Page 1 of 9

STANDARD SPECIFICATION FOR

CONTROL PANELS, GAUGE BOARDS

AND
PANEL INSTRUMENTS

DOCUMENT NO : 44-LK-5100-00/J.02/0012-A4

Rev No. Issue Date Pages Rev Description Prepared Checked Approved
By By By

A 12.08.08 9 Issued for Approval / RCK GDR BSP

Comments
JACOBS ENGINEERING INDIA PRIVATE LIMITED
_________________________________________________________________________

DOCUMENT NO : 44-LK-5100-00/J.02/0012-A4 Date : 12 Aug 2008

STANDARD SPECIFICATION FOR CONTROL PANELS, Page 2 of 9
GAUGE BOARDS AND PANEL INSTRUMENTS Revision No. : A

TABLE OF CONTENTS

1.0 PURPOSE

2.0 SCOPE

3.0 TECHNICAL REQUIREMENTS

3.1 CONTROL PANELS

3.2 LOCAL CONTROL PANELS
3.3 LOCAL GAUGE BOARD
3.4 PANEL INSTRUMENTS

4.0 RELATED DOCUMENTATION

5.0 ATTACHMENTS
JACOBS ENGINEERING INDIA PRIVATE LIMITED
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DOCUMENT NO :44-LK-5100-00/J.02/0012-A4 Date : 12 Aug 2008

STANDARD SPECIFICATION FOR CONTROL PANELS, Page 3 of 9
GAUGE BOARDS AND PANEL INSTRUMENTS Revision No. : A

1.0 PURPOSE

The purpose of this specification is to define the minimum requirements of design and
manufacture of Control Panels , Gauge Boards & Panel Instruments.

2.0 SCOPE

The scope of work shall include design, manufacture, testing and supply of Control
Panels, Gauge Boards & Panel Instruments.

3.0 TECHNICAL REQUIREMENTS

3.1 CONTROL PANELS

3.1.1 All control panels / cabinets shall be supplied in pre-tubed / pre-wired condition and shall
be completely tested at manufacturer's works prior to despatch.

3.1.2 Control panels shall be free standing type and fabricated preferably from 3 mm thick cold
rolled steel sheet. Hot rolled steel sheet of higher thickness shall be used in case 3 mm
thick sheets are not available.

3.1.3 Enclosed cubicle panels shall have removable hinged doors, generally at the side or
back for easy maintenance and accessibility of the instruments. Doors shall be double
leaved type with handle and shall be provided with lock and key. Cubicles inside control
room shall be provided with exhaust fans and louvers.

3.1.4 Panels shall be provided with lifting hooks.

3.1.5 Adequate illumination shall be provided inside the panel. All light fittings shall be suitable
for 230 V, 50 Hz ac.

3.1.6 The panel finish shall include sand blasting, grinding, chemical cleaning, surface finishing
by suitable filler and two coats of high grade lacquer with wet sanding between coats.
Two coats of paint in panel colour shall be given for non-glossy high stain finish

3.1.7 No process fluid of any kind, except instrument air shall enter the control panel. Also
power supply greater than 230 V shall not enter the local panel.

3.1.8 All cable entries to the local panel shall be from panel bottom only. Cable glands of
adequate size must be used for all cable entries. Cable gland plate thickness shall be of 3
mm cold rolled cold annealed (CRCA) as a minimum. All unused cable entries must be
provided with plugs.

3.1.9 Space heater shall be provided where condensation is expected.

3.1.10 The design of control panel shall incorporate provision for expansion by installing
adequate spare capacity. Each panel shall be designed to accommodate the following
additional equipment, as a minimum :

− 20% of panel front / inside mounted instruments including lamps, push

buttons, switches, relays, etc.
− 20% additional power feeders each provided with switch fuse assembly.
− 20% additional spare windows in alarm annunciators.
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DOCUMENT NO : 44-LK-5100-00/J.02/0012-A4 Date : 12 Aug 2008

STANDARD SPECIFICATION FOR CONTROL PANELS, Page 4 of 9
GAUGE BOARDS AND PANEL INSTRUMENTS Revision No. : A

− 20% of spare terminals.

− 20% spare cable entry points (plugged).

3.1.11 Panel layout shall be designed considering ease of operation. No push button or hand
switch shall be located below 600 mm. Instrument mounting Heights, in general, shall be
as follows :

− Miniature and subminiature Bottom row 1100 mm

instruments (3 rows) Middle row 1350 mm
Top row 1600 mm

− Annunciators - 1950 mm

− Electric push buttons / - 700 mm

Switches, lamps, etc.

3.1.12 The internal panel layout shall be designed considering proper approach for instruments,
terminals and other accessories for maintenance, easy removal and online calibration.
No instrument, terminals, power distribution box etc. shall be mounted on the panel side
plates inside the panel. Terminals shall be preferably arranged in single layer. Two layer
termination shall be avoided as far as possible.

