CONTRACTOR : M/s. BHARAT HEAVY ELECTRICALS LTD.

TRICHY

END USER : M/s. MRPL PH-III UNIT 1-4

SYSTEM : OXYGEN ANALYSER

REF. NO : PO NO: FB-170-7100068965 /18
DTD.31.01.2011





































BILL OF MATERIAL






END USER : M/s.MRPL
JOB REF NO : FC0B110076
MATERIAL :ZIRCONIA OXYGEN ANALYSER
PO NO: FB-170-7100068965/18 DTD 31.01.2011
QTY: 8 SETS
SL.NO DESCRIPTION QTY MAKE
1 Zirconia probe 1 No YOKOGAWA
Model ZR22G-100-S-C-E-T-T-E-A/F1/CV
2 Zirconia Converter 1 No YOKOGAWA
Model ZR 402G-T-E-E-A with 2 Nos isolated 4-20 mA output
3 Interconnection between probe and Conveter / Transmitter
a Power cable 2 C X 1.5 Sq mm 30 MTRS/RUN
Polycab/AFW/
Universal / Finolex
b Signal cable 6 C X 1.5 Sq mm 30 MTRS/RUN
Polycab/AFW/
Universal / Finolex
4 Interconnection between Auto calibration unit and Converter
a Power cable 3 C X 1.5 Sq mm for SOV command from converter 15 MTRS/RUN
Polycab/AFW/
Universal / Finolex
b Power cable 3 C X 1.5 Sq mm for converter power supply 15 MTRS/RUN
Polycab/AFW/
Universal / Finolex
5 Matching flange & Blanking Flange 1 set VK INDUSTRIES
6 Auto calibration unit mounted in IP55 Enclosure with FRP canopy.Below items from
Sr.no 6.1 to 6.4 are mounted inside of auto calibration unit
1 No
VK INDUSTRIES
6.1 Rotameter (Air flow meter) 2 NOS PLACKA
Range: 7-70 l/hr
Inlet/Outlet="NPT(F)
Material SS316
6.2 Air filter regulator 1 NO Shavo Norgren
Model: BO7 with gauge of
0-7 Kg/cm2
Inlet/Outlet="BSP(F)
6.3 Solenoid Valve 2 NOS Rotex
2/2 way, Brass
Power Supply: 110 VAC
6.4 24 VDC coil voltage relay 2 NOS Phoenix
with 1NO + 1 NC contact
7 Inch OD SS Tubing between probe head and Auto calibration unit (distance
between probe and auto calibration unit is 30M)
60 MTRS
PRIME
8 Cable glands & Mounting Accessories ( Only for Probe and Converter ) As reqd
9 4-20 mA multi pair cable (2 individual signal) cable for Remote Disply Unit(RDU)
and HART to RS485 Converter mounted in analyser shelter (2 pair x 1.0 Sq mm
signal cable shall be twisted,pair sheilded ARM.FR Cable)
200 MTRS
Polycab/AFW/
Universal / Finolex
10 4-20 mA output signal cable (Retransmission Output from RDU)to DCS JB located
in analyser shelter. (1 pair x 1.0 Sq mm signal cable shall be twisted,pair sheilded
ARM.FR Cable)
20 MTRS
Polycab/AFW/
Universal / Finolex
11 RS485 cable to CDSU (from HART to RS485 converter) (1 pair x 1.0 Sq mm signal
cable shall be twisted,pair sheilded ARM.FR Cable)
20 MTRS
Polycab/AFW/
Universal / Finolex
12 Remote display unit 1 NO NISHKO
Power Supply: 230 VAC
13 HART to RS485 converter (HMT 01) 1 NO
SCAN ELECTRONIC
SYSTEM
Power Supply: 230 VAC
14 Cylinder Rack,MOC:M.S
1 NO
VK.INDUS. /
MAHA.ENGG
15 IP 55 Enclosure for mounting the above item sl.no. 12 & 13 with fixing fasteners
(the enclosure shall be mounted inside the analyser shelter)
(1 BOX FOR 2 SETS)
1 NO VK INDUSTRIES
16 O&M manual (1 set hard copy +2 CD)+ 1 copy with analyser YOKOGAWA
17 Calibration Gas cylinders
a 10ltrs. WC AL 0.4Vol% O2 in N2 zero gas cylinder with 5 Mtr/run. SS tubing,
Fitting, Brass regulator
1 set
INOX
b 10ltrs. WC AL 8 Vol% O2 in N2 span gas cylinder with 5 Mtr/run. SS tubing,
Fitting, Brass regulator
1 set
INOX
CYLINDERS WILL BE SUPPLIED AT THE TIME OF COMMISSIONING
CONTRACTOR : M/s. BHARAT HEAVY ELECTRICALS LTD, TRICHY














