TRAINING MANUAL - INSTRUMENTS DOC No.

: 29040-IC-UFR-0011

Rev. : R0
CONTROL PANEL
Uhde India Limited Page :1

CONTENTS

Page

0.0 Cover Sheet 1

1.0 Introduction 2
2.0 Types Of Panels 3
3.0 Control Panel Engineering 3~9
4.0 Handy tips for Panel Engineering 9
5.0 Pressurised / Purged Panels 9 ~ 11

Annexure I : Slides 23sheets

Annexure II : G.A. drawings of Control Panel of RCF NH3 storage project 6 sheets
Annexure III: Panel drawings of Type Z Pressurised Panel of Makeup 2 sheets
Gas Compressor Package – Nirma Front end Project.

Applicable Revision:
Prepared: Checked: Approved:

Date: Date: Date:

First Edition: R0
Prepared: Checked: Approved:

N. SUDHA M.B. JOSHI N.C. JAIN

Date:07/8/2000 Date: Date:
File Name:Control [Link] Server: KUMUS 206

Directory: /conversion/tmp/activity_task_scratch/[Link]
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1.0 INTRODUCTION:
Control panel serves as the nerve centre for plant operation wherein the instrumentation
required for the safe and efficient operation of the plant is contained. It serves as
operator interface when panel instruments based control is used for the plant. Control
panels located in control room shall be aesthetically pleasing . The control room of a
chemical plant is frequently visited by V.I.P visiting the plant.

Nowadays, in most of the Process plant applications, panel instrument based control is
replaced by DCS / PLC based systems. Panel instrument based controls are mainly
encountered in Packages , where due to limited controls involved , the use of DCS
/PLC system is not cost effective. However, we may also come across some non-
package application for remote units in a process plant where an independent local
control is sufficient.

Control panel engineering is done for plants operating on panel based instruments
and, in case of package related panel, the engineering is carried out by the package
vendor.
The following paragraphs deal with various aspects of panel engineering including sizing
of panel, enquiry and inspection

2.0 TYPES OF PANELS :

Panels are classified based on the following criteria :

 Type

 Style

 Mounting

 Protection

Type of panel :
Open end panel : These panels are generally preferred only in controlled
and dust free environments . Their design is not aesthetic as the rear end of
the panel is open and the wiring is seen.
Enclosed panel : These panels are preferred for better protection , aesthetics
and to prevent unauthorised access to panel components.
Style of Panel :
Flat Face Panel : This is the most economical design wherein all the panel
instruments are mounted in one vertical plane.
Break front Panel : This type of panel increases the surface area available for
mounting the instruments without increasing the overall height of the panel . The
sub classification of the panel is Console type and desk top type wherein the
panel front is broken into a vertical section and a horizontal section for mounting
the panel instruments.
Mounting Of panel :
Floor mounting : This is generally provided when the panel instrument
concentration is high requiring a vertical height of 2m
Wall mounting : This is provided usually with analysers or small packages
wherein the panel instruments can be accomodated in a smaller dimension panel
Protection of Panel :
Pressurised / Purged Panel : These panels are opted when
 Panel location is in a electrically hazardous area and the location
cannot be shifted to a safe area due to operational constraints
 Panel is located where the external atmosphere is corrosive
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Standards applicable for pressurised panels and the salient features are
listed in clause V
Non-pressurised Panel : These are of standard construction and are used
where the panel location is in a safe and non-corrosive atmosphere

3.0 CONTROL PANEL ENGINEERING:

This involves the following:

Preparation of panel enquiry specification

Evaluation

Interface during manufacture

Inspection and installation

3.1 PREPARATION OF PANEL ENQUIRY SPECIFICATIONS:

The document ‘ Standard specification for Control Panel ‘ is available in the server \
kumus206\dat\ standard\specs\gsinst\icusp069. This document can be customised to
accommodate requirements for a particular project. The following clauses in control panel
specifications need careful considerationm:

Approximate dimensions of the panel

Components which are to be supplied by the panel vendor
Specific make of items to be supplied as part of the panel.

