CUSTOMER : ULTRATECH CEMENT LIMITED

END USER : GUJARAT CEMENT WORKS.

SYSTEM : GAS ANALYSIS SYSTEM FOR MEASUREMENT
OF SOx,NOx & O2 AT STACK
PO NO. : LOI dtd : 14.12.17

JOB NO. : WL17/3473

QTY. : 2 NOS. (P1 & P2)

Issue Remarks Date Name

The Reproduction,transmission or use of this document or it's contents is not permitted

without written consent.
2 AS BUILT 09.02.18 VK
1 REV-01 06.01.18 VK
Quantity per panel Func.
Sr. No. Description PART NO Make Qty. Unit/ Item Remarks
P1 P2 Total Loc. Design
Scavenging Panel
1 Scavenging Panel with plate 500(H) X 400(W) X210(D) 18802001 Rittal 2 2 4 Nos.
SV01,SV02,SV03,SV06,SV07,SV
2 Solenoid Valve, 2/2 Way,1/2"BSP(F), Brass NC 230 VAC 78309050 Asco/Burkert,Germany 6 6 12 Nos. 08
3 Solenoid Valve, 2/2 Way,1/4"BSP(F), SS316 230 VAC, NC 78409060 Asco/Burkert,Germany 4 4 8 Nos. SV04,SV09
4 Male Connector 1/2" BSP X1/2" OD SS316 18401001 Adage Approved Vendor 1 1 2 Lot. As Required
5 Equal Tee 1/2" OD SS316 18405001 Adage Approved Vendor 1 1 2 Lot. As Required
6 Bulk head 1/2" OD X 1/2" OD SS316 18402001 Adage Approved Vendor 1 1 2 Lot. As Required
7 SS316 Tube 1/2" OD 18406001 Sandvik 1 1 2 Lot. Mtr. As Required
8 Male Connector 1/4" BSP X1/2" OD SS316 18401007 Adage Approved Vendor 1 1 2 Lot. As Required
9 Bulk head 1/2" OD X 1/4" OD SS316 18402004 Adage Approved Vendor 1 1 2 Lot. As Required
10 Clamps & accessories Adage Approved Vendor 1 1 2 Lot. As Required

Sample Conditioning System

11 Analyser Panel (2000+100) (H) x 1200 (W) x 600(D) 48801091 Rittal 1 1 2 Nos.
12 Gas Cooler, 230 VAC 18519001 Adage 1 1 2 Nos.
13 Peristaltic Pump 28708003 Adage Approved Vendor 2 2 4 Nos. PP01,PP02
14 Flow Meter 10-100 LPH 18709001 Adage 3 3 6 Nos. FM01,FM02,FM03
15 Needle Valve 18408015 Baldota 1 1 2 Nos. NV01
16 Temprature Sensor 18607001 Tempsen 1 1 2 Nos.
17 Condensate Monitor 18710001 Adage 1 1 2 Nos. CM01
18 Switching Unit For Condensate Monitor 18611003 P&F 1 1 2 Nos. SU01
19 Sample/Bypass Gas Pump, 230 VAC 28519087 Buhler, Germany 2 2 4 Nos. MP01,MP02
20 Five Way Ball Valve 1/4" BSP,PVDF 28214001 EM Technik GmbH, Germany 1 1 2 Nos. BV02
21 Air Filter Regulator 1/4' 18728013 Airmax 1 1 2 Nos. AFR01
22 Acid Filter Assembly 48919001 Adage 1 1 2 Nos. AF01
23 Condensate Vessel 18901001 Adage 2 2 4 Nos. CV01,CV02
24 Solenoid Valve 3/2 Way 1/4" BSP,SS316,230 V 78409061 Asco/Burkert,Germany 5 5 10 Nos. SV11,SV12,SV14,SV15,SV16
25 Solenoid Valve, 2/2 Way,1/4"BSP(F), SS316 230 VAC, NC 78409060 Asco/Burkert,Germany 1 1 2 Nos. SV13
26 Membrane Filter (pack of 25) 18106001 Imported 1 1 2 Pack
27 PTFE Tube, 6mm OD 28209001 EM Technik GmbH, Germany 1 1 2 Lot. Internal As Required
28 Viton Tube, 6mm OD 28216001 EM Technik GmbH, Germany 1 1 2 Lot. Internal As Required
29 PLC CPU S7 1200, CPU 1214C, SIEMENS 18606070 Siemens 1 1 2 Nos. PLC
30 DIGITAL OUTPUT SM 1222, 8 DO 18606072 Siemens 1 1 2 Nos. PLC
S7 1200 - 16 Digital Output Module -SIMATIC S7-1200, DIGITAL
18606074 Siemens 1 1 2 Nos. PLC
OUTPUT SM 1222, 16 DO, RELAY 2A
31
Date 26.12.17 GAS ANALYSER SYSTEM FOR
Client:- ULTRATECH CEMENT LIMITED System MEASUREMENT OF SOx,NOx & O2
VK ADAGE
Prep AT STACK Control No WL17/3743 Qty:- 2x P1 & P2
AUTOMATION
Ckd. SP Project Title SOx,Nox & O2 GAS ANALYSIS SYSTEM P.O. No. LOI dtd : 14.12.17
End User:- GUJARAT CEMENT WORKS
PVT LTD. Sh. No. 1
Appv. SM Details:- BILL OF MATERIALS Document No. WL17/3743/BOM
No of Sh. 2
Issue Remarks Date Name