DRAWING






A
GAS FIDW'
B
c
D
E
F
G
200 M1RS
1PAIRX1SQMM
4-20 m Amp
SHELTER
1.5 SQ MM X 2 CORE
POWER CABLE
ENCLOSURE
I I fORBOTH 30 M1RS
j ------
r---------1)=------
200 MTRS
1PAIRX1SQMM
4-20
1
m Amp
*
I zR402 I
JB
v SCOP
1.5 SQ MM X 6 CORE
l
SIGNAL CABLE
30 M1RS

II ii
II II X 3 CORE
II
_u_ II 1.5 SQ MM X 3 CORE
SUPPLY CABLE15 M1RS
II II
I"" ouBE
L...-----H(J------------1! Aum !
UNIT
.-- 20 MTRS1 PAIR X 1 SQ MM
RS485
lcosu I
I
COMMON ENCLOSURE FOR 2 NOS ANALYSERS
I
FOR APPROVAL
I
+ Yokogawa India Limited
4 FOR APPROVAL 02/08/11 (N VN N; CONTRACTOR : BHARAT HEAVY ELECTRICAL LTD, TRICHY
3 FOR APPROVAL 05/07/11 (N VN N;
END USER : M/s.MRPL
Material : Zirconia Oxygen Analyser
2 FOR APPROVAL 24/05/11 (N VN N; Cust PO No: FB-170-7100068965/18 DTD 31.01.2011
1 FOR APPROVAL 16/03/11 (N VN N; TITLE : OVERALL CONNECTION DIAGRAM
0 FOR APPROVAL 10/02/11 (N VN N;
(FOR 02 ANALYSER)
REV. REVISION DATE DRN CHK APPD
f3 \t) I SCALE I Job Ref I DWG. NO.I SHEET I REV.
NTS FCB110078 0076-1 1 OF 1 4
A
B
c
D
E
F
G
A
8
c
D
E
F
G.AS FLOW 1.5 mm
2
2 CORE
SHIELD CABLE
I I CONVERTER 1)
*

I >--1------
1 """''"""_____ t- 1---r-------
MlSC 2 PAIR X 1.0 SQ MM
---- --------------! =...,
DO
RDU HART
TO
l
-.--.<;;; L- 1.5 6 CORE L:::::::::;:::::::::::::;::=J
.__ OYERAI..l. SHIELD CABLE f
2X4-20mA
OUT PUT
SS Tube 1/4" OD
Sr:N COMMAND
FOR CEU. OUT PUT. I A
THERMOCOUPLE OUT PUT I \::::) 1 00-2401/AC, 50/60 Hz
,-FU7METER
I REFERENCE GAS
CALIBRATION GAS
I
'8"""
f-T
I
Ll
1.5 mm? 3 CORE
c::p>-------- CABLE (FOR SCN POWER)
I
-

AIR FILTER
REGULATOR
1 SS Tube 1/4" OD
I
PRESURE REGULATOR
I FOR CYLINDER
I SPAN GAS Blll:
I
23r:N/11r:NAC, 50 Hz
POWER SUPPLY
1 PAIR X 1.0 SQ MM
RS 485

