Norma Pdvsa K-337

PDVSA
ENGINEERING DESIGN MANUAL

VOLUME 9II ENGINEERING SPECIFICATION
PDVSA N
TITLE
K337
FURNACE AND BOILER INSTRUMENTATION
2 1 0
REV.
DIC.99 AUG.96 AUG.94

DATE
GENERAL REVISION APPROVED FOR APPROVAL

DESCRIPTION DATE
26 27 21
PAG. APPD.BY Jess E. Rojas
Y.K. L.T. L.T.

REV.
A.A. E.J. E.J.

APPD. DATE
J.E.R. A.N A.N.

APPD.
APPD.BY Alexis Arvalo
DIC.99
DIC.99
E PDVSA, 1983
ESPECIALISTAS
ENGINEERING SPECIFICATION
PDVSA K337 REVISION DATE
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Index
1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 CODES, STANDARDS AND PRACTICES . . . . . . . . . . . . . . . . . . . . . 3 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FIRED HEATERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1 4.2 4.3 4.4 4.5 4.6 5.1 5.2 5.3 5.4 5.5 5.6 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Burner Management System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarms and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Burner Management System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarms and Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 2 3 4
4 5 6 9 9 12
5 BOILERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
14 14 15 17 17 19
6 FLAME DETECTION / BURNER MANAGEMENT SYSTEM . . . . . 7 PROTECTION SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 INSTALLATION AND COMMISSIONING . . . . . . . . . . . . . . . . . . . . . . 9 QUALITY ASSURANCE / QUALITY CONTROL . . . . . . . . . . . . . . . 10 APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 23 24 25 26
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SCOPE
This document covers minimum PDVSA instrumentation requirements for the design, specification, installation and commissioning of fired heaters and boilers located at petroleum refineries and production facilities. This standard applies to all fired heaters and boilers and is based on NFPA 8502, ASME CSD1 and API 556. The user of this standard must recognize the complexity of firing fuel with regard to the type of equipment and the characteristics of the fuel. It is intended that the designer shall be capable of applying a rigorous analysis to special or unusual problems. The validity of the design shall be approved by PDVSA. This specification does not cover the following: S Steam control systems used for purging natural draft process fired heaters prior to burner light off. S Pilot gas system supplies (filters and LPG vaporizers). S Instrumentation systems for inert gas generators, incinerators, pulverized fuel and sulfur furnaces.
CODES, STANDARDS AND PRACTICES