The Reproduction,transmission or use of this document or it's contents is not

permitted without written consent.
2 AS BUILT 09.02.18 VK
1 REV-01 06.01.18 VK
Quantity per panel Qty. Func. Item
Sr. No. Description PART NO Make Remarks
P1 P2 Total Unit Design
32 MMI Display 18610007 Adage 1 1 2 Nos. MMI
33 Power Socket 18538011 Adage Approved vendor 1 1 2 Nos. PS01
34 Cooling Fan, 230 VAC 18538001 Rexnord 2 2 4 Nos. CF01,CF02
35 Tube Light, 230 VAC 18538003 Philips 1 1 2 Nos. TL01
36 Gas Analyser for SOx,NOx Ultramat 23 Siemens 1 1 2 Nos. GA01
37 Gas Analyser for O2 Oxymat 61 Siemens 1 1 2 Nos. GA02
38 Temprature indicator with Alarm O/P 18604001 Honeywell 1 1 2 Nos. TI01
39 Male Connector,1/4"BSP(M) X 6 mm OD,WI 28210001 Adage Approved Vendor 23 23 46 Nos.
40 Male Elbow ,1/4" BSP (M) x 6 mm OD 28221002 Adage Approved Vendor 8 8 16 Nos.
41 6 mm OD X1/4" BSP(M) X 6mm OD Unequal TEE 28219006 Adage Approved Vendor 5 5 10 Nos.
42 6mm OD X 6mm X 1/4" BSP(M) Unequal TEE 28219002 Adage Approved Vendor 1 1 2 Nos.
43 Bulk Head Connector 1/2" OD X 6 mm(L) OD (WI) SS316 18402002 Adage Approved Vendor 5 5 10 Nos.
44 Bulk Head Connector 1/4" OD X 6 mm(L) OD (WI) SS316 18402005 Adage Approved Vendor 6 6 12 Nos.
45 MCB's - Siemens 23 23 46 Nos. MCB'S
46 Wires & Accessories - Finolex 1 1 2 Lot As Required
47 Ferrules, Lugs - Adage Approved Vendor 1 1 2 Lot As Required
HS PROBE ASSEMBLY/ Loose Items
48 Probe Head with gasket & O rings 18416050 Adage 2 2 4 Nos.
49 Ceramic Filter 28903015 Schumacel , Germany 2 2 4 Nos.
50 Tube Assembly 1200mm,SS316 18418001 Adage 2 2 4 Nos.
51 Bushing Tube, 900mm length 18814001 Adage 2 2 4 Nos.
52 Male Connector 1/2" BSP (M) X1/2" OD SS 18401001 Adage Approved Vendor 2 2 4 Nos.
53 Male Connector 1/4" BSP (M) X 1/4" OD, SS 18401006 Adage Approved Vendor 2 2 4 Nos.
54 Ring Heater, 230 VAC 18524006 Adage Approved Vendor 2 2 4 Nos.
55 Prefabricated Heat Traced 230 VAC Tube 1/4" PTFE 18902001 Thermopad 100 100 200 Mtrs. Sample Tube

Date 26.12.17 GAS ANALYSER SYSTEM FOR

ULTRATECH CEMENT
Client:- System MEASUREMENT OF SOx,NOx & O2
VK LIMITED ADAGE
Prep AT STACK Control No WL17/3743 Qty:- 2x P1 & P2
AUTOMATION
Ckd. SP Project Title SOx,Nox & O2 GAS ANALYSIS SYSTEM P.O. No. LOI dtd : 14.12.17
End User:-GUJARAT CEMENT WORKS
PVT LTD. Sh. No. 2
Appv. SM Details:- BILL OF MATERIALS Document No. WL17/3743/BOM No of Sh. 2
 DESIGN INSTRUCTIONS