-1-.0-SQ ___ M_M_---..J

INSTRUMENT AIR
FOR REFERENCE
GAS.
11-----
0
--i : PRESURE REGULATOR
SS Tube 1/4" OD I
j- -Rack will be provided by YIL far bath cylindere
SS Tube 1/4" 00 I
-.I ZERO GAS
1-----Jc:>lf__JL...J 11-----0--i I CYLINDER (CS)


r-J
FROM ANANLYSER
I--s
1--5
1-i-

I

M
1
TO CONVERTOR
11r:NAC, 50 Hz UPS
I 0 POWER
_ _j
BY CUSTOMER PRESURE REGULATOR I
0
"
4
" bal - N
FOR CYLINDER I
__ _j
" AUTO CAIJBRATION UNIT
SS Tube 1/4" OD
Legend: P - Pressure Gauge
I
FOR APPROVAL
I Yokogawa India Limited
4 FOR APPROVAL 02/08/11 (;/ VN IC
CONTRACTOR : BHARAT HEAVY ELECTRICAL LTD, TRICHY
3 FOR APPROVAL 05/07/11 (;/ VN IC END USER : M/s.MRPL
MSC - Multi Shield, AR, FRLS CABLE
2 FOR APPROVAL 24/05/11 (;/ VN IC
Material : Zirconia Oxygen Analyser
G * - COMMON ENCLOSURE FOR 2 NOS ANALYSERS
1 FOR APPROVAL 16/03/11 (;/
Cult PO No: FB-170-7100068965/18 DTD 31.01.2011
VN IC
TITLE : OVERALL CONNECTION DIAGRAM
0 FOR APPROVAL 10/02/11 (;/ VN IC
(FOR 02 ANALYSER)
REV. REVISION DATE DRN CHK APPD
f3 {f) I SCALE I Job Ref I DWG. NO.
NTS FCOB110076 0076-1
SHEET 1REV.
1 OF 5 4
A
B
c
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E
F
G
A
B
c
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;---- - --- - --- - --- - --- - -
FIN 1-1 AFR01
REFERENCE GAS 4 1 L ~ ~ \ 7 ~ t
1 INSTRUMENT AIR
TO PROBE
FIN 1-2
-------------------,
I
I
CALIBRATION GAS 5 1 L ~ 'J...:.J---r-----1 1----------l 2 SPAN GAS CYLINDER
L ___ _
SV2-14I1
FROM CONVERTER
r-----
1 I
~
I
L ---- ---- -SV2-14I2 --- -
3 ZERO GAS CYLINDER
SCHEMATIC DRAWING
CONNECTION DETAILS :-
1. INSTRUMENT AIR : 1I4"0D x 114" OD BULKHEAD
I
FOR APPROVAL
I
2. SPAN GAS CYLINDER : 1 I 4"0D x 1 I 4" OD BULKHEAD
3. ZERO GAS CYLINDER : 1I4"0D x 114" OD BULKHEAD
4. REFERENCE GAS : 1 I 4 "OD x 1 I 4" OD BULKHEAD
F 5. CALIBRATION GAS : 1I4"0D x 114" OD BULKHEAD
+ Yokogawa India Limited
4 FOR APPROVAL 02/08/11 GV VN AC CONTRACTOR: BHARAT HEAVY ELECTRICAL LTD, TRICHY
3 FOR APPROVAL 05/07/11 GV VN AC END USER : M/s.MRPL
2 FOR APPROVAL 24/05/11 GV VN AC
Material : Zirconia Oxygen Analyser
Cust PO No: FB 170 7100068965/18 DTD 31.01.2011
G
NOTES :- 1 FOR APPROVAL 16/03/11 GV VN AC
TITLE : SCHEMATIC DRAWING FOR
1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 0 FOR APPROVAL 10/02/11 GV VN AC
AUTO CALIBRATION UNIT
2. OVERALL DIMENSIONS ARE SUBJECT TO TOLERANCE OF 5 mm.
REV. REVISION DATE DRN CHK APPD
9 * I SCALE I Job Ref I DWG. NO. I SHEET I REV.
NTS FCOB110076 0076-2 2 OF 5 4
A B E F H J
A
B
c
D
E
F
G
A
8
c
D
E
F
G
5
LEGEND :



r--:t-

fi"ii
slr-n'/2
INSIDE PLATE
2 WAY SOLENOID VALVE
AIR FILTER REGULATOR
2
3
20
4HOLES010

460 "
[!:

(j)
L.t:::t=======+=::::iJ!
LOCK/
GASKET
FRONT VIEW
SV2-14
AFR01
FIN1 FLOW INDICATOR WITH NEEDLE VALVE
CONNECTION DETAILS :-
1. INSTRUMENT AIR 1I4"0D X 114" OD BULKHEAD
FRPCANOPY
MOUNTING
CLAMP
I
EARTH BOLT
(M6x25 MS)
210
I
'
[
c=J
0
c=J
0
c=J
[
0
R.H.SIDE VIEW
NOTE :
210
, .---------L
c=J
0
c=J
0
0
0
L.H.SIDE VIEW
1. SHEET STEEL ENCLOSURE : 500(W) x 500(H) x 21 O(D) mm
SIDES OF 1.6 mm THICK
2. ENCLOSURE AND DOOR
EXTERNAL
INTERIOR
MOUNTING PLATE
ENCLOSURE PROTECTION
DOOR OF 1.6mm THICK
: RAL 7035
: BRILLIANT WHITE
: COATED IN TEXTURED ORANGE
: IP 55
2. SPAN GAS CYLINDER
1I4"0D X 1 I 4" OD BULKHEAD
1I4"0D X 1 I 4" OD BULKHEAD
MOUNTING CLAMP
DETAILS
I FOR APPROVAL I
Yokogawa India Limited
3. ZERO GAS CYLINDER
:
4. REFERENCE GAS 1I4"0D x 114" OD BULKHEAD CONTRACTOR : BHARAT HEAVY ELECTRICALS LIMITED, TRICHY
5. CALIBRATION GAS : 1I4"0D x 114" OD BULKHEAD
4 FOR APPROVAL 02/08/11 fN VN IC
END USER : M/s. MRPL
J FOR APPROVAL 05/07/11 fN VN IC
Material : Zirconia Oxygen Analyser
NOTES :- 2 FOR APPROVAL 24/05/11 fN VN IC Cust PO No: FB-170-7100068965/18 DTD 31.01.2011
1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED OTHERWISE. 1 FOR APPROVAL 16/03/11 fN VN IC
TITLE : GENERAL ARRANGEMENT DRAWING
2. OVERALL DIMENSIONS ARE SUBJECT TO TOLERANCE OF 5 mm.
0 FOR APPROVAL 10/02/11 fN VN IC
FOR AUTO CALIBRATION UNIT
REV. REVISION DATE DRN CHK APPD
9-$ I SCALE Offer REF . I DWG. NO. I SHEET I REV.
NTS FCOB11 0076 0076-3 3 OF 5 4
A B E F G H J
A
8
c
D
E
F
G
A
B
c
D
0
0
"
E
GASKET---.._

92


.. ITH GASKET
FRONT VIEW
A B
[!] MOUNTING
BRACKETS
"'-HINGES
EARTH BOLT

E
DETACHABLE TYPE
/_CANOPY 1
EARTH BOLT
(M6x25 MS)
..
210
SIDE VIEW
J; 70
2x01D
BRACKET FOR UNIVERSAL MOUNTING
NOTES:-
1. ALL DIMENSIONS ARE IN MM UNLESS SPECIFIED
2. J.B.MADE OF WELDED CONSTRUCTION SYSTEM
USING 1.6 mm THICK MS SHEET.
3. GLAND PLATE WILL BE MADE OF 3mm THICK
MSSHEET
4. FRONT DOOR WILL BE MADE OF 2mm THICK
MSSHEET
5. CANOPY WILL BE MADE OF 1.6mm THICK
MSSHEET
6. SURFACE FINISH:- POWDER COATING (RAL 7035) (OUTSIDE)
INSIDE:BRILLIANT WHITE
7. MOUNTING FASTENERS:- SIZE:M 8 X 20-4 NOS
8. COMMON ENCLOSURE FOR 2 NOS ANALYSER
I
FOR APPROVAL
I + Yokogawa India Limited
4 FOR APPROVAL 02/08/11 (;./ VN N;
CONTRACTOR : BHARAT HEAVY ELECTRICALS UMITED, TRICHY
END USER : M/s. MRPL
J FOR APPROVAL 05/07/11 (;./ VN N;
Material : Zirconia Oxygen Analyser
2 FOR APPROVAL 24/05/11 (;./ VN N; Cust PO No : FB-170-7100068965/18 DTD 31.01.2011
1 FOR APPROVAL 16/0J/11 (;./ VN N;
TITLE :GENERAL ARRANGEMENT DRAWING FOR
0 FOR APPROVAL 10/02/11 (;./ VN N;
MOUNTING HART to RS485 converter & REMOTE DISPLY
REV. REVISION DATE DRN CHK APPD
f3-$ I SCALE II Offer REF., I DWG. NO.I SHEET I REV.
NTS FCOB11 0076 0076-3A JA OF 5 4
G H J
A
8
0:::
w
(/)