NFPA 8502 NFPA 8501 API RP551, 552 API 555 API Std 560 API RP556 ASME CSD1 ANSI Z83.3 PDVSA B201PR PDVSA K300 PDVSA K303 PDVSA K334 PDVSA K335 PDVSA K336 PDVSA K369 PDVSA IRE01 Standard for the Prevention of Furnace Explosions/Implosions in Multiple BurnerBoilers. Standard for Single Burner Boiler Operation. Process Measurement Instrumentation Process Analyzers Fired Heaters for General Refinery Services Instrumentation and Control System for Fired Heaters and Steam Generators. Controls and Safety Devices for Automatically Fired Boilers. Gas Fired Boilers Calentadores de Fuego Directo Introduction Level Instrumentation Instrumentation and Thermocouple Extension Cables Packaged Unit Instrumentation Safety Instrumented Systems Instrumentation QA/QC Clasificacin de Areas
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Separacin entre Equipos e Instalaciones Sistemas de Parada de Emergencia, Bloqueo, Despresurizacin y Venteo de Equipos y Plantas Filosofa de Diseo Seguro PDVSA IRS01 Obras Elctricas PDVSA N201 Even though the NFPA 8502 standard scope does not cover process heaters, this standard (PDVSA K337) considers that, from the security point of view, the principal purpose of both standards contribute to operating safety and to prevent furnace explosions and implosions is the same and the premises of the NFPA 8502 shall be followed for the design, installation, operation, and maintenance of fired heaters and boilers and their fuel burning systems. NOTE: This document originated as a compilation of the PDVSA K337 Furnace Instrumentation Rev1, Aug.1996 and PDVSA K338 Boiler and Instrumentation Rev1, Aug. 1996 standards.
PDVSA IRM01 PDVSA IRP01
DEFINITIONS
The following definitions are included to understand this standard. Continuous pilot An igniter applied to the fuel input through the burner and to support ignition under any burner lightoff or operating conditions. This pilot burns throughout the entire period the unit is in service whether or not the main burner is firing. This type of pilot requires a reliable gas source. This term is equivalent to igniter, class 1 according to NFPA 8502. Intermittent pilot An Igniter applied to the fuel input through the burner under prescribed light off condition. This pilot is automatically lighted each time there is a call for heat. It burns during the entire period the main burner is firing. This term is equivalent to igniter, class 2 according to NFPA 8502. Interrupted pilot The pilot is automatically lighted each time there is a call for heat. The pilot fuel is cut off automatically at the end of the main burner flameestablishing period. This term is equivalent to igniter, class 3 according to NFPA 8502. Reliable gas source A pilot gas source that meets all of the following conditions: S Separate from the main fuel gas supply such that both supplies will not be simultaneously interrupted by a single contingency such as power or instrument air failure or inadverted valve closing.
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S Available during startup. S Liquefied petroleum gas vaporizers are not considered a reliable source. Supervised Manual System A system in which a trained operator has primary responsibility for the proper startup, operation and normal shutdown of a heater or boiler with interlocks to ensure that the operation follows established procedures. See Section 68 and figures A.6.8.1.1 (a) and (b) on NFPA 8502. Furnace The portion of the heater or boiler enclosure within which the combustion process takes place and wherein heat transfer occurs predominantly by radiation. Blowdown Control The primary purpose of blowdown is to maintain the dissolved solids concentration and silica content of the water in the steam generator within acceptable limits. Proper blowdown control will limit scale formation on heat transfer surfaces, limit the solids content of the steam drum, and assure maximum benefit from water treatment chemicals. Note: For further definitions on Heater And Boiler instrumentation refer to NFPA 8502, Chapter 3, Definitions.
FIRED HEATERS
4.1
4.1.1
General
All fired heaters have the following functional requirements: S Process control. S Burner Management System. S Decoking systems for plugged tubes, if applicable (process flow).
4.1.2
The instrumentation system shall ensure the safe operation of the heater and include a control system to ensure optimum heat transfer at maximum, normal, and minimum loads. Electrical equipment or instruments shall be specified and installed according to the intended service (fuel, gas, etc.) and the area classification. Special care shall be taken to position the local control panel and push button station in a safe area to be operated under emergency and harsh environment conditions according to PDVSA IRP01 and HAZOP study results. The main fuel heater safety shutoff valves shall be located at a safe distance from the furnace, according to PDVSA IRP01 and HAZOP study results.
4.1.3
4.1.4
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4.1.5
For cable routing, see specification PDVSA K334. and PDVSA N201.
4.2
4.2.1 4.2.2
Fuel systems
The fuel for pilot burners (igniters) shall be natural gas. A selfoperated pressure regulator shall be installed in parallel with the main gas flow control valve to ensure safer light off and reduce the occurrence of flame out. For multiple burner heaters, this selfoperated pressure regulator shall be able to handle light off requirements for any amount of operating burners in the unit. A mechanical stop on the flow control valve is not recommended. Safety shutoff valves (for igniters and main burners) shall be fail safe and not readily bypassed or blocked open and shall not be used as modulating control valves. Modifications to this requirement shall be supported by costbenefit and risk analysis, considering equipment dimensions, operation site, operating conditions, etc.
4.2.3
4.2.4
The main shutoff valve shall be tight shutoff and either fire safe or located in a fire safe area. Valve closure time shall not exceed 10 seconds. The main shutoff valve shall be manually and locally reset. The valves shall be class VI tight shutoff and of a failclose design. Vent valve shall be failopen. Main fuel control valve shall failclosed and shall have a closed position switch to be monitored by the BMS. This control valve shall be sized and arranged to ensure a fuel flow adequate for all operating requirements of the units. The fuel gas system arrangement for pilots and burner shall be in accordance to NFPA 8502, Part 6.3 System Requirements and 7.3 for fuel oil system. Any modification in existing heaters (i.e. revamping) shall consider as first option to design the fuel gas system arrangement for pilots and burner recommended by NFPA 8502, Part 6.3. As a second option for existing heaters with few burners, a Supervised Manual System (NFPA 8502, Part 6.8, Figures A.6.8.1.1 (a) and (b)) shall be considered. Modifications to this arrangement shall be supported by costbenefit and risk analysis, considering equipment dimensions, operation site, operating conditions, etc. All individual burner safety shutoff valves shall be located as close to the burner as practical, to minimize the volume of fuel left downstream of the burner valves in the burner lines. The double block and vent arrangement shall consist of two (2) shutoff valves and one (1) vent valve, each one independent from the others. An integral type valve might be considered and shall be approved by PDVSA.
4.2.5
4.2.6 4.2.7
4.2.8
4.2.9
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4.2.10
Provision should be made to leaktest the individual shutoff valves. On dual fuel units with combination burners, leak tests may be done on one fuel system while unit is operated with the other. On forced draft heater automatic shutoff for the combustion air, isolating dampers shall be provided. This damper shall close when the main flame is not alight. Provision shall be made to open these dampers during furnace purging, burner lightoff, and postpurging if required. Furnaces with a large number of small burners, making pilots impractical, and a constant firing rate, shall have a Main Fuel Low Pressure Indicator with a Main Fuel Low Pressure Alarm for shutoff of fuel to all burners on main fuel low pressure.
4.2.11
4.2.12
4.3
Measurement
Typical measurements used to maintain automatic control or to actuate alarm devices are discussed below. Sensors and instruments shall be accessible for reading and maintenance. Certain local check measurements at the source are necessary. Refer to API RP 551 and PDVSA MID, Volume 9, for installation details. Modifications to this requirement shall be supported by costbenefit and risk analysis, considering equipment dimensions, operation site, operating conditions, etc.
4.3.1
Temperature Temperature measuring elements complete with thermowells shall be provided at, but not limited to, the following locations:
d. e. f. g. h. i.
Radiant section. Convection Section. Flue gas stack, before the damper, at approximately 2 diameters from stack entrance, and preferably near the sampling point for flue gas analysis. At inlet and outlet manifolds of process fluid. On multiplepass furnaces, each individual tube process outlet temperature shall be measured by the installation of thermocouples or temperature indicators. On furnaces with high risk of coking, tube skin temperature measurement on radiant coil tubes shall be considered. Measurement points shall be within two or three tube diameters of the outlet, but may be best selected by considering the expected temperature profile. It is important that the temperature be determined at or near the highest section of the temperature profile. Multiple skin thermocouples distributed along the potential coking area should also be considered.
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j.
Radiant coil tube skin metal thermocouples shall be installed according to Figures 2 and 3 on API RP 556. The thermocouples must be in direct contact with the tube. All scale and oxide must be cleaned from the tubes before attaching the thermocouple sheath or block. Consult the fired heater manufacturer for recommended location for tube skin temperature measurement points Where steamair decoking is specified, to prevent damage from spalling, the thermowells shall be located downstream of swing bends. To measure decoking effluent temperature, additional thermowells with thermocouples shall be located in decoking outlet lines. Where reverse steamair decoking is specified, additional skin thermocouples shall be installed in each pass, on one of the shock tubes.
k.
l.
Where provision is made for future reverse steam air decoking, a thermowell with thermocouple shall be installed at the normal inlet end of each individual pass which will become an outlet during decoking. This thermowell shall be located in the decoking piping, not the process piping, on the side of the swing bend away from the heater. In the liquid fuel manifold, as close to the burners as possible.
m.
4.3.2
a.
Pressure
The pressure shall be measured at, but not limited to, the following points: Fuel gas and liquid fuel: Main supply line downstream of control valve. Individual heater fuel supply downstream of control valve. At burner manifold. Across filters to measure pressure drop.
b.
Pilot gas: Main supply line, when it is independent of main burner supply line. On the pilot manifold. Across filters to measure pressure drop.
c. d.
Atomizing steam: Downstream of pressure control valve. Process: At process fluid in inlet manifold. At process fluid in Convection section outlet. At process fluid in inlet to each pass, downstream of the regulating valve. At process fluid in outlet manifold.
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Pressure tapings only shall be provided in each crossover on all vaporizing duty furnaces. e. Draft: Pressure measurements should be made at the outlet of the forceddraft fan, across the air preheater, in the preheated air duct before the burners, in the firebox (near the burners and at the top of the radiant section), and across the dampers. At firebox in natural draft burners. On induced draft fired heater fitted with natural draft burners, if natural draft backup is not inherent in the fired heater design, the heater shall be shutdown on loss of the induced draft fan(s). In any case loss of the induced draft fan(s) shall be alarmed. Plugged draft connection for test purposes shall be provided in the furnace firebox at different positions. At outlet of the convection section.
4.3.3
a. b. c. d.
Flow
The flow shall be measured at, but not limited to, the following points: Combustion air flow in forced draft heaters locating the primary element (for example, venturi, averaging pitot, etc) in the forced draft duct system. Fuel gas and oil flow in the main line located upstream of the fuel control valves. An additional flow element for pilot fuel gas if it is piped independently of the main gas supply. Flow meter located upstream of the heater coil; if the process fluid is divided into two or more streams through the heater the flow in each pass shall be measured, if practical.
4.3.4
a. b.
Level
In pyrotubular type heaters a level indicator shall be installed. A low level signal shall be required for interlock purpose. A high level switch shall be installed in the fuel gas K.O. drum for interlock purpose.
4.3.5
a.
Analysis
Sample point facilities shall be provided for taking samples of the flue gas at the exit of each combustion chamber, just above the radiant section, and in the exit of the convection section so the composition of flue gas may be determined by analysis.
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b.
If required both oxygen and unburned combustibles shall be measured on the flue gas and indicated on the local firing panel and in the control room to obtain a good measurement of the quality of combustion. Samples shall be taken as near as possible to the point where combustion is completed, normally at the exit of the radiant section. The sample points shall be provided with screwed closures. When toxic gases or liquids are burnt in the furnace, analyzers shall be installed in the stack to monitor exhaust gas quality. Sample points shall also be provided near the damper and near the stack temperature thermocouple. All analyzer sample points must include facilities for manual sample takeoffs.
c. d. e. f.
4.4
Burner Management System

