Instrumentation for Fired Heaters IP 15-1-1

INTERNATIONAL Page 1 of 14
PRACTICE Rev. 1 March 1998

Changes shown by 

SCOPE
I  1.1 This practice covers instrumentation and protection systems for single, dual, and multi-fuel fired heaters.
Specific heater arrangement, design, and operating conditions will require Owner's Engineer to select
alternatives and provide further definition of requirements.
I 1.2 An asterisk () indicates that either a decision by the Owner's Engineer or Purchaser is required, that
additional information is to be furnished by the Owner's Engineer, or that information for the Owner's
Engineer's approval is to be supplied by the vendor or Purchaser.

SUMMARY OF ADDITIONAL REQUIREMENTS

I  2.1 Table 1 lists the practices and standard which shall be used with this practice.

TABLE 1

PRACTICES

IP 1-1-1 Drawings, Diagrams and Line Lists IP 15-2-1 Temperature Instruments

IP 3-4-1 Piping for Fired Equipment IP 15-3-1 Pressure Instruments
IP 3-6-1 Piping for instruments IP 15-4-1 Flow Instruments
IP 3-6-2 Piping at Control and Protective System Valve IP 15-7-2 Protective Systems
Stations IP 15-7-3 Alarm Systems
IP 3-12-1 Valve Selection IP 15-9-1 Control Valves
IP 7-1-1 Fired Heaters
STANDARD
API Standard
RP551 Process Measurement

DEFINITIONS
I  3.1 Reliable Pilot gas source: A source that supplies pilot gas to the fired heater battery limit and meets all
of the following conditions:
a. 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 inadvertent valve closing.
b. Available during startup.
c. Liquefied petroleum gas vaporizers are not considered a reliable source.
I 3.2 Fail-Action (Fail-Safe) Design: Failure or loss of energy or loss of circuit continuity to any protective
system component causes the protective system to take a predetermined corrective action and move the
process to its safe state. A circuit which is energized and uses closed contacts during normal operation is
fail-action.
I 3.3 Control Damper: A damper used to regulate flue gas or combustion air flow or firebox draft.

GENERAL REQUIREMENTS
O   4.1 All natural draft fired heaters shall, as a minimum, have the instrumentation and controls shown in
Figure 1, unless specified otherwise.
S,E   4.2 Control systems for the regulation of fuel, air, or both shall maintain a safe air-fuel mixture under all
conditions. Cross limiting air-fuel ratio control shall be provided for fired heaters with forced draft fans in
accordance with the minimum requirements as shown in Figure 2. The design of airflow measurement
devices shall be approved by the Owner’s Engineer.

THIS INFORMATION FOR AUTHORIZED COMPANY USE ONLY

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 IP 15-1-1 Instrumentation for Fired Heaters
Page 2 of 14 INTERNATIONAL
PRACTICE
Rev. 1 March 1998

FLUE GAS INSTRUMENTATION

O  5.1 A draft gauge or draft transmitter shall be provided at the following locations.
a. The bridgewall.
b. Downstream of stack or duct control dampers.
c. Upstream of stack or duct control dampers.
d. In the side wall at the floor.
S 5.2 Firebox high pressure alarm shall be provided on all fired heaters to detect and alarm on high pressure
at the bridgewall. The pressure measurement shall be by a differential pressure transmitter with a
calibrated span of -0.5 to 1 in. H 2O (-12 to +25 mm H2O). The atmospheric pressure tap shall be shielded
to prevent any errors caused by wind effects. Pressure switches should not be used.
S,E   5.3 A combined oxygen/combustibles analyzer shall be provided to permit continuous analysis of the flue
gas in the stack. If a zirconia type oxygen analyzer is used, then it should be equipped with flame
arrestors to prevent flame propagation in the event of ignition by the heated sensor. The sensor shall be
located below the stack damper. For multiple cell fired heaters with individual firing controls, an
oxygen/combustibles analyzer shall be provided near the top of each radiant cell.
E  5.4 Connections for manual sampling of flue gas shall be provided at the stack damper and bridgewall
near the flue gas analyzer. If an air preheater is installed, flue gas sampling is required in the flue gas
ducting upstream and downstream of the preheater. Connections shall not be located near possible
sources of air leakage. Unless otherwise specified:
a. Stack connections shall be 4 in. (100 mm) flanged.
b. Air preheater connections shall be 2 in. (50 mm) NPT.
c. All other connections shall be 1 in. (25 mm) NPT.
Additional connections required for environmental compliance shall be specified by the Owner's Engineer.
O 5.5 Thermocouples and thermowells shall be provided:
a. In the stack below the damper.
b. At the bridge wall. When possible, the thermocouples shall be placed in the arch out of view of the
shield tubes.
O 5.6 Control damper and louver designs shall include:
a. A manual loading station mounted at grade or at the local panel, capable of manually setting the
damper position.
b. A remote/local control switch mounted at grade or at the local panel. This switch may be combined
with the manual loading station in Par. 5.6a.
c. "Fail-Action” operation such that upon loss of instrument air, loss of control signal or linkage
failure, the flow path shall be opened.
O  5.7 Each stack shall be provided with a multi-bladed control damper capable of being operated by hand
and mechanically locked into position. A position transmitter shall be provided for each remotely actuated
stack control damper. This transmitter shall be directly connected to the damper or actuator linkage and
position indication shall be transmitted to a local indication at grade and to the control house. These
requirements also apply to combustion air control dampers.
S,O 5.8 Actuators for pressure relief dampers shall:
a. Be capable of fully opening the damper within ten seconds.
b. Fail open on loss of instrument air or control signal.