3.1.13 All lamps status as well as alarm, shall be provided with lamp test facility. One single
lamp test push button shall be used for each panel.

3.1.14 Colour scheme

- Status Lamps
On / Open / Permissive : Green
Off / Close / Emergency : Red

- Alarms
Normal / Pre-trip alarms : White
Shutdown alarms : Red

- Push / Pull buttons

On / Open : Green
Off / Close : Red
- Emergency shut-down (ESD) : Red
(Push-button with cover /
Mushroom push button)

3.1.15 Panel piping and tubing

3.1.15.1 The instrument air header shall be adequately sized with 1/2" branches, with brass
packless isolation valves and shall be complete with suitable dual filter-cum-air reducing
station. Pressure Relief Valve to be provided at the downstream of the pressure reducing
station.

3.1.15.2 Panel tubing from the bulk head to the panel instruments and instrument air supply to the
panel instruments shall be of 6 mm x 1 mm polyethylene tubing. Bulkhead fittings shall
have ferrules suitable for both inside and outside tubing.

3.1.15.3 The tubing shall be laid in plastic slotted ducts. Panel air header and tube fittings shall be
of brass, suitably protected against corrosion.
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DOCUMENT NO :44-LK-5100-00/J.02/0012-A4 Date : 12 Aug 2008

STANDARD SPECIFICATION FOR CONTROL PANELS, Page 5 of 9
GAUGE BOARDS AND PANEL INSTRUMENTS Revision No. : A

3.1.15.4 Shut off valves shall be installed in all branch lines taking off the transmission and output
signal. Each tube shall be identified at both the terminating ends.

3.1.16 Panel wiring

3.1.16.1 All wiring shall conform to API-RP-550 Section 7 b&12. Different signal levels cable shall
be routed with distance of separation as recommended by API-RP-550 section 7

3.1.16.2 Open terminals shall generally be avoided. Terminal strips shall be of reputed make.
Terminals shall be mounted in an enclosure. Fused terminals shall be used wherever
necessary.

3.1.16.3 All terminals shall be mechanical screw clamp type with pressure plates. Self insulating
crippling lugs to be considered for terminations. Wire lugs to be used for all terminations
on terminal blocks whereas forked tongue type lugs to be used for termination on relays,
alarm annunciator, instruments etc., Terminal shall be suitable to accept 2.5 sq. mm size
conductors. Ferrules shall be sleeve type.

3.1.16.4 Terminal strips and terminals shall be suitably numbered.

3.1.16.5 A minimum of 1 mm2 multi stranded PE insulated copper conductor shall be used in
general.

3.1.16.6 All wiring shall be laid in PVC troughs. No trough shall be more than 70% full.

3.1.16.7 Wires carrying measurement signals associated with thermocouples, resistance

thermometers, pH instruments and other low level signals shall be routed in separate
troughs / wire ways and not along with power cables. Separation between Power cables
and control cable shall be minimum 150mm. The crossing of power cables and control
cable shall be avoided as far as possible and if unavoidable, shall be as close to right
angles as possible. Parallel runs of AC and DC wiring closer than 300mm shall be
avoided.

3.1.16.8 Thermocouple extension cables / wires shall be used for all thermocouple inputs. These
wires shall be routed in separate troughs / wire-ways.

3.1.16.9 All intrinsically safe wires shall be routed in separate wire ways from non-intrinsically safe
and power wiring. Intrinsically safe wiring shall be screened type. Intrinsically safe wiring
and terminals shall be light blue in colour and shall be separated from non-intrinsically
safe terminals at least by 50 mm.

3.1.16.10 All incoming power feeders shall be terminated on separate terminals suitable for the
incoming feeder size. These shall be located at the bottom of the panel and shall be
suitably covered for protection against accidental shorting and for human safety.

3.1.16.11 All conductors to be made of using crimp type connectors to suit termination fitting. All
conductors shall be identified using markers.

3.1.16.12 The last terminal of any row shall not be lower than 300mm from gland plate in any
cabinet
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DOCUMENT NO : 44-LK-5100-00/J.02/0012-A4 Date : 12 Aug 2008

STANDARD SPECIFICATION FOR CONTROL PANELS, Page 6 of 9
GAUGE BOARDS AND PANEL INSTRUMENTS Revision No. : A

3.1.16.13 Following design philosophy shall be followed while deciding the internal layout of panels,
as a minimum :

- Distance between terminal strip and :100 mm (min.) + trough

side of the panel upto 50 terminals width

- Distance between two adjacent terminal :100 mm (min.) + trough

strips width

- Distance between gland plate and bottom :300 mm (min.)

bottom of the strip

- Distance of terminal strip :100 mm (min.)

from instrument / trough / panel top

3.1.16.14 Wiring colour code within cabinet framework and accessory equipment shall be as
follows
Power supply (Line) : Red
Power supply (Neutral) : Black
Ground : Green
Alarm system : White
Control & Shutdown : Yellow
Analog signal intrinsically safe : Light blue
DC Wiring : Red positive
: Black negative.