For Burner Management System see section 6.
4.5
4.5.1 a. b. c.
Controls
Load Control Continuos control functions shall be executed on independent devices (sensors, controllers, final control elements) different from sequential control devices. A fuel gas pressure controller (for natural draft heaters) or flow controller (for forced draft heaters) shall be installed in the heater fuel supply header. The furnace load controller (outlet temperature) shall be actuated on the fuel and combustion airflow controller set points. The basic principle is that both fuel and combustion airflow are controlled in parallel, with limit (maximum for fuel, minimum for air) to avoid substoichiometric combustion. See API RP556 FIG. 5 for forced Draft Heater and FIG. 6. For Natural Draft Heater. In case that load variation is expected a heater feed process flow controller with P.I. actions should be implemented. It should guarantee process flow stability. The process flow control valve shall be failopen. For single and multiple burner heaters minimum combustion air flow shall be ensured by an adjustable mechanical minimum stop on the combustion air damper, while the maximum combustion air flow is limited by the capacity of the blower and air register resistance. Minimum fuel flow condition (during start up or minimum burner load operation) shall be ensured by an active minimum stop, implemented by a pressure controller or a self regulated valve, on the fuel gas or fuel oil control valve.
d.
e.
f.
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g.
The combustion control system shall maintain heater fuel and air ratio in accordance with demand. The air/fuel ratio shall be set to provide a small amount of excess air for efficient and safe combustion. Atomizing steam for the fuel oil burner is controlled at a constant pressure differential to the burner fuel oil pressure. Depending on the variation in the MW of the fuel gas, flow measurement shall be corrected for changes in gas density. For multiburner heaters, a master flow controller shall be located in a common header, cascading via individual bias and ratio relays to individual pass flow controllers. In forced and induced draft heaters, control systems for regulation of fuel or air, or both, shall maintain air/fuel ratio at the optimum design excess air rate (for natural gas normally 5%, for oil 6%, and for coal 10%). All fired heater stack dampers shall be positioned manually or automatically with a manual loading station located at grade adjacent to the fired heaters or with a signal from the combustion control system, if it is required that the loop be closed. Damper position shall be indicated. Fuel oil firing system shall ensure a constant differential between steam and oil pressures. The recommended value of differential pressure shall be specified by the burner supplier. With any change of the rate of furnace input, the airflow and fuel flow shall be changed simultaneously to maintain proper air/fuel ratio during and after the changes. This shall not eliminate the requirements for air lead and lag during changes in the fuel firing rate. A control strategy shall be implemented such that setting fuel flow control on automatic without the airflow control on automatic shall not be permitted. Control action to increase fuel and decrease air shall be blocked when the air/fuel ratio falls below a preset value. Sequential Control Startup and shutdown sequence recommendations shall be submitted to PDVSA by heater manufacturer. However manufacturer shall guarantee that the startup and shutdown systems execute, at least, the following functions:
h. i. j.
k.
l.
m.
n.
o. p. 4.5.2
4.5.3 a.
StartUp Sequence Automatic verification of , but not limited to, the following interlocks: High burner fuel pressure. Low igniter fuel pressure.
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Low process flow in passes. High and low combustion air Automatic startup push button activation check. b. Purging For forced draft heaters the system shall be equipped with an automatic purge sequence. Upon activation of the purge start the combustion air damper is fully opened during the period set on the purge timer. After the purge time has elapsed and all permissive conditions are cleared, the burner can be started. A new purge cycle is only required in case of a combustion air failure. After any other sequence failure, a waiting time of 1 minute to restart is sufficient. For natural draft heater purging shall be performed based on an operational procedure. Igniters lightoff. Burners lightoff. 4.5.4 Shutdown Sequence A master fuel trip that results from any of the emergency conditions tabulated on the table below shall stop all fuel flow to the furnace for all burners by tripping the main and individual burner safety shutoff valves. All vent valves shall be opened. The main igniter safety shutoff valve and individual igniter safety shutoff valves shall be tripped, except for continuous igniter types which only can be tripped by a Manual ESD Station. The igniter sparks shall be deenergized. If a furnace inerting system is installed, the inerting system shall be operated simultaneously with the master fuel trip. Master fuel trips shall operate to stop all fuel flow into the furnace within a period that does not allow a dangerous accumulation of fuel in the furnace. A master fuel trip shall not initiate a forced draft fan or induced draft fan trip. Electrostatic precipitators, fired reheaters, or other ignition sources shall be tripped.
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a.
Partial Shutdown The main control valve shall be closed to minimum flame condition. If after a predetermined period of time normal condition is not reestablished (through an operator local reset action), shutoff valve shall be closed automatically. For partial shutdown signals, refer to section 4.6, Alarms and Shutdown.
b.
Total Shutdown A master trip is activated after a predetermined period of time in a partial shutdown condition, or at least, when any signal listed in section 4.6, Alarms and Shutdown, is activated: Prior to startup, the fuel safety shutoff valves shall be closed, and the fuel flow controllers are automatically set to manual with zero output. This will drive the fuel control valves to the minimum stop setting.
4.6
4.6.1 4.6.2
Alarms and Shutdown

