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Cable Management and Safety Standards in Industrial Facilities

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Cable Management and Safety Standards in Industrial Facilities

1. Introduction

In industrial facilities, cable management is not just about “fixing cables somewhere”;

  • Electrical safety (electric shock, short-circuit, fire),

  • Operational continuity (faults, downtime, maintenance periods),

  • Auditability and traceability (labelling, documentation),

  • Compliance with regulations and standards

it is a critical issue in terms of these aspects.

At the international level, the reference series for low-voltage installations is IEC 60364, while in Türkiye its adapted version is the TS HD 60364 series of standards.

2. Main Objectives of Cable Management

  1. Safety

    • To minimize electric shock and fire risks arising from insulation damage, loose connections, improper cross-sections and routes.

  2. Operational continuity

    • To reduce planned/unplanned downtime and speed up fault detection.

  3. Ease of maintenance

    • To shorten maintenance time thanks to clean routes, accessible cable trays and readable labels.

  4. Compliance and auditability

    • Compliance with national/international standards; avoiding problems during labour inspections and insurance audits.

3. Standards and Regulatory Framework

3.1. International Standards

  • IEC 60364 – Low-voltage electrical installations
    Defines the general rules for the design, equipment selection and installation of low-voltage electrical installations. In particular, Part 5-52 is the main reference for the selection and installation of cables and cable support systems.

  • IEC 61537 – Cable tray and ladder systems
    Defines the requirements for cable trays and cable ladders such as mechanical strength, corrosion, load capacity and test methods. Industrial cable support systems must be selected in accordance with this standard.

  • IEC / EN 60204-1 – Safety of machinery – Electrical equipment of machines
    Is the main standard for the electrical equipment of machinery; it contains detailed provisions on cable installation inside panels, cable colours, protective arrangements and the connection of flexible cables.

  • European Union Directives
    Low Voltage Directive (LVD) and the EMC Directive are supported by harmonized EN standards prepared by CENELEC and define the limits of cable systems in terms of both safety and electromagnetic compatibility.

3.2. Relevant Standards and Regulations in Türkiye

  • TS HD 60364 series – The adapted version of IEC 60364 for Türkiye. Provides the main framework for the design, installation and verification of low-voltage installations.

  • Regulation on Fire Protection of Buildings
    Regulates issues such as shafts, service penetrations, fire resistance periods, and sealing of cable and other services passing through fire walls; it requires that installations be protected against the passage of fire and smoke for at least as long as the fire resistance of the wall.

  • Regulation on the Protection of Workers from the Risks Related to Explosive Atmospheres
    (aligned with ATEX 137) Requires risk assessment, zone classification (Zone 0–1–2 / 20–21–22) and the preparation of an Explosion Protection Document in areas with explosive atmospheres; cable and equipment selection is also within the scope of this document.

  • Regulation on Health and Safety Conditions in the Use of Work Equipment
    Makes periodic inspections of electrical installations and similar equipment mandatory; it requires that inspection intervals generally do not exceed 1 year.

4. Cable Selection and Sizing

When selecting cables in an industrial facility:

  1. Voltage level and insulation class

    • System voltage (e.g. 400/230 V, 690 V) and impulse voltages are taken into account.

    • The insulation classes and clearance/creepage distance rules given in the IEC / TS HD 60364 series are taken as a basis.

  2. Current carrying capacity and short-circuit withstand

    • The cross-section of the cable must be determined according to continuous current load, ambient temperature, installation method (air, ground, tray), grouping factors and short-circuit duration.

  3. Suitability for the environment

    • Factors such as temperature, chemical environment, UV, oil, humidity, mechanical impacts and risk of rodents are considered.

    • If necessary, armoured cables or installation in metal conduit is preferred.

  4. Fire performance

    • Especially in escape routes and critical control circuits, flame-retardant, low-smoke, halogen-free cables are preferred. This is in line with the spirit of the standards and facilitates evacuation in the event of a fire (see the fire protection sections of IEC 60364).

5. Route Planning and Support Systems for Cables

5.1. Route Planning Principles

  • Cables must be installed along the shortest yet safest route; they must be accessible for maintenance and protected from mechanical damage.

  • There must be minimum interaction with hot surfaces, steam lines, aggressive chemical lines and moving mechanisms.

  • Power cables and low-voltage / communication cables should be routed on separate trays or on partitioned trays as far as possible to reduce EMC problems.

  • At fire wall and shaft penetrations, fire-stopping fillings must be applied to meet the fire resistance period required by the regulation.

5.2. Types of Support Systems

Support systems must be selected and tested in accordance with IEC 61537.

  • Cable tray – For general distribution, provides good ventilation.

  • Cable ladder – High mechanical strength for heavy power cables and long spans.