3.1.17 Earthing system

3.1.17.1 Panels shall have a fully wired earthing system connecting all metal components back to
panel earthing points. Earthing cable shall be minimum 6mm2 stranded copper and shall
have a yellow/green sheath. Earth stud shall be brass, 10mm OD, with a minimum 30mm
projection. Two brass nuts and washers shall be provided.

3.1.17.2 Earthing bars shall be of copper fixed at rear of panels and having bolted links between
panel sections. An earth bolt shall be provided for connecting main earth conductor to the
bar.

3.1.17.3 Equipment Earth Bar - this shall be solidly bonded to the panel sections, to which all
power equipment, power earthing, instrument cases, etc. shall be connected.

3.1.17.4 Intrinsically Safe Earth Bar - this shall be insulated from panel and other earth bars and
all intrinsically safe equipment and cable screens shall be connected to it.

3.1.17.5 Computer Equipment Earth Bar - this shall be insulated from panel and other earth bars
and all computer compatible equipment shall be connected to it

3.2 LOCAL CONTROL PANELS

3.2.1 Local control panel for the package units shall be installed within the battery limit of the
package considering operational and maintenance requirements and accessibility. In
case of skid mounted packages, panel shall be located away from the skid.
JACOBS ENGINEERING INDIA PRIVATE LIMITED
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DOCUMENT NO :44-LK-5100-00/J.02/0012-A4 Date : 12 Aug 2008

STANDARD SPECIFICATION FOR CONTROL PANELS, Page 7 of 9
GAUGE BOARDS AND PANEL INSTRUMENTS Revision No. : A

In case local control panel is housed outdoor i.e. not in a local control room, it shall be
designed to meet IP-66 requirements. In addition, panel shall be provided with a rain
cum sun shade canopy / shed.

3.2.2 Local control panels shall be totally free standing, pre-wired enclosed cubicles
3.2.3 Panel size shall be selected considering the maintenance clearances and easiness.
Typical panel dimensions of the Panel shall be 2100 mm (height) x 800 mm (width) x 800
mm (depth). However the panel dimensions shall be guided by actual requirement. The
Panel Height shall be inclusive of Base frame height ( 100 mm).

3.2.4 Panel shall be fitted with Lifting lugs.

3.2.5 The panels shall be painted as per painting specification. In any case, contractor shall
not proceed with panel manufacturing before getting prior approval from the Owner /
PMC.

3.2.6 Fabricated panels shall be of minimum 3mm plate with folded edges and welded
construction. The supporting framework shall be provided with a drilled baseplate
capable of supporting the weight of the panel taking into account wind forces. The
baseplate shall not extend beyond the outline base dimensions of the panel. Vibration
damping mounts shall be provided where required. Opening doors shall have robust
stainless steel hinges as standard, and shall have a tee-key door fastening system. All
hinges, screws and other non-painted metallic parts shall be of stainless steel material.

3.2.7 Panel stiffeners, wherever required, shall be welded to the rear of the panel and shall not
interfere with instrument installations.

3.2.8 All cable entries to the local panel shall be preferably from panel bottom. All cable entries
shall be provided with cable glands of adequate size. Cable gland plate thickness shall
be a minimum of 3 mm cold rolled cold annealed (CRCA) as a minimum. All unused
cable entries must be plugged. Cable gland plate shall be preferably removable type.

3.2.9 Local panels mounted in hazardous area shall be preferably Ex-proof type including all
the components ( such as switches, lamps etc. ). If purged panel is used the same shall
be pressurised as per NFPA 496 requirements to render space within the panel non
hazardous. For all panels located in IEC Zone II, protection shall meet the requirements
of Type-Z purging.

An alarm shall be provided on local panel and a contact shall be provided for remote
annunciation, whenever the panel pressurisation falls below 2.5 mm of H2O. A protective
device to protect the panel from over pressure must be provided.

3.2.10 Panel pressurisation with start-up panel purging scheme shall be fully automatic however
it shall be started manually from a push button. Solenoid valves and differential pressure
switch required for panel purging shall be flameproof, however other items like relays,
switches / pushbuttons, timers etc. shall be located in flameproof housing. Other items
like valves, restriction orifice plates, dual filter regulators, pressure gauges, rotameters
etc. required for pressurisation shall also be located in the non-pressurised section of the
panel.