All shutdown valves shall remain in the shutdown position until manually reset. The following typical alarms and shutdown signals shall be provided. Application depends on the process conditions and furnace design. A risk analysis and HAZOP study should support the final design. For instrument taps locations refer to Figure A6.5.1.2(b) of NFPA 8502.
4.6.3
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Description
Alarms
Local Control Center X X x X X x
Partial Total Shutoff Shutoff
Low flow in passes Low flow process Lowlow flow process Pass outlet high temperature Highhigh process outlet temperature Lowlow and highhigh gas pressure at igniter header Lowlow and Highhigh pressure at fuel supply (gas and liquid) Highhigh pressure at burner header Lowlow pressure at burner header Low atomizing steam pressure at burner Low percentage oxygen in the flue gas High percentage combustibles in the flue gas Low combustion air flow on forced draft burners High wind box pressure Low wind box pressure Flame failure (one burner) in a single burner heater Flame failure in multiburner heaters High stack temperature Highhigh stack temperature High smoke density (on fire) Highhigh tube skin Fan failure Stack damper closed Combustible gas on air duct intake Loss of air preheater driver Manual ESD station Low energy supply (Instrument air or electrical supply) Loss of energy supply (Instrument air or electrical supply) High level in fuel gas K.O. drum Highhigh level in fuel gas K.O. drum
x x x x x x
x x X x
x x
x x x x x x x x x x x x x x x x x x x x x x
x x
x Note 3 Note 3 x Note 1 x Note 4 Note 4 Note 2 x x x Note 5
Note 6
Note 1: Depending on the numbers of burners and their physical arrangement.
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Note 2: See Part 4.3.2 item e. Note 3: Applies only for forced draft heaters. Note 4: Only in unattended facilities. Note 5: This command shall shutoff all burners and igniter valves, even when continuous igniter type is used. Note 6: Not necessarily automatically initiated. A risk costbenefit analysis should support the final decision.
BOILERS
5.1
5.1.1 5.1.2
General
This chapter applies to boilers in which steam or vapor is generated at a pressure exceeding 15 psig. For lower pressure boilers refer to ASME CSD1. All boilers have three basic functional requirements: S Maintain steam production automatically at the required pressure and temperature under varying operating conditions (e.g. a sudden increase or decrease in demand of steam). S Burner startup management system S Automatic shutdown system in the event any of the variables reach an unsafe condition.
5.1.3
The instrumentation system shall ensure the safe operation of the boiler and include a control system to ensure optimum heat transfer under varying load conditions. Boiler designs vary depending upon the specific process design power plant, waste heat, etc. Electrical equipment or instruments shall be specified and installed according to the intended service (fuel, gas, etc.) and the area classification. Special care shall be taken to position the local control panel and push button station, so that they are located in a safe area to be operated under emergency and harsh environment conditions according to PDVSA IRP01 and HAZOP study results. The main fuel safety shutoff valves shall be located at a safe distance from the boiler. Refer to PDVSA IRP01 and HAZOP study results. For cable routing, see specification PDVSA K334. and PDVSA N201.
5.1.4 5.1.5
5.1.6 5.1.7
5.2
Fuel System
For fuel system see section 4.2.
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5.3
Measurement
Typical measurements employed to maintain automatic control or to actuate alarm devices are discussed below. Sensors should be accessible for reading and maintenance. Certain local check measurement at the source are necessary. Refer to API RP 551 and PDVSA MID volume 9 for installation details.
5.3.1 a.
Temperature Temperature measuring elements complete with thermowells shall be provided, at least, at the following locations: Boiler feed water Battery limit inlet Entrance to the steam drum Steam Steam drum liquid phase Steam drum vapor phase Saturated steam supply line Superheated outlet
b.
The type of thermowell and its immersion length shall be carefully selected. Special tapered well shall be considered for high pressure and high velocity service. Tapered wells shall be designed for particular installations to prevent cracking due to metal fatigue caused by velocityinduced vibration. Typically, wells in superheated steam service are flanged (RF). Radiant coil tube skin metal thermocouples shall be installed according to figures 2 and 3 on API RP 556, appendix 2.0. The thermocouple must be in direct contact with the tube. All scale and oxide must be cleaned from the tubes before attaching the thermocouple sheath or block. Consult the boiler manufacturer for recommended location for tube skin temperature measurement points Pressure Pressure shall be measured at, but not limited to, the following locations: Boiler feed water Battery limit inlet Steam Steam drum vapor phase Steam header Upstream of superheated steam supplies flow meter
c.
5.3.2 a.
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5.3.3 a.
Flow Flow shall be measured at, but not limited to, the following locations: Boiler feed water Battery inlet limit Economizers, desuperheaters, etc., one in each line, for large and complex boilers Steam Steam drum outflow Steam header Condensates (Purge) Purge flow
Chemicals One for each of the chemicals added to the boiler, if applicable 5.3.4 a. Level Level shall be measured at, but not limited to, the following locations: Continuous steam drum water level in accordance with details in specification K303. One d/p cell for control and a second d/p cell for high and low alarms Level gauge in accordance with ASME Boiler and Pressure Vessel Code Condensate (Purge) separators 5.3.5 a. Analysis Some of the recommended quality measurements are: FeedWater: PH Conductivity Hardness Turbidity
Combustion quality measurement: Oxygen contents in flue stack CO
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Required by regulatory agencies: SOx NOx Additional information on installation can be obtained in API Technical Paper 555.
5.4
Burner Management System

