully functional.

4 Conflicts with Mandatory Standards

Any recommendation in this SABP is not mandatory. In the event of a conflict between
this Best Practice and other Mandatory Saudi Aramco Engineering Requirement, Saudi
Aramco Engineering Procedures (SAEPs), Saudi Aramco Engineering Standards
(SAESs) and Saudi Aramco Materials System Specifications (SAMSSs), the Mandatory
Saudi Aramco Engineering Requirement shall govern.

5 References

The selection of material, equipment, and the design, construction, testing, calibration,
maintenance, and repair of equipment at different facilities covered by this practice
shall comply with the applicable parts of the latest editions of the references listed
below, unless otherwise noted.

5.1 Saudi Aramco References

Saudi Aramco Engineering Standard

SAES-J-902 Electrical Systems for Instrumentation

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Document Responsibility: Instrumentation Standards Committee SABP-J-902
Issue Date: 1 September 2016
Next Planned Update: TBD Installation Guidelines for Instrumentation Wiring and Terminal Blocks

Saudi Aramco Material Systems Specification

34-SAMSS-913 Instrumentation and Thermocouple Cable

5.2 Industry Codes and Standards

National Fire Protection Association

NFPA 70 National Electrical Code (NEC)

Underwriters Laboratories, Inc.

UL 94 Standard for Safety Test for Flammability of Plastic
Materials for Parts in Devices and Appliances

6 Safety Precautions

Certain precautionary steps must be addressed clearly and adhered to prior to and
during the performance of maintenance and inspection of instrumentation wiring and
terminal block such as, but not limited to the following:
 All required work permits shall be obtained prior to starting any work.
 Maintenance personnel shall be adequately trained accordingly. Only trained
electrical and instrumentation technicians are allowed to work on electrical and
instrumentation components.
Commentary Note:

Trained Electrical and Instrumentation technicians are able to work independently on

electrical equipment and instrumentation and recognize/avoid potential hazards as a
result of their training, knowledge, and experience, as well as their familiarity with
standards and regulations.

 Tools must be inspected to be fit for the service.

 Obtain relevant ISS for the instrument, loop drawings, applicable manuals, and
terminal block datasheet.
 If applicable, Gas/H2S test must be performed prior to and during the job execution
(for potential toxic/hazardous services).
 Person performing work shall have proper PPE, including personal gas detector.
 Work area should be inspected and easily accessible. Proper scaffolding access
should be provided as needed.
Caution:

Touching live parts is a direct risk to life. Damage to the insulation or individual
components may result in fatal injury.
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Document Responsibility: Instrumentation Standards Committee SABP-J-902
Issue Date: 1 September 2016
Next Planned Update: TBD Installation Guidelines for Instrumentation Wiring and Terminal Blocks

Never use damaged or worn-out power cables and never bypass fuses or take them
out of operation.

Inappropriate handling of the product can lead to injuries. All activities must therefore
be carried out by qualified personnel only.

7 Recommended Tools and Wiring Preparation

7.1 These recommended tools can be used for preparing wiring that will be used to
connect instrumentation to terminal block.
 Electrical Wire Cutter

 Electrical Wire Stripper

 Wire End Ferrules and Crimping

 Torque Screwdriver

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Document Responsibility: Instrumentation Standards Committee SABP-J-902
Issue Date: 1 September 2016
Next Planned Update: TBD Installation Guidelines for Instrumentation Wiring and Terminal Blocks

7.2 The following steps show the work to be carried out to prepare instrumentation
wiring prior termination.
 Cut the instrumentation wire with proper cutter to ensure that the wire
insulation and strands cut straight. In addition, correct wiring cutting makes
the wire last longer and more reliable in term of connections. Figure 7.2.1
compares between incorrect wire cutting and correct wire cutting.

Figure 7.2.1 - Correct Wiring Cutting

 Use the correct stripping length (given on terminal block datasheet).

Use additional margin when wire end ferrules are used. Ensure the electrical
stripper is suitable for standard PVC insulation material, UL-conductors or
halogen free materials. Comparison between failure stripping pattern and
correct stripping can be found in Figure 7.2.2.

