API RP 556-2011 Instrumentation Control and Protective Systems for Gas Fired Heaters (Second Edition)《燃气加热器的仪表、控制及保护系统.第2版》.pdf

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1、Instrumentation, Control, and Protective Systems for Gas Fired HeatersAPI RECOMMENDED PRACTICE 556 SECOND EDITION, APRIL 2011Instrumentation, Control, and Protective Systems for Gas Fired HeatersDownstream SegmentAPI RECOMMENDED PRACTICE 556 SECOND EDITION, APRIL 2011Special NotesAPI publications ne

2、cessarily address problems of a general nature. With respect to particular circumstances, local, state, and federal laws and regulations should be reviewed.Neither API nor any of APIs employees, subcontractors, consultants, committees, or other assignees make any warranty or representation, either e

3、xpress or implied, with respect to the accuracy, completeness, or usefulness of the information contained herein, or assume any liability or responsibility for any use, or the results of such use, of any information or process disclosed in this publication. Neither API nor any of APIs employees, sub

4、contractors, consultants, or other assignees represent that use of this publication would not infringe upon privately owned rights.API publications may be used by anyone desiring to do so. Every effort has been made by the Institute to assure the accuracy and reliability of the data contained in the

5、m; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly disclaims any liability or responsibility for loss or damage resulting from its use or for the violation of any authorities having jurisdiction with which this publicati

6、on may conflict.API publications are published to facilitate the broad availability of proven, sound engineering and operating practices. These publications are not intended to obviate the need for applying sound engineering judgment regarding when and where these publications should be utilized. Th

7、e formulation and publication of API publications is not intended in any way to inhibit anyone from using any other practices.Any manufacturer marking equipment or materials in conformance with the marking requirements of an API standard is solely responsible for complying with all the applicable re

8、quirements of that standard. API does not represent, warrant, or guarantee that such products do in fact conform to the applicable API standard.All rights reserved. No part of this work may be reproduced, translated, stored in a retrieval system, or transmitted by any means, electronic, mechanical,

9、photocopying, recording, or otherwise, without prior written permission from the publisher. Contact the Publisher, API Publishing Services, 1220 L Street, NW, Washington, DC 20005.Copyright 2011 American Petroleum InstituteForewordNothing contained in any API publication is to be construed as granti

10、ng any right, by implication or otherwise, for the manufacture, sale, or use of any method, apparatus, or product covered by letters patent. Neither should anything contained in the publication be construed as insuring anyone against liability for infringement of letters patent.This document was pro

11、duced under API standardization procedures that ensure appropriate notification and participation in the developmental process and is designated as an API standard. Questions concerning the interpretation of the content of this publication or comments and questions concerning the procedures under wh

12、ich this publication was developed should be directed in writing to the Director of Standards, American Petroleum Institute, 1220 L Street, NW, Washington, DC 20005. Requests for permission to reproduce or translate all or any part of the material published herein should also be addressed to the dir

13、ector.Generally, API standards are reviewed and revised, reaffirmed, or withdrawn at least every five years. A one-time extension of up to two years may be added to this review cycle. Status of the publication can be ascertained from the API Standards Department, telephone (202) 682-8000. A catalog

14、of API publications and materials is published annually by API, 1220 L Street, NW, Washington, DC 20005.Suggested revisions are invited and should be submitted to the Standards Department, API, 1220 L Street, NW, Washington, DC 20005, standardsapi.org.iiiContentsPage1 Scope . . . . . . . . . . . . .

15、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16、 . . . . . . 11.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.1 Normative References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.2 Other References. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Fired Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 General . . . . . . . . . . . . . . .

19、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2 Process Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.3 Pr

20、ocess Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193.4 Protective Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21、. . . . . . . . . . . . 21Figures1 Forced Draft Fired HeaterFuel Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 Natural Draft Fired HeaterFuel Side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22、 . . . . . . . . . . . . . . 233 Natural Draft Fired HeaterProcess Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Tables1 Alarm Summary Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23、 . . . . . . . . . . . . . . . . . . . 552 Safe State Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 563 Cause and Effects Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614 Startup Sequence, Natural Draft Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625 Startup Sequence, Forced Draft and Balanced Draft Heaters . . . . . . . . . . . .

25、. . . . . . . . . . . . . . . . . . . . . . . 64Annex A (normative) Tube Rupture Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66v1Instrumentation, Control, and Protective Systems for Gas Fired Heaters1 Scope1.1 Purpose1.1.1 This recom

26、mended practice (RP) provides guidelines that specifically apply to instrument, control and protective system installations for gas fired heaters in petroleum production, refineries, petrochemical and chemical plants. 1.1.2 A gas fired general service heater defined in this practice liberates heat b

27、y the combustion of fuel gas and this heat is transferred to liquids and/or gases in tubular coils all contained within an internally insulated enclosure. 1.1.3 Not covered in this RP are the following: oil fired and combination fired heaters; water tube boilers which consist of single or multiple b

28、urners and are designed for utility operation or where the primary purpose is steam generation (covered by NFPA 85); fired steam generators used to recover heat from combustion turbines i.e. heat recovery steam generators (HSRG); oven and furnaces used for the primary purpose of incineration, oxidat

29、ion, reduction or destruction of the process medium (covered by NFPA 86); water bath or oil bath indirect fired heaters (covered by API 12K); CO boilers, pyrolysis furnaces (e.g. ethylene and hydrogen reformers), and other specialty heaters.1.1.4 This RP includes primary measuring and actuating inst

30、ruments, controls, alarms, and protective systems as they apply to fired heaters. For additional subject matter review, refer to the referenced or industry standards.1.2 General1.2.1 Instrumentation and control applications incorporate systems and devices to satisfy equipment specific requirements.