3.2.11 It shall be possible to switch off incoming power to panel from panel front. All such
power on / off switches shall be flameproof type. Emergency push buttons shall be fitted
with shrouds to prevent inadvertent operation.
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DOCUMENT NO : 44-LK-5100-00/J.02/0012-A4 Date : 12 Aug 2008

STANDARD SPECIFICATION FOR CONTROL PANELS, Page 8 of 9
GAUGE BOARDS AND PANEL INSTRUMENTS Revision No. : A

In addition, all those devices and terminals, which can't be powered off from on/off
switches shall also be located inside flameproof enclosures.

3.2.12 All equipment shall be certified for use in the environment and applicable hazardous
area.

3.2.13 For purged panels in the Hazardous area, the Switches, Push-Buttons, Lamps etc.
mounted the outside surface of the panel shall be Ex-proof type.

3.2.14 Panels shall be provided with sun screens using side enclosures and overhead
deflectors such that all front of panel indications/lamps can be easily seen under direct
sunlight conditions.

3.2.15 Lighting arrangement outside the local control panel shall be provided at the top of panel
in addition to the lighting arrangement inside the local control panel.

3.2.16 Anti-condensation heaters ( with temperature cut-off & Manual Control ) shall be provided
where required.

3.2.17 Ventilation louvers shall be at high level and shall be covered with mesh.

3.2.18 Wherever it is an operational and safety requirement, local panels shall be provided with
pneumatic hooter for high volume annunciation.

3.2.19 All other requirements as specified in clause 3.1 of this specification shall also be
applicable for Local Control Panels.

3.3 LOCAL GAUGE BOARD

3.3.1 Local gauge board shall be used to install skid mounted instruments like pressure
gauges, temperature gauges, process switch and transmitters.

3.3.2 Location of local gauge boards shall be such that easy access is available at the rear and
front for all instruments and accessories for maintenance and operation.

3.3.3 Gauge board shall be constructed from 3 mm cold rolled cold annealed steel sheet with
other necessary steel supporting structure and shall be painted sky blue shade No. ISC-
101 as per IS-5. The front facing shall be 5 mm plate.

3.3.4 Local gauge board shall be supplied with all instruments installed and complete in tubed /
wired condition before shipment. Tubing and fittings shall be 316 stainless steel as a
minimum. Gauges shall be flush mounted and situated to maintain the integrity of the
blow-out facility.

3.3.5 All pressure gauges shall be provided with block and bleed valves, securely fastened.
Identification tags shall be securely fastened for easy identification.

3.3.6 Local panels and gauge boards shall have all visible instruments installed between 1.4 to
1.6 metres above grade or the fixed platform. Push-buttons shall be between 1.0 to 1.5
metres above the same level.

3.3.7 Space in front of the panel shall be unobstructed for 1500mm minimum. Rear access
space shall be 1000mm minimum.
JACOBS ENGINEERING INDIA PRIVATE LIMITED
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DOCUMENT NO :44-LK-5100-00/J.02/0012-A4 Date : 12 Aug 2008

STANDARD SPECIFICATION FOR CONTROL PANELS, Page 9 of 9
GAUGE BOARDS AND PANEL INSTRUMENTS Revision No. : A

3.4 PANEL INSTRUMENTS

3.4.1 Panel Instruments shall be generally multibin subminiature type of size 6”X3” except
recorders. Recorders shall be of size 6”x6”. Instruments like microprocessor based
recorders , temperature scanners etc. shall be as per manufacturer standards.

3.4.2 Panel Board Instruments shall have the following graduations in general.

Differential Pressure Flow Meters : 0 to 10 square root

Variable Area Flow Meters : 1 to 10 linear
Pressure : Direct Reading
Level : 0 to 100 Linear
Temperature : Direct Reading.

Multiplying factor for flow scales shall be specified on manufacturer’s name plate.
Recorder charts shall be dual graduated, in general, in 0 to 10 square root and in 0 to 100
linear.

3.4.3 Subminiature recorders shall have 100 mm strip chart with chart speed of 25 mm/h.
Microprocessor based recorders shall have strip chart of 250mm approx. and chart
speed of 50 mm/h with a provision to change speed at site.

3.4.4 Annunciators , in general , shall be solid state type with plug in modules , in a cabinet with
back lighted engraved windows and general power supply. Alarm logic module shall be
single channel type. In case multi-input alarm module are selected, only one channel shall
be used. Intrinsically safe annunciator circuit , when used , shall have power supply unit in a
safe area. Annunciator alarm sequence shall be as per F3A of ISA.The design of the
annunciator system shall be such that transient alarms of less than 330 miliseconds shall
be automatically rejected.

4.0 RELATED DOCUMENTATION

Nil
5.0 ATTACHMENTS

Nil