  • Wire mesh tray – Especially for data and low-voltage systems.

  • Duct and conduit systems – Where mechanical impact and chemical protection are critical.

Points to consider in planning:

  • Hanger spacing must be determined according to the load tables of the tray/ladder manufacturer; typically between 1.5–3 m.

  • Fill factor; for cable trays, generally 40–60% fill is targeted and reserve space is left for future cable additions.

  • Bending radius; the minimum bending diameter specified by the cable manufacturer must be strictly observed (especially for fibre-optic and screened cables).

6. Electrical Safety, Earthing and EMC

6.1. Electrical Safety

IEC / EN 60204-1 and relevant parts of IEC 60364 contain detailed provisions for conductor connections, insulation distances, terminal types and conductor termination techniques.

  • Use of ferrules for fine-stranded conductors,

  • Applying appropriate torque values in screw terminals to avoid loosening,

  • The IP protection class must be selected appropriately against dust and moisture.

6.2. Earthing and Equipotential Bonding

IEC/TS HD 60364-4-41 and 4-54 define the rules for protection against electric shock, earthing and equipotential bonding.

  • Cable screens, armours and metal trays must be connected to the system earthing at appropriate points,

  • In large facilities, main equipotential bonding bars (MEBB) should be used to connect structural steel, pipes, cable trays, etc., thereby reducing potential differences.

  • The Regulation on Fire Protection of Buildings requires that metal installations be arranged in a way that does not compromise fire and evacuation safety.

6.3. EMC (Electromagnetic Compatibility)

  • Power and signal cables should be physically separated as far as possible,

  • The strategy for earthing cable screens at both ends or at a single end must be determined according to the EMC analysis of the system,

  • For cables feeding equipment such as frequency converters and large motor drives, manufacturer manuals (screening, filters, special terminals) must be followed.

7. Explosive Atmospheres (ATEX Zones) and Cable Management

In industrial facilities with explosive atmosphere risk (chemicals, paint, silos, refineries, etc.), cable systems must be designed within the framework of the Regulation on the Protection of Workers from the Risks Related to Explosive Atmospheres and ATEX principles.

Points to consider:

  • Zone classification (Zone 0/1/2 gas, 20/21/22 dust) must be completed before finalizing the cable route.

  • Cables and additional equipment (boxes, glands, terminals, devices) to be used in Ex zones must have the appropriate category and certification.

  • Details such as sealing at cable entries, sheath stripping length and earthing of armour must be in accordance with the installation instructions of Ex-certified glands.

  • All these arrangements must be defined in the Explosion Protection Document and cable systems must comply with this document.

8. Labelling, Numbering and Documentation

This is perhaps the least discussed but most critical part of good cable management.

  • Each cable must have a unique cable number;

    • Readable labels must be present at terminals in the panel, at the field equipment side and at critical intermediate points.

  • Cable labels must be made of materials resistant to UV, heat and chemicals.

  • As-built drawings, cable lists, cable cross-section and route plans must be kept up to date; revisions must be consistent with field labels.

  • In case of inspection or failure, the goal is that a technician can reach the diagram and trace the fault using only the cable number.

9. Periodic Inspection, Maintenance and Improvement

The Regulation on Health and Safety Conditions in the Use of Work Equipment makes periodic inspections of electrical installations and work equipment mandatory; the interval is generally set as at most once a year.

A practical view for cable systems:

  1. Visual inspections

    • Sagging, overstretched, cut or crushed cables,

    • Corroded cable trays, broken brackets,

    • Cable bundles that exceed the fill factor or are overheated.

  2. Electrical tests and measurements

    • Insulation resistance tests,

    • Continuity checks of earthing and equipotential bonding,

    • Thermal imaging scans for hot spots, if necessary.

  3. In terms of fire and explosion safety

    • Whether fire-stopping materials are cracked,

    • Unsealed spare entries and improper glands in Ex zones.

  4. Management of Change (MOC)

    • For every new cable addition or removal, updating the project, labels and the risk assessment.

10. Practical Checklist (Summary)

When doing a site walk-through or design review, you can use the following as a check-list:

  • Has cable selection been verified according to IEC / TS HD 60364 criteria in terms of current, short-circuit and environmental conditions?

  • Are cable trays and ladders compliant with IEC 61537, with load capacity calculated?

  • Has sufficient separation/screening been provided for power and low-voltage cables?

  • Has fire-stopping been applied at fire wall and shaft penetrations in accordance with the regulation?

  • In explosive atmosphere zones, has compliance been ensured with the Ex classification and the Explosion Protection Document? Are all cables labelled legibly on both ends and consistent with the as-built documentation?

  • Have cable trays and installations been included in the list of periodic inspections under the Regulation on Health and Safety Conditions in the Use of Work Equipment?