1. PANEL CONSTRUCTION

1.1 Make : RITTAL

1.2 Dimensions (H x W x D) mm : 2000 (100)(H) x 1200(W) x 600(D) mm

1.3 Installation
.1 Mounting : Floor Mounting
.2 Additional channel frame : 100 mm
.3 Lifting eye bolt : Removable type provided.
.4 Doorlock : Latch type locking system (Flush to door)
.5 Rear Door : Nill
.6 Available Min. Clearance At Front : 1000 mm
.7 Available Min. Clearance At Rear : 1000 mm
.8 Available Clearanace from both side : 1000 mm
.9 Degree of Protection : IP 54
.10 Gland plate construction : Sectioned removable 2mm thick MS gland plate.
.11 Side Wall : Screwed On
.12 Equipment Mounting Plate : 2.5 mm THK

1.4 Paint
.1 Shade inside : RAL - 7035
.2 Shade outside : RAL - 7035
.3 Painting Procedure Inside/Outside : Powder Coated
.4 Mounting Plate : Orange

1.5 Name Plates

.1 Material Of Name Plate : Tri Colour Backlite
.2 Cubicle Label : Line 1 : GAS ANALYSIS SYSTEM FOR
Line 2 : SO2,NO & O2 AT STACK

.2 Device Label : Relevant circuit/device number or description

Client :- ULTRATECH CEMENT LIMITED

End User:- GUJARAT CEMENT WORKS

Date: 26.12.17 SYSTEM GAS ANALYSER SYSTEM AT STACK

Prep: VK P.O.No. LOI dtd : 14.12.17
2 AS BUILT 09.02.18 VK Chkd: SP QTY 2
1 REV-01 06.01.18 VK Document No WL17/3743/P1&P2/DI Sh. No. 1
JOB NO : WL17/3743
Index Remarks Date Name Details DESIGN INSTRUCTION No of Sh. 2
 2. WIRING SCHEME

2.1 Wire colour

.1 AC voltage 230 VAC : Line : RED
Neutral : BLACK
Ground : Yelow / Green

.2 DC control voltage (24 VDC) : Positive : Grey ; Negative : Blue for 24 VDC

.3 Analog Output / Input Analyser : Positive : Orange ; Negative : Blue

.4 Digital Input Output Analyser : Positive : Grey ; Negative : Blue

2.2 Ferruling : According to drawing (Numbering Method)

3. TERMINATION ARRANGEMENT

3.1 Main Power Cable Entry From : Bottom

3.2 Control Cable Entry From : Bottom

3.3 Drilling of gland plates : At Site

3.4 I/O Channels Wiring Termination : At works

3.5 Power Terminal Type : Screw Type

3.6 Power Terminal Size : 2.5 & 6sq. mm

3.7 Control Terminal Type : Screw Type

3.8 Control Terminal Size : 2.5 sq. mm

Client :- ULTRATECH CEMENT LIMITED

End User:- GUJARAT CEMENT WORKS

Date: 26.12.17 SYSTEM GAS ANALYSER SYSTEM AT STACK

Prep: VK P.O.No. LOI dtd : 14.12.17
2 AS BUILT 09.02.18 VK Chkd: SP QTY 2
1 REV-01 06.01.18 VK Document No WL17/3743/P1&P2/DI Sh. No. 2
JOB NO : WL17/3743
Index Remarks Date Name Details DESIGN INSTRUCTION No of Sh. 2
 TRANSPORTATION TIME CALCULATIONS:-

Size of Tube = 6 mm OD / 4 mm / ID Volume = 3.14 X r2 X L

For 1 mtr tube = 12.56

Time = Volume / Flow

Flow @ = 77.77777778
Length of Tubing Used cc/sec

External = 50 meters
Time for 1 meter = 0.16149
Internal = 5 meters Volume / Flow sec/meter