For Burner Management System see section 6
5.5
5.5.1
Controls
General The control system must be adequate to cover all operation conditions of the boiler during startup, normal operation, shutdown, and any emergency situation. Provision shall be included for indication at the local control panel and convenient operator adjustment of all necessary set points at the main control location. The control system shall guarantee steam demand, evaporated water make up and efficient use of the fuel; in order to achieve these three functions the following automatic controllers have to be implemented: steam pressure, drum level, fuel flow, air flow and furnace draft pressure.
5.5.2
Steam pressure control Each fired steam boiler or system of commonly connected steam boilers shall have, at least, one steam pressure control device that will shutoff the fuel supply to each boiler when the steam pressure reaches a preset maximum operating pressure. In addition to the steam pressure control, each fired steam boiler shall have a high steam pressure limit control that will prevent generation of steam pressure in excess of the maximum allowable working pressure. In multiple boiler installation one master steam pressure controller shall serve as the primary control for a group of boilers. If the fuel pressure is subject to significant fluctuation, the steam pressure controller might be cascaded to a fuel flow or pressure controller. The master pressure controller compares the pressure in the main steam heater with its set pressure and automatically adjusts its output to each boilers combustion controls to request more or less steam. If steam demand is subject to significant fluctuation, consideration should be given to use feed forward control strategy on the master pressure controller. When two or more boilers operate in parallel, they must share the total load in various proportions. In order to divide the total load, the output signal of the master
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pressure controller is fed into a loading station (Boiler master) provided for each boiler. 5.5.3 Feedwater control There are three basic types of water makeup control. These are: S Single element S Two element S Three element The single element water makeup control is used on small capacity boilers below 75,000 pph. This control consists of adding water to the boiler by means of a level controller on the boiler drum. See Figure 1 on Appendix. Two element water makeup control operates in accordance with the variation in steam flow and drum level, is used on medium capacity boilers (75,000 to 200,000 pph), where load changes are not too severe, and where the water pressure is relatively constant. See Figure 1 on Appendix . Three element water makeup control (recommended for new installations) operates in accordance with the variation in feedwater flow, steam flow and drum level, is used on higher capacity boilers (200,000 pph and up), or on medium capacity boilers where load changes are severe and for boilers with steaming economizers. See Figure 1 on Appendix . Three element water makeup control shall be used when drum level is unsteady due to: small drum size, swell and shrink effect, poor heat input regulation, or high solids concentration; or when boilers are not equipped with modern steam separating devices. 5.5.4 Combustion controls The combustion controls shall act to increase airflow before increasing fuel flow and to decrease fuel flow before decreasing airflow in order to maintain safe air/fuel ratio. Oxygen controllers may be used to adjust air/fuel ratio to obtain efficient combustion. The air/fuel ratio shall be set to give a small amount of excess air for efficient and safe combustion. The excess air in the flue gas shall not exceed 15% (corresponding to 5% oxygen) at any boiler operating condition other than during startup and shutdown. 5.5.5 Furnace Draft Control Furnace pressure is controlled to about 0.2 in.w.g on balanced draft boilers and to 10 in.w.g on pressure fired boilers by sensing the furnace pressure and adjusting either the stack damper or the induced draft fan speed to maintain the desired furnace draft.
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5.5.6
Blowdown control Blowdown analysis shall be made periodically, by means of conductivity tests. Blowdown shall be controlled by chemical injection by means of a manual or automatic control valve.
5.6
Alarms and Shutdown