Figure 7.2.2 - Correct Wiring Stripping

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Document Responsibility: Instrumentation Standards Committee SABP-J-902
Issue Date: 1 September 2016
Next Planned Update: TBD Installation Guidelines for Instrumentation Wiring and Terminal Blocks

 Ensure to use the ferrule that fits the outer diameter (ØD2) of the insulation
(4.8 mm) and take note of the longer stripping length (12 mm) as compared to
installation without ferrules. For larger insulation diameters, refer to vendor
catalogue for corresponding ferrules. Adjust stripping length to have the
strands flush with the end of the wire ferrule as illustrated in Figure 7.2.3.

Figure 7.2.3 - Wire Correct Stripping Length

 Insert the ferrule into the crimping insert with its full length without
crimping on the plastic collar. Press the handles of the tool completely until
they are released. Remove ferrule for optical inspection. Figure 7.2.4 shows
the proper crimping pattern.

Figure 7.2.4 - Ferrule Crimping

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Document Responsibility: Instrumentation Standards Committee SABP-J-902
Issue Date: 1 September 2016
Next Planned Update: TBD Installation Guidelines for Instrumentation Wiring and Terminal Blocks

8 Termination Procedure

SAES-J-902 mandates that the terminal block material is fire retardant in accordance
with UL 94, V0. Terminals and accessories shall be made of halogen free, high strength
material such as polyamide, or equivalent materials. Brittle materials such as melamine
shall not be used.

8.1 Modular Terminal Block Wiring Termination Procedure

The modular terminal block has two tubular box clamp connector and
compression bar or yoke, which are connected by a current bar. The electrical
conductor is inserted into the wire entrance and it is tightened by screw.
Figure 8.1.1 demonstrates the cut out view of modular terminal block.

Figure 8.1.1 - Modular Terminal Block

The following is a recommended procedure for wiring termination of modular

terminal:
 Check the modular terminal block for any external damage and install it on
the DIN rail mounted plate ensuring tight seating
 Cut the wire to the required length and strip its insulation
o This step should be carried out in accordance to paragraph 7.2.
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Document Responsibility: Instrumentation Standards Committee SABP-J-902
Issue Date: 1 September 2016
Next Planned Update: TBD Installation Guidelines for Instrumentation Wiring and Terminal Blocks

 Push a wire end ferrule over the strands

o Ensure the right size of ferrule is selected and correct stripping length is
used according to terminal block datasheet
 Crimp the ferrule onto the conductor strands. Refer to Figure 7.2.4
 Insert ferrule with cable into the yoke of the modular terminal block
 Adjust the Torque Screwdriver torque to the correct torque value obtained
from the data sheet of the used terminal
 Tighten the screws and perform tug test which can be conducted by slowly
pull the wire to check for wire

8.2 Pressure Loaded (Screw-less) Terminal Block Procedure

The pressure loaded terminal block consists of two elements: the clamp and the
current bar. These two form a self-contained contact unit, which does not
transfer any load to the insulation housing. Figure 8.2.1 shows this terminal
block.

Figure 8.2.1 - Pressure-Loaded Terminal Block

Pressure-Loaded Terminal Blocks are easy to be terminated compares to

Modular Terminal Block. After satisfying wiring preparation steps illustrated in
paragraph 7.2, the next procedure should be performed to wire these terminal
blocks are:
 Check the terminal block for any external damage and install it on the DIN
rail mounted plate ensuring tight seating
 Cut the wire to the required length and strip its insulation
o This step should be carried out in accordance to paragraph 7.2

Saudi Aramco: Company General Use

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Document Responsibility: Instrumentation Standards Committee SABP-J-902
Issue Date: 1 September 2016
Next Planned Update: TBD Installation Guidelines for Instrumentation Wiring and Terminal Blocks

 Push a wire end ferrule over the strands

o Ensure the right size of ferrule is selected and correct stripping length is
used according to terminal block datasheet
 Crimp the ferrule onto the conductor strands. Refer to Figure 7.2.4
 Press down the Clamp with a screw-driver
 Insert the wire into the clamping
 Remove the Screw-driver
 perform tug test which can be conducted by slowly pull the wire to check for
wire

Revision Summary
1 September 2016 New Saudi Aramco Best Practice. The purpose of this document is to establish installation
guidelines and recommended procedures for instrumentation wiring and terminal blocks
installed at Saudi Aramco facilities.

Saudi Aramco: Company General Use

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