3.1.1 Sizing of panel :

Height of the Panel:

Height of the panel is decided by the ergonomics so that human operator can operate
the panel instruments effectively and conveniently. Thus in a control panel the
instruments are located as per the following example.

1900mm
ALARM ANNUNCIATOR

1700mm
PANEL INDICATORS /
CONTROLLERS

PANEL RECORDERS

INDICATING LAMPS /
PUSHBUTTONS 700mm

0 mm
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The height of the panel is decided by ergonomics and hence the same is more or
less constant around 2000mm.

Depth of the panel

Depth of the panel is decide by the following factors:

Depth of the front panel instruments

Space required By Back of panel instruments and accessories e.g. Power supply
transformer, Switch & Fuse units, signal converters, repeaters , relays etc.

Space required by the wire ducts

Maintenance space required

The depth of the panel is decided based on the above factors for a given project.
However it is recommended that minimum panel depth should not be less than
1000mm for floor mounted panel.

Length of the panel

Generally panels are ordered in standard length (usually 1000mm), when one has
requirement of multiple panels. The total length of the panel is decided by following
factors:
Quantity and size of front panel instruments (Alarm annunciators, Controllers,
Indicators , Recorders, Pushbuttons & Lamps)

Quantity and Size of back of panel instruments. It may be noted that to

accommodate back of panel instruments, either the length or depth of the panel
can be optimised

Spacing between adjacent instruments on the front panel

In case of annunciator, controllers, indicators and recorders , spacing is decided
by the bezel dimension of these instruments. Whereas , in case of pushbuttons
and lamps , rather than the bezel dimension, the size of the contact block
at the back side of the panel is the deciding factor to determine minimum
distance between adjacent pushbuttons/ lamps.

The grouping of front panel instruments is dictated by plant operational

requirements and human engineering aspect mentioned under ‘ Height of the
panel’

Guidelines on number of instruments / accessories that can be accomodated in a

Control Panel :
Assume standard dimension of :1000 mmx1000mm x2000mm (LxDxH) – Floor
mounted panel
S. Name of Instruments / Guideline
no Accessories
1. Bar graph Indicators / In one row, 10 instruments can be accomodated . Normally three rows
Controllers ( 3”x 6”x20”)- can be accomodated . Hence 30 instruments can be accomodated
(L x H x D) Ensure that Panel indicators / Controllers are not placed beyond a
height of 1700mm from panel bottom.
When deciding the depth , note that most of panel instruments are
drawout type and hence ensure that min. 100 mm clear space is
available from the instrument end and wire duct, for easy
maintenance.
2. Relays In case of rail mounted relays, the relays can be stacked without any
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gap. For e.g. Omron relays on DIN rail with a dimension of 30mm
(4NO+4NC) - 25 relays can be accomodated with space for wire duct
on either side in a width of 1000mm
In case of relays requiring separate mounting arrangement, the
clearance between adjacent relays shall be atleast 10mm between the
edges of the relays. Since most of these relays come with clamping clip
of atleast 5 mm.
3. Back of Panel 10 instruments can be accomodated in one row
instruments(3”x8”x12”) Minimum 300mm C-C distance is recommended between two rows
of panel instruments including wiring duct between the rows.
4. Terminal strips (For 2.5 When placed vertically , 200 terminals can be placed in one column of
mm2 wire) 1650mm. Generally 200 mm from bottom and 150 mm form top is given
as clearance from the extreme ends of the terminal block. Width of
terminals suitable for 2.5mm2 wire is approximately 7~ 8 mm.
Minimum C-C distance is recommended between column of terminal
strip and wire duct is 100mm as indicated in the subsequent figure.
Recommended clearance from the edge of the terminal block to
the starting of wire duct is 40mm.
When placed horizontally, 100 terminals can be placed in one row and
generally not more than two rows of terminal blocks are placed to avoid
crossing of wires. Horizontal arrangement is generally not preferred
for extensive marshalling. 1000 mm

150mm
40mm

80 4
m 0
m m
m

w
I
w
D I
E D
E 2000 mm high
W
I
R T
E E
R
M
D
I
U N
C A
T L

S
T
R
I
P

200mm
100mm typ
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Examples of Panel drawings:

Apart from the guidelines given above, some aspects of Panel sizing can be learnt only
through experience. To help engineers in designing the sizing of the panel, examples from
executed project are attached as annexure II

Responsibility of sizing of panel:

It can be noted from above discussion that the sizing of the panel is detailed job which
requires experience. Hence we should indicate the quantity of panel instruments
during the enquiry stage so that the sizing of panel with respect to both front and
back of panel instruments can be cross checked with the vendors, during
evaluation.