<(
I I
0 z ::::2::
0::: c...<( ::::2::
w 0
N Vl (.)
I I I
C!: 2 3 4 5 6 7 8 9 10
c
D
E
F
4Al 1
"'rf11E
110 V AC, 50 Hz, UPS
_..._ .....
8@JE8E
r
POWER SUPPLY WITH GROUND _I
BY CUSTOMER
8 SV2-141 8
*24 v DC

4
J
2
G NOTES :-
1
1. 110V AC, 50 Hz, 480 VA POWER SUPPLY TO BE PROVIDED BY CUSTOMER.
0
* 24 V RELAY DRIVED FROM CONVERTOR.
REV.
A E
I
FOR APPROVAL
FOR APPROVAL 02/08/11 GV
FOR APPROVAL 05/07/11 GV
FOR APPROVAL 24/05/11 GV
FOR APPROVAL 16/03/11 GV
FOR APPROVAL 10/02/11 GV
REVISION DATE DRN
_t_
A
8
c
D
E
I
F
Yokogawa India Limited
VN N;
CONTRACTOR : BHARAT HEAVY ELECTRICAL LTD, TRICHY
VN N; END USER : M/s.MRPL
VN N;
Material : Zirconia Oxygen Analyser
Cust PO No: FB-170-7100068965/18 DTD 31.01.2011
VN N;
G
TITLE : WIRING DIAGRAM FOR
VN N;
AUTO CALIBRATION UNIT
CHK APPD
9-$ I SCALE I Job Ref I DWG. NO. I SHEET I REV.
NTS FCOB11 0076 0076-4 4 OF 5 4
_tt __.j_
A
B
c
D
E
F
G
ANALYSER CONVERTER ( MODEL NO : ZR402G ) ANALYSER PROBE ( MODEL ZR22G )
,- --------------, r--- --------l
: TD SiELlER I I I l :
I I I I I
I
I
:C :C lcEU.IcEU.ITC Ire ICJ ICJ I
lwlHlWHWIH :
1
1
12 I, 13 14 15 16
FG IDI-1 Dl-2 DI-C (:)
17 18 19 20 21 122
AI N:.- - N:.- FG FG
(-) ZERO SPAN COM
(TO BE LOOPED
AT SITE)
I
27 30 31
r-0 r-r-1 0-r-2 D- DO- HTR
HTRLNGFG
321331341;m 38
o--
$. I ! ! ! ! ! ! ! !

1
:uuuu
autput1 output2 output3 output4
I J. 50
MMING
SUPPLY

Contact Contact Contact

---------------------
110 VII:., 50 Hz POWER SUPPLY
LOOPED WITH ANALYSER INPUT
(TB NO 33& 34, 38)
0
1 GROUND RESISTANCE IS 100 OHM OR LESS
I I
AUTO CALIBRATION UNIT
1