PROCESS INSTRUMENTATION
O  6.1 Total process feed flow meters shall be provided for all fired heaters. Flow meters shall be in
accordance with IP 15-4-1. The Owner's Engineer will specify flow distribution and measurement design
for heaters with two-phase flow at the process feed inlet.

THIS INFORMATION FOR AUTHORIZED COMPANY USE ONLY

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 Instrumentation for Fired Heaters IP 15-1-1
INTERNATIONAL Page 3 of 14
PRACTICE Rev. 1 March 1998

O   6.2 All fired heaters in liquid process or vaporizing process service shall have control house flow
indication for each pass.
a. A low flow alarm shall be provided on each pass.
b. Coking services shall have an automatic flow controller for each pass.
c. Non-coking services shall have local manual flow control for each pass.
Unless otherwise specified the distribution of flow in all vapor services will be controlled by the manifold
design.
S 6.3 All fired heaters shall have a low flow cut-out (FL(CO)) with pre-alarm which shuts off the main fuel(s)
on low total process feed flow. The FL(CO) for low process feed flow shall be located on the fired heater
inlet side only. In multi-cell fired heaters, any FL(CO) shall result in shutdown of all cells. Low flow trip
shall take place after a time delay of 10-20 seconds.
S 6.4 If a pressure relief valve is specified on the fired heater feed line, the total feed flow meter used to sense
low feed and actuate the fuel cut-out shall be located downstream of this pressure relief valve.
O   6.5 A pressure gauge or pressure transmitter shall be provided at the following locations:
a. Common coil inlet.
b. Each pass downstream of individual pass valves.
c. Common coil outlet.
d. In vaporizing service, at each pass crossover.
O  6.6 Temperature indication, using measuring elements and thermowells, shall be provided in the control
house for:
a. Common coil inlet.
b. Each pass crossover between convection and radiant sections.
c. Each coil or pass outlet.
d. Combined coil outlet.
S  6.7 All fired heaters shall be provided with a Priority 1 high temperature alarm in the combined coil outlet.
The measuring element shall be installed in a separate thermowell less than 18 in. (450 mm) from the coil
outlet temperature controller's thermowell. The measuring element shall also serve as a check sensor for
the coil outlet temperature controller. The Owner's Engineer will specify if individual pass alarms are
required.
R,M 6.8 Coil outlet thermowells in coking service shall be designed to minimize coke buildup on thermowells.
O 6.9 Fired heater coil outlet temperature controllers shall be capable of having both a suppressed range for
normal control in accordance with IP 15-2-1, and a range which covers all other operations such as
startup, shutdown, and decoking.
S,O  6.10 If valves have been specified in each pass to provide for flow distribution in multi-pass heater, protection
against low process flow and subsequent tube overheating shall be provided by:
a. The valve closure shall be limited to a specific minimum percent of the design flow rate to that pass.
This shall be done by a mechanical limit stop.
b. Control valves shall fail open or remain stationary and drift to the open position on actuating medium
or signal failure.
O  6.11 Valve installations shall be able to