Total = 55 meters Total Time = 8.88171

Flow Rate = 280 LPH Volume / Flow sec

# Note : Distance from Probe to Analyser Panel is taken as 50 meters

Client :- ULTRATECH CEMENT LIMITED

End User:- GUJARAT CEMENT WORKS

Date: 26.12.17 SYSTEM GAS ANALYSER SYSTEM AT STACK

Prep: VK P.O.No. LOI dtd : 14.12.17
2 AS BUILT 09.02.18 VK Chkd: SP QTY 2
1 REV-01 06.01.18 VK Document No WL17/3743/P1&P2/TT Sh. No. 1
JOB NO : WL17/3743
Index Remarks Date Name Details TRANSPORTATION TIME No of Sh. 1
 SL No DESCRIPTION VA/Unit QTY TOTAL VA
Per Panel
230 VAC NON-UPS POWER SUPPLY
1 Tube Light 230 VAC 15 1 15
2 Fan 230 VAC 20 2 40
3 Cooler 230 VAC 275 1 275
4 Temperature Indicator 12 1 12
5 Solenoid Valve 12 16 192
6 Sample Gas Pump 115 2 230
7 Ring Heater 125 1 125
8 Power Socket 250 1 250
9 Peristaltic Pump 18 2 36

SUB TOTAL 1175

STARTING CURRENT (No. of Times) 1.2
TOTAL 1410

230 VAC NON-UPS POWER SUPPLY FOR HEAT TRACED TUBE

1 Heat traced Tube 56 100 5600
STARTING CURRENT (No. of Times) 1.2
TOTAL 6720

230 VAC UPS POWER SUPPLY

1 PLC 45 1 45
2 Gas Analyser Ultramat -23 60 1 60
3 Gas Analyser Oxymat -61 37 1 37
4 Switching Unit 4 1 4
5 MMI (Touch Screen) 10 1 10

SUB TOTAL 156

STARTING CURRENT (No. of Times) 1.2
TOTAL 187.2

Client :- ULTRATECH CEMENT LIMITED

End User:- GUJARAT CEMENT WORKS

Date: 26.12.17 SYSTEM GAS ANALYSER SYSTEM AT STACK

Prep: VK P.O.No. LOI dtd : 14.12.17
2 AS BUILT 09.02.18 VK Chkd: SP QTY 2
1 REV-01 06.01.18 VK Document No. WL17/3743/P1&P2/LC Sh. No. 1
JOB NO : WL17/3743
Index Remarks Date Name Details LOAD CALCULATION No of Sh. 1
INSTALLATION DRAWINGS
Application
Electrical Supply Quality/Consumption

Utilities

Instrument Air Quality

Recommended Installation Site Conditions

Instrument Air Consumption

Analyzer Measuring Range :

SCHEMATIC DRAWINGS
 GA02 GA01
O2 SO2/NO
ULTRAMAT23
OXYMAT 61

PROBE-1

PROBE-2

NOTE :
GA & IGA DRAWINGS
 EYE BOLT EYE BOLT
EYE BOLT

GAS ANALYSIS SYSTEM FOR Adage Automation Pvt. Limited

SO2,NO & O2 AT STACK

SAMPLE GAS
OUTLET-01
SAMPLE GAS
OUTLET-02 FAULT
BYPASS GAS
OUTLET-01 COOLER
MMI
TEMPERATURE
BYPASS GAS HONEYWELL

PV
D C1 010

OUTLET-02 SP

L
L
AFR01 PURGE GAS AFR01
INLET

CASE
PURGING

SAMPLE GAS
INLET - 01
SAMPLE GAS
INLET - 02

ZERO GAS
INLET(N2)
SPAN GAS
(NO)
SPAN GAS
(SO2)

CONDENSATE
DISCHARGE-01 & 02

NOTE :

LH SIDE VIEW FRONT VIEW WITH DOOR RH SIDE VIEW

 EYE BOLT EYE BOLT

O2 ANALYZER SO2/NO ANALYZER

CF01
OXYMAT 61 ULTRAMAT23

GA02 GA01

DLS PVC DUCT PVC DUCT

PVC DUCT
SO01

SU01
SO02

PVC DUCT
PLC
BO01 PVC DUCT
MP02 MP01 FM03 FM02 FM01
MCB01 TO 16

PVC DUCT
BO02

PGI NV01

CM01 PVC DUCT

CPI MCB17 TO 23
SV11 SV16 SV15

SI01
PS01
SI02 SV13 SV14
PVC DUCT

PVC DUCT
AF01
PVC DUCT

ZG(N2) TB01
SV12
SG(NO) PVC DUCT
BV01
TB01 TB02
SG(SO2)
PVC DUCT
PVC DUCT
TL01

TB03 TB04 TB05

PVC DUCT

GAS COOLER
TB06 TB07 TB08
CF02
CF02

PVC DUCT
PVC DUCT

CD01 CV01 CV02

PP02
CV02 PP01 CV01
PP01 PP02 PP02 PP01

LH SIDE VIEW RH SIDE VIEW

INTERNAL ARRANGEMENT
 GLAND PLATE DETAILS FOR ANALYZER PANEL

GLAND PLATE GLAND PLATE

GLAND PLATE GLAND PLATE

Removable Type
Gland Plate

GLAND PLATE GLAND PLATE

BASE FRAME DETAILS FOR ANALZER PANEL

 SCAVENGING SYSTEM-01
FOR STACK SAMPLE GAS
Adage Automatiom Pvt. Ltd.
OUTLET-01

INNER
PURGING-01

OUTER
PURGING-01

PURGE GAS
INLET-01

LH SIDE VIEW FRONT VIEW RH SIDE VIEW REAR VIEW

Removable Type
Gland Plate

SV04
SO01 BOTTOM VIEW

IP01
SV03

OP01
SV02

PG01
SV01

MOUNTING PLATE
 SCAVENGING SYSTEM-02
FOR STACK SAMPLE GAS
Adage Automatiom Pvt. Ltd.
OUTLET-02

INNER
PURGING-02

OUTER
PURGING-02

PURGE GAS
INLET-02

LH SIDE VIEW FRONT VIEW RH SIDE VIEW REAR VIEW

Removable Type
Gland Plate

SV08
SO02 BOTTOM VIEW

IP02
SV07

OP02
SV06

PG02
SV05

MOUNTING PLATE
WIRING DRAWINGS
 4 4 5 5

101

101
101

101

105
104
102

TB01 1 101A 101 3

13 14 14
102

102

102

106

109
107

108
31 100A 100 33
49
50
103

E
48
49
50 51 51 52

100

100

100

100

100
100

100

100

100

36 100 36 37 37
100 34 34 35 35 38
 100 111 110 101

38
6

52
100 112

39
53
100 114 113

39
53

100 116 115

40
54

100 119 118 117 101

40
6

15

54

100 119
41
16

55

IL01(FAULT)
120
41

100
 TB09

42
18
17
100 100 SV01-N 122 121 101
7

SV01-L

6
11
100 100

E
SV01-N

55
19
2
20
SV02-N 123
SV02-L

7
12
SV02-E

3
21
SV03-N 124
SV03-L

8
13
SV03-E 4
22

SV04-N 125
SV04-L

9
14
SV04-E

100
10
15
23

100 126
1

SV05-N
24

42
25
100 100 128 127 101
7

SV05

E
11

100 100
SV05-N

56
26
2
27

SV06-N
129
7

SV06
12

SV06-E
3
28

SV07-N 130
8

SV07
13

SV07-E
100
4
29

SV08-N 131
9

SV08
14

SV08-E
10
15
30

132
TB10

69
68
8

100 133 101

43
TB01

TB01
56
70
72
71
8

100 134 101

43
TB01

TB01
57
73
 201 4 4

201

200
202

203
TB02 1 201A 201 3

14 TB 02 17 TB 02

6 200A 200 8
16 19
15 18

TB02 TB02

200

200
12 13
11

12

200 9 9
 3 4

301

301

301
8
301 302 302
L
TB06 10
9 601 301 304 304 TB06
1 L 605
300 303 303 N 602 5
301A 301
2
TB03 : 1 3 606 6
11
300 305 305
N
TB06
603
3
604
4

300A 300 14
12

TB07
401
5
406 401
TB07
6
10
19 401 408
7
407
11
8 408A
300

300

407A 12
9

TB01-57 TB01-58

14 15
4 5 TB04:1 TB04, 24VDC 2 2

401

401
301

301
TB05 :1
TB07
TB07 3 4

401

400
1 2

401
306

405
402

403
401
404

301 307

TB03:20

902
901
TB03:19
300

400

400

400
300

15 16 TB05, 0 V DC 2 3
 (AC/DC/Relay) (AC/DC Relay)
TB05 TB04 (14/Digital Input)
(10 Digital Output)
TB07
3
MCB10
1 2
3
3 4
3
5 6
4
7 8
4
10 11
5
13 14
5

15 16
6

17 18
6
MCB11

MCB20
TB03-16
TB03-19
TB04-7 (Relay O/P-1) (Relay O/P-1)
TB05-4

TB03-20 TB08

MCB04

TB08

MCB05
TB04-7 (Relay O/P-2)
TB05-4

TB03-21

MCB08
TERMINAL DETAILS
TB01 TB01 TB01 TB02 TB03 TB04 TB05

NOTES :
 TB06 TB07 TB08 TB09 TB10

SCAVENGING PANEL-01 SCAVENGING PANEL-02

TERMINAL DETAILS TERMINAL DETAILS

CONTACT TO CCR :

NOTES :