31、Equipment specific requirements include safety, process control, data collection, environmental reporting and other local applications.1.2.2 Documentation including schedules, drawings, sketches, specifications and other data should be provided to install the equipment in the desired manner and for

32、the users to maintain, inspect, test and operate the system in a safe manner. 1.2.3 The various industry codes and standards as well as laws and rules of local regulating bodies shall be followed where applicable. 1.2.4 Although it is no substitute for experience and proficiency in these fields, thi

33、s document is intended to assist users with achieving such experience and proficiency. Because of the lack of uniformity in the design and requirements of the processes, the complete instrumentation and control system must be studied to determine if it will enable the unit to be started-up, operated

34、, and shut down satisfactorily and safely.2 API RECOMMENDED PRACTICE 5562 References2.1 Normative ReferencesThe following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of t

35、he referenced document (including any amendments) applies. API Specification 6FA, Specification for Fire Test for ValvesAPI Specification 12K, Indirect Type Oil-Field HeatersAPI Recommended Practice 534, Heat Recovery Steam GeneratorsAPI Recommended Practice 535, Burners for Fired Heaters in General

36、 Refinery ServicesAPI Recommended Practice 551, Process Measurement InstrumentationAPI Recommended Practice 553, Refinery Control ValvesAPI Recommended Practice 554, Process Control Systems, Part 1 through 3API Recommended Practice 555, Process AnalyzersAPI Standard 560/ISO 13705, Fired Heaters for

37、General Refinery ServicesAPI Recommended Practice 573, Inspection of Fired Boilers and HeatersAPI Standard 598, Valve Inspection and TestingAPI Standard 607, Fire Test for Quarter-turn Valves and Valves Equipped with Non-Metallic SeatsANSI/ISA 84.00.01-2004 (IEC 61511-Mod) 1, Functional Safety: Safe

38、ty Instrumented Systems for the Process Industry SectorNFPA 325 2, Guide to Fire Hazard Properties of Flammable Liquids, Gases, and Volatile Solids, 1994 edition.2.2 Other ReferencesCertain systems are not covered in this document because of their specialized nature and limited use in petroleum refi

39、nery, hydrocarbon-processing, petrochemical, and chemical plants. When one of these systems gains general usage and installation reaches a fair degree of standardization, this document will be revised to provide additional information. The following documents are not directly applicable to refinery

40、heaters. These are referenced as they may be cited by regulatory bodies.ANSI/FCI 70-2 3, Control Valve LeakageASME, CSD-1 4, Controls and Safety Devices for Automatically Fired Boilers1American National Standards Institute, 25 West 43rdStreet, 4thFloor, New York, New York 10036, www.ansi.org.2Nation

41、al Fire Protection Association, 1 Batterymarch Park, Quincy, Massachusetts 02169-7471, www.nfpa.org.3Fluid Components International, 1755 La Costa Meadows Drive, San Marcos, California, .INSTRUMENTATION, CONTROL, AND PROTECTIVE SYSTEMS FOR GAS FIRED HEATERS 3EN 746-2 5, Industrial thermo processing

42、equipment, Part 2, Safety requirements for combustion and fuel handling systems. ISA TR.84.00.05 6, The Application of ANSI/ISA 84.00.01-2004 (IEC 61511) for Safety Instrumented Functions (SIFs) in Burner Management SystemsNFPA 85, Boiler and Combustion Systems Hazards CodeNFPA 86, Standards for Ove

43、ns and Heaters3 Fired Heaters3.1 GeneralAPI 560 contains instrumentation requirements for fired heaters and their auxiliaries. 3.2 Process MeasurementInstallation of instrumentation should consider accessibility for efficient maintenance and for good operation. Flow elements, control valves, transmi

44、tters, thermowells, level gauges, and local controllers, as well as analyzer sample points, generally should be readily accessible from grade or from permanent platforms or fixed ladders. In this document, special consideration is given to the location, accessibility, and readability of the elements

45、. Refer to API 551 for installation details.3.2.1 TemperatureContinuous temperature measurement in fired heater applications generally uses thermocouples.3.2.1.1 Bridgewall TemperatureThe bridgewall temperature is the temperature of flue gas leaving the radiant section. Each heater and each cell of

46、a heater should have a bridgewall temperature thermocouple located at least two feet into the firebox and just upstream of the convection section. This temperature is used for trending the approximate flue gas temperature. Highly accurate temperature measurement here is not necessary for normal refi

47、nery service heaters. Long/large fireboxes may require several bridgewall temperature measurements along the length of the box. These measurements may be useful in assessing the uniformity of heat distribution along the length of the firebox. Thermocouples in the radiant section should be installed

48、with wells or other protective devices. The point of measurement should not have flame impingement. The thermocouples should extend past the shadow of the tube and be placed to avoid dead spots. A sample port next to the thermowell location is recommended to allow temperature verification. Thermowel

49、l materials must be suitable for the firebox temperatures and atmosphere. American Iron and Steel Institute (AISI) Types 446 and 347 stainless steel are generally acceptable materials. For some severe services, 310 stainless steel, nickel chromium iron alloy, ceramic, or ceramic-coated thermowells have been used. 4ASME International, 3 Park Avenue, New York, New York 10016-5990, www.asme.org.5European Committee for Standardization, Avenue Marnix 17, B-1000, Brussels, Belgium, www.cen.eu.6International Society of Automation, 67 Alexander Drive, Res