Main shutdown valves shall remain in the shutdown position until manually reset. The following table is referential, Its application depends on process conditions and furnace design. A risk analysis and HAZOP study should support the final design. The following are typical alarms provided on the local panel and the main control center:
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Description
1 2
Boiler feed water to drum Boiler drum
3 4
Boiler drum (steam phase) Steam
5 6 7 8 9 10 11 12
Boiler drum blowdown Chemical additive tank Chemical to boiler drum Superheater outlet Main fuel gas supply Main fuel oil supply Main atomizing steam Pilot gas
13
Main burner (gas)
14
Main burner (fuel oil)
Low flow Lowlow flow Low level Lowlow level High level Highhigh level Low pressure High pressure Highhigh pressure Low temperature High temperature Low flow High temperature High flow High conductivity Low level Low level Low temperature High temperature Low pressure High pressure Low pressure Low pressure Low pressure Lowlow pressure High pressure Highhigh pressure Flame failure Low pressure Lowlow pressure High pressure Highhigh pressure Flame failure Low pressure Lowlow pressure High pressure
Alarm Local Control Center x X x x X x x X x x x X x x x x x x x x x x x x x x x x X x x X x X x x X x x X x X x x X x x
Shutdown
NOTE 1 x x
NOTE 1
NOTE 2 NOTE 2 NOTE 3 X x NOTE 4 x
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15 16 17 18
Main burner (atomizing steam) Main burner (air) Wind box (forced draught) Flue gas outlet
19
Boiler tube skin
Highhigh pressure Flame failure Low pressure Lowlow pressure Low flow Lowlow flow Low pressure High pressure High oxygen High temperature High % combustibles High CO / SOx/ NOx High temperature
X X
x x x x x x x x x x x x x
x X x x
NOTE 1: NOTE 2: NOTE 3 :
NOTE 4:
For boiler without steam drums this shall be considered as a shutdown condition. Only for continuous and intermittent igniter types. Depending in the numbers of burners and their physical arrangement, individual igniter valves shall be closed or the whole burner is shutdown. This applies to continuous and intermittent igniter types. Depending in the numbers of burners and their physical arrangement.
FLAME DETECTION / BURNER MANAGEMENT SYSTEM