I
I I I
U L ________ j
I
4
3
2
1
0
REV.
PAIR X 1.0 SQ mm


4-20rnA
TD ,.n,.u.-,..,,.,-:mm
COLOUR CODE:
Rd - Red
Bl - Blue
Bk - Block
Note:
* *
TC- THERMOCOUPLE
CJ- COOLED JUNCTION
HTR- HEATER
NOTE 11 OVAC, UPS POWER SUPPLY WILL
BE TEMINATED AT OBNE PLACE BY BHEL FOR THIS
02 ANALYSERS SYSTEM.
* * - COMMON ENCLOSURE FOR 2 NOS ANALYSERS
FOR APPROVAL
I
Yokogawa India Limited
FOR N'PROVAI. 02/08/11 IN 'IN N:.
CONlRACTDR : BHARAT HEAVY ELECTRICAL LTD, TRICHY
FOR N'PROVAI. 05/07/11 IN 'IN N:. END USER : M/a.MRPL
FOR N'PROVAI. 24/05/11 IN 'IN N:.
llahrlal : Zirconia Oxygen Analyser
Cull PO No: FB 170 7100088965/18 DTD 31.01.2011
FOR N'PROVAI. 16/03/11 IN 'IN N:.
nTLE : WIRING DIAGRAM FOR ZR 402G,
FOR N'PROVAI. 10/02/11 IN 'IN N:.
ZR22G ANALYSER & AUTO CAL UNIT
REVISION DAlE DRN CHK APPD
I SCALE I Job Ref I DWG. NO.I SHEET I REV
NT'S FCOII110070 0071-5 5 OF 5 4
A
B
c
D
E
F
G





















DATA SHEET
























SL.
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
15.0
16.0
17.0
REPEATABILITY
SENSING ELEMENT ZIRCONIA PROBE
GS 11M12A01-01E 6th Edition: JUNE 2004
0.5% OF FULL SCALE
ELECTRONICS MICRO PROCESSOR BASED
FEATURES
TYPE
1% OF SPAN OR LESS
ZERO & SPAN 2% OF FULL SCALE / MONTH
100 - 240V AC 50/60 Hz
RESPONSE TIME WITHIN 5 SEC FOR 90% RESPONSE
PROBE LENGTH 1500MM
CONNECTION & DIMENSIONS
DIGITAL COMMUNICATI0N HART WITH RS 485 CONVERTER
GENERAL
MAKE
Freely configurable range.
CATALOGUE NO.
DATA SHEET FOR ANALYSER
DESCRIPTION SPECIFICATION
PROBE: ZR22G-100-S-C-E-T-T-E-A/F1/CV
CONVERTER IP66
OPERATING VALUE & RANGE
ECO OUTLET AH OULET
DIRECT INSERTION TYPE (INSITU)
LINEARITY
REMARKS
YOKOGAWA
0 - 5 VOL% TO 0 - 100 Vol% O2 (DRY VOLUME)
CONVERTER: ZR402G-T-E-E-A
MODEL NO.
0-20% 0-20%
1.63% 3.27%
ENCLOSURE
4 Nos. CONTACT POINT CAPACITY 30V DC 3 A, 250 V AC 3A
(RESISTIVE LOAD)
DRIFT
SUPPLY
POWER SUPPLY
OUTPUT
INSTRUMENT RANGE
CONTACT OUTPUT
4-20 mA DC @ 550 Ohms (2NOS)
18.0
19.0
20.0
21.0
22.0
23.0
2 FOR APPROVAL 24/5/2011 PRD
1 FOR APPROVAL 16/3/2011 CHK
0 FOR APPROVAL 9/2/2011 APP END USER: M/s.MRPL
REV DESCRIPTION DATE REV. BY
CABLE ENTRY 1/2" NPT
CONNECTION & DIMENSIONS
ANSI CLASS 150 # 4", RF FLANGE
1/4" NPT
PROBE CONNECTION
ACCESSORIES
PROVIDED TO PREVENT ENTRY OF PROCESS GAS INTO
CALIBRATION LINE.
PROVIDED
CHECK VALVE
DUST FILTER
GAS CONNECTION
PAGE 1 OF 1 PROJECT: MRPL PH-III UNIT -I
PROVIDED STAINLESS STEEL TAG PLATE
76 CONTRACTOR: M/s.BHEL,TRICHY TITLE: DATA SHEETS FOR OXYGEN
ANALYZERS