3.1.2 Components to be supplied by panel vendor:

This is referred as bought-out components in the panel enquiry specifications and refer to
those components which are supplied as part of the panel by the vendor. Such
components are sourced from sub vendors , as the panel vendor may not be a
manufacturer of them.
E.g. MCB’s, Relays and contactors, Power packs, Transformer, Annunciator ,
Pushbuttons , Indicating Lamps and Pressure switches, Pressure gauges, Air filter
regulators in case of pressurised panels.
In some cases where only one or two panel indicator or controller is required, for ease of
processing, these are also listed under bought-out components instead of floating a
separate enquiry for the panel instruments.

To finalise the list of bought –out components, the following should be available:

 Power supply distribution diagram indicating the different voltage

levels required along with all the loads .
It may be noted that this diagram will not indicate any requirement of panel
vendor which he has to take care during quotation and engineering. The
quantity of MCB’s along with their rating have to be estimated in such a way
that in case of any fault it is possible to isolate the fault with minimum
disturbance to operation of Process. This philosophy has to be decided on
project to project basis .
 Quantity of relays , contactors based on logic.
If the logic diagram has not been completed at the time of floating panel
enquiry, then the number of relays may be approximately estimated referring
to a similar project. However, unit price for relays may be asked from the
vendor to take care of any additions after finalising the logic diagram.

 Components associated with pressurisation(Applicable for pressurised

panel)
Required components may be estimated based on the type of pressurisation
used and referring to the applicable standard
e.g. Pressure switch, rotameter, solenoid valve, timer etc for Type X
pressurisation

3.1.3 SPECIFIC MAKES OF BOUGHT-OUT COMPONENTS:

The bought-out components are tabulated in the enquiry specifications and there is
provision to indicate the preferred vendor from whom these have to be sourced. The
preferred vendors are taken from the approved vendor list of the project for major
components like power pack , relays and contactors etc.

3.2 EVALUATION AND ORDER PLACEMENT :

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During evaluation the following points are to be taken care:

Compliance to UIL specifications and special requirements
Size of the panel shall be cross checked with all the vendors for adequacy

Ensure that unit prices of components like MCB’s, Relays are frozen with the vendor
during order placement to take care of any additions during panel engineering and
execution

3.3 INTERFACE DURING PANEL ENGINEERING/ MANUFACTURE:

This can be viewed as two distinct set of activities:

Information to be furnished to panel vendor
Drawing approval stage

3.3.1 Information to be furnished to the panel vendor:

Usually the panel is ordered based on approximate dimensions, quantity of bought out
components etc. However, all such approximations have to be replaced with firm
requirements before the start of panel manufacture. The following shall be finalised and
given to Panel vendor so that vendor can start design drawings for Panel

 Cut-out and Bezel Dimensions of Panel instruments:

These dimensions have to be sourced from the specific vendor/vendors on whom the
panel instruments are ordered. Based on the cut-out and spacing required, the
arrangement on front panel is decided by the vendor
 Back –of panel instruments – dimensions
The overall dimensions and mounting arrangement of back of panel instruments
which are procured directly by us ( Excluded from panel vendor’s scope) have to be
furnished. This detail shall be taken from the vendor catalog / drawing on whom the
instruments are ordered.
 Panel layout:
This refers to any specific grouping of instruments to be followed on front panel layout
based on process operational requirements
 Power distribution philosophy :
All the loads which are to be powered from the panel and the number of MCB’s with
rating are furnished based on frozen loads and spare mcb’s indicated based on
philosophy. This will enable the panel vendor to finalise the mounting of MCB’s based
on distribution / arrangement of panel instruments on the back of panel
 Loop diagrams:
Loop diagrams released for construction is to be furnished to the panel vendor. This
will enable the vendor to arrange the various components of particular loop so that:
No. of intermediate terminations is reduced
Wiring length is minimised
Components of a particular loop are grouped together for easy maintenance as
far as possible.
 Relay logic diagrams:
Frozen relay logic diagram will indicate the actual quantity of relays required and the
interconnection between them. Panel vendor uses this diagram to mount the various
relays and connect them , so that tracing of a step in the ladder logic is made easy.
 Junction box termination diagram:
Released for construction version is furnished to the vendor.
This will enable the vendor to provide appropriate number of terminals based on the
type of Multi cables .
In case of multi section panel, it will enable the vendor to decide the section in which
the various multi cables from field have to be terminated and also the inter panel
wiring and terminations as explained below:.
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For e.g. Multi cable from field having 12 signals may have its associated loop
components in two sections of the panel – 4 control loops in section 1and 2 control
loops in section 2. In such cases, the multi cable is terminated in that section which
has maximum loops and hence in this example in section 1. Inter panel wiring from
section 1 and section 2 will take care of the other 2 control loops.
 Terminal block identification philosophy:
This shall be decided based on client’s requirement and will be designed for easy
tracing of any loop.
For eg: First terminal block where the field multi cable is terminated may be identified
by the combination of :
Section of panel in which it is located along with the field multi cable number
E.g.
Terminal block in section 1 of panel where IM-101 field cable is terminated can be
designated as : TX1 – IM 101
 Ferruling philosophy:
The terminal block identification is group identification and does not deal with
individual termination identification and interconnecting terminations identification.

Ferrules are plastic sleeves or individual plastic numbered loops provided on

individual wires to identify the terminal on which the wire has to be terminated
and also identifies the terminal on which the other end is terminated. Ferrules help in
re- termination in case the wires have become loose from the terminal or after
completion of isolation and maintenance of the loop.
There are two different types of ferruling – Cross ferruling and Self ferruling.
Generally combination of self and cross ferruling is followed as indicated below:

SELF FERRULING
TX1A CROSS FERRULING TX4A
TX1A-1-TX4A11 TX1A-1-TX4A11
1 11

2
12
TX1A-2-TX4A12 TX1A-2-TX4A12

3.3.2 Drawing approval:

The following drawings shall be submitted by the panel vendor for approval:

1. General arrangement drawing of control panel

2. Front Panel arrangement showing cut-out dimensions and spacing
3. Internal arrangement indicating the back of panel instruments and terminal blocks
4. Base frame details showing the number and size of mounting holes , Gland plate
details including the number of sections and removable sections clearly
5. Inter panel wiring as applicable

IC engineer shall check all the dimensional details indicated ( Cut-out, spacing etc) for
correctness and check whether any special grouping indicated for the project has been
followed. Remember any error in cut-out dimension cannot be rectified once the panel
manufacture is over.
Proper access doors and louvers/ ventilation fans wherever required have been indicated
on the drawing. Ensure that no component is mounted on the sides of the panel.
In case of Pressurised panels for locating in hazardous area, ensure that NFPA 496
requirements are met . Ensure that non purged portion inside the panel does not contain
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any source of ignition / or such components are suitable for mounting in the non purged
portion- Explosion proof. Interconnection between purged to non purged sections shall be
through explosion proof glands/ conduits.

3.4 Inspection and installation:

Refer clause 9.0 of specifications for detailed inspection procedure. However, some
important check points not explicitly listed are given below:

Check that holes on the base frame for mounting the panel is properly drilled

Special mounting arrangement required (if any) is done as per requirement

Earth bus bars are clearly identified as safety earth and Intrinsically safe earth

Fused terminals are provided on phasor side for all field powering/MCC interconnections

Ensure that no component is mounted on the sides of the Panel

If panel is shipped in sections, check for proper identification of interconnecting wiring etc
is provided

Installation of control panel is generally done by the instrument erection contractor at site.