6.1
The system shall be designed with a local panel containing a Burner Management System with Emergency Master Fuel Trip pushbuttons, Interlock System (Automatic shutdown system) to limit improper sequence of events and to shutdown the related equipment, Alarm System and Combustion Control System measurement indications and controls necessary for heaters and boilers operation. Main and pilot burner flame failure equipment is required, in accordance with NFPA 8502. The type and manufacturer shall be approved by PDVSA. Any deviation from NFPA 8502 shall be (mandatory) supported by a costbenefit and a risk study and approved by PDVSA. The burner management safety functions shall include, but shall not be limited to, proper purge interlocks and timing, mandatory safety shutdown, trial timing for ignition, and flame monitoring. The burner management system shall be a dedicated stand alone failsafe and failchecking system, in accordance with NFPA 8502. An option of a high integrity
6.2
6.3
6.4
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PLC may be used for BMS and Sequence and Control functions. This option shall be PDVSA approved.
6.5
The flame detectors shall be ultra violet type, dedicated, stand alone, failsafe with continuous and dynamic selfchecking. Ultra violet detectors shall operate on 24Vdc, or 120Vac (only in existing systems) depending on the power available. The UV Flame controller unit shall have an indication of the signal level generated by the UV detector. Flame sensor design shall minimize all possible causes of spurious trips (x rays, ground faults, etc). If adverse conditions are unavoidable for continuous pilot, an alternate design approach must be considered, such as the use of flame rods. Power supply for control and protection panels shall be independent from the igniter system power supply. If this is not possible, provisions shall be made to install isolating transformers in the igniter system power supply in order to avoid electrical interference with the rest of the equipment. The flame detection logic shall be determined by the type of pilot burner (i.e. Class 1, 2 or 3). For Fired heaters with more than one burner and continuous pilots, each pilot shall be equipped with a detector. These detectors shall be connected to an interlock system which prevents any fuel gas protective system valve from opening during startup. A common alarm in the control room shall be provided to indicate when flame failure is detected on one or more pilots when continuous pilot type is used. In fired heaters with one burner and continuous pilot type, continuous main flame verification using redundant detectors should be provided. Redundant flame sensors shall be justified by a risk analysis, and shall also be approved by PDVSA. For intermittent and interrupted type pilots the flame detector shall be located in such a way that it can sense pilot flame during startup sequence and main burner flame during normal furnace operation. Data hiway communications between the burner management system and other systems is permitted, but signals that initiate mandatory master fuel trip shall be hardwired.
6.6 6.7
6.8
6.9 6.10
6.11 6.12
6.13
6.14
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6.15
All measurements / process control functions shall be available in the local panel or the control room. For facilities with control room panel, the local field control panel shall be provided with the minimum required control and indication functions to allow heater startup and lightoff. The heater startup and lightoff shall always be performed locally and supervised by the operators, even when automatic startup and automatic combustion control systems are provided. The system design shall ensure that the maximum flame establishment period is 5 seconds for gas and 10 seconds for fuel oil.
6.16
6.17
PROTECTION SYSTEMS
7.1 7.2
Protection Systems (Automatic shutdown system) shall conform to PDVSA K336, PDVSA IRP01 and NFPA 8502. The protection system function is to protect against improper operation by limiting actions to a prescribed operating sequence or by initiating trip devices when approaching an undesirable or unstable operating condition. The protection system shall be failsafe i.e. in normal operating conditions initiating contacts shall be closed, relays and solenoid valves energized by DC voltage. Both main shutoff valve and main vent valve shall be provided with limit switches in the open and closed position. Automatic shutoff and lockout of main fuel control valve on low fuel flow shall be provided, with manual reset. A hardwired Emergency Shutdown switch or pushbutton shall be provided in the control room, at the fired heater local or remote control panel, and where the risk analysis so recommends, to close all fuel and pilot gas protective system valves. Forced and induced draft fans shall be continually supervised. Gas detector(s) shall be installed at the inlet of the fan. Gas detection shall be a shutdown initiator. Minimum fuel flow and pressure limiting devices are required to assure that each burner has sufficient fuel for safe operation.
7.3
7.4 7.5 7.6
7.7 7.8 7.9
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7.10 7.11 7.12
Lockup devices shall be installed to lock fuel and feedwater valves and dampers in position on instrument air failure. The boiler shall be shutdown on lowlow level and also on highhigh pressure in the steam drum. The protection system for boiler feed water pumps shall be in accordance with specification PDVSA K339.
INSTALLATION AND COMMISSIONING