4.0 Handy tips during panel engineering:

• TERMINAL SIZES : Main incomer power supply cable generally requires terminal size
of 4 mm2 or more. Check with electrical and specify .

• SWITCHES : Make-before-break contacts for Auto-manual switches shall be

specified instead of normal selector switches so that the associated motor
circuit , power supply is not interrupted while transferring from auto to manual
mode of control and vice versa. In normal selector switches, there is a break in
power supply when transition from one position to another position occurs

• MUSHROOM BUTTONS : Stayput type

• RELAYS : Check for contact rating for interposing relays of MCC

preferably go for relays with LED indication

 TERMINAL BLOCKS: Fused Terminals on phasor side for all field powering as well as
for MCC command interface signals

• LUGS: Round lugs shall be used for power supply connections , so that wire cannot
become loose unless the restricting screw is taken out completely. Fork or pin type for
field terminations
• Bus bar terminations : Shall be through tapped screws and not using through holes
since disconnection due to vibration or shock is more likely when not using tapped
holes.

5.0 Pressurised / purged panels:

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The following paragraphs elaborate more on pressurised/ purged panels along with
extracts from NFPA 496 since nowadays we come across control panels with packages
only and in most cases these are of pressurised design.
E.g. Hydrogen compressor panel for Nirma front end project. The Panel arrangement
drawing is attached as an annexure to this document

Pressurisation /purging of panels is required to prevent the formation and accumulation of

flammable vapors within the panel which contains a source of ignition, so that an
explosion hazard is prevented.

Hence based on the hazardous area classification in which the panel is located, there are
three types of pressurisation recommended by NFPA 496.

TYPE X :
educes the classification within the protected enclosure from class I, Div I or Class I ,
Zone 1 to unclassified area.

TYPE Y:
Reduces the classification within the protected enclosure from Div I to Div 2 or Zone 1
to Zone 2 .

TYPE Z:
Reduces the classification within the protected enclosure from class I, Div 2 or Class I ,
Zone 2 to unclassified area.

Generally Type Y pressurisation is not widely used as most of the application falls under
type Z category.

5.1 EXTRACTS FROM NFPA 496:

NFPA standard is for Purged and pressurised enclosures for electrical equipment.
This standard outlines general requirements of any pressurised/ purged enclosure in
chapter 2.0.
Chapter 3.0 deals with specific requirements of pressurised enclosure in Class I locations
followed by requirements for Class II locations in chapter 4.0
Salient features from this standard as applicable to panel engineering is presented in
slides 15 – 18.

If the pressurisation is for prevention of entry of corrosive components inside the panel
enclosure, then AFR, Rotameter and a pressure gauge may be sufficient.

5.2 COMPONENTS OF PRESSURISATION SCHEME/ PNEUMATIC SCHEME :

Pressure switch – To detect fall in pressure inside the panel

Pressure gauge - Visual indication of pressure inside the panel

Rotameter - To maintain a desired flowrate during purging operation
Timer - To initiate purge circuit or isolate power based on type of purge
schemes chosen as per NFPA 496
Solenoid valves - To regulate the pressurising medium based on Pressurising or
Purging operation
Overpressure relieving device – Safety device in case of overpressure

There are two distinct operations associated with any pressurised panel
Pressurisation
Purging

Refer Pneumatic scheme of Pressurised Panel attached as Annexure III.

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It may be noted that positive pressure inside the panel is maintained by leakage
compensation – i.e. panel is initially pressurised to the desired level and after this small
continuous supply of pressurising medium, required to compensate for any leakage
losses is maintained through a flowmeter and a solenoid valve on the supply line.

Purging of Panel is carried out every time the panel is opened for maintenance and
before reapplying power to the panel after completion of maintenance. Purging is done to
displace any accumulated vapors inside the panel and usually four to five purge volumes
are passed through the panel. Solenoid valves are usually used to supply Pressurising
medium and are provided on both supply line and exhaust line from pressurised panel.

Solenoid valves on supply and exhaust line are in operation during Purging of panel,
whereas during pressurisation, solenoid valve on supply line is only energised.
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