8.1 8.2
All field mounted electric / electronic equipment shall be protected adequately against environmental damages. Connections Instrumentation coupling connections shall be: Furnace and Stack Draft Gauge Pressure Thermowell O2 and other Analyzers Flue Gas Sampling Connection Size, NPS (inch) 11/2 11/2 11/2 Connection per Analyzer Manufacturers requirement 11/2
8.3
Connections shall be selfdraining into the heater. Flexible connections shall be used when exposed to vibration. Instruments shall be preferably installed in a place without vibration. Separate nozzles shall be installed for flue gas sampling, smoke and temperature measurements. On applications where there may be coking or solidification, orifice flanges shall have a double set of tappings, one for flow control and the other for alarm/shutdown. Ignition transformers shall be installed close to the burner in order to minimize the length of the high voltage lead wire to the sparking device electrodes. The view path tube must be installed downwards to minimize accumulation of falling soot on the sensor glass.
8.4 8.5
8.6 8.7
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8.8 8.9 8.10
For flame sensors that might get soot on their cover glass, a forced air purge/cleansing system should be considered. Shutdown signals are to originate from their own process taps and are to be completely separated from transmitters used for control and prealarms. UV design and installation must consider the following: S A clear view path of the flame being monitored is required at all times. S Sensors shall not be affected by sparks during start up. S Detectors view path must focus on the first third of the flame.
8.11 8.12 8.13
If flame rods are used, they shall be in contact with the center of the flame. Flame rod electrode shall have a good ground connection. For horizontal or slightly tilted pilots, flame rods must be placed sideways or under the pilot. Fire resistant isolated wire shall be used for ignition sparking devices and flame rod electrodes.
QUALITY ASSURANCE / QUALITY CONTROL

All items shall conform to the procedures detailed in specification PDVSA K369.
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10 APPENDIX
Figure 1. Feedwater Control Schemes

Norma Pdvsa K-337

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Norma Pdvsa K-337

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PDVSA

ENGINEERING DESIGN MANUAL

FURNACE AND BOILER INSTRUMENTATION

DIC.99 AUG.96 AUG.94

GENERAL REVISION APPROVED FOR APPROVAL

Y.K. L.T. L.T.

A.A. E.J. E.J.

J.E.R. A.N A.N.

APPD.BY Alexis Arvalo

PDVSA K337 REVISION DATE

FURNACE AND BOILER INSTRUMENTATION

PDVSA K337 REVISION DATE

FURNACE AND BOILER INSTRUMENTATION

CODES, STANDARDS AND PRACTICES

PDVSA K337 REVISION DATE

FURNACE AND BOILER INSTRUMENTATION

PDVSA IRM01 PDVSA IRP01

PDVSA K337 REVISION DATE

FURNACE AND BOILER INSTRUMENTATION

PDVSA K337 REVISION DATE

FURNACE AND BOILER INSTRUMENTATION

PDVSA K337 REVISION DATE

FURNACE AND BOILER INSTRUMENTATION

PDVSA K337 REVISION DATE

FURNACE AND BOILER INSTRUMENTATION

PDVSA K337 REVISION DATE

FURNACE AND BOILER INSTRUMENTATION

PDVSA K337 REVISION DATE

FURNACE AND BOILER INSTRUMENTATION

Burner Management System

PDVSA K337 REVISION DATE

FURNACE AND BOILER INSTRUMENTATION

PDVSA K337 REVISION DATE

FURNACE AND BOILER INSTRUMENTATION

PDVSA K337 REVISION DATE

FURNACE AND BOILER INSTRUMENTATION

Alarms and Shutdown

PDVSA K337 REVISION DATE

FURNACE AND BOILER INSTRUMENTATION

Partial Total Shutoff Shutoff

x Note 3 Note 3 x Note 1 x Note 4 Note 4 Note 2 x x x Note 5

Note 1: Depending on the numbers of burners and their physical arrangement.

PDVSA K337 REVISION DATE

FURNACE AND BOILER INSTRUMENTATION

PDVSA K337 REVISION DATE

FURNACE AND BOILER INSTRUMENTATION

PDVSA K337 REVISION DATE

FURNACE AND BOILER INSTRUMENTATION

Combustion quality measurement: Oxygen contents in flue stack CO

PDVSA K337 REVISION DATE

FURNACE AND BOILER INSTRUMENTATION

Burner Management System

PDVSA K337 REVISION DATE

FURNACE AND BOILER INSTRUMENTATION

PDVSA K337 REVISION DATE

FURNACE AND BOILER INSTRUMENTATION

Alarms and Shutdown

PDVSA K337 REVISION DATE

FURNACE AND BOILER INSTRUMENTATION

Boiler feed water to drum Boiler drum

Boiler drum (steam phase) Steam

Main burner (gas)

Main burner (fuel oil)

Alarm Local Control Center x X x x X x x X x x x X x x x x x x x x x x x x x x x x X x x X x X x x X x x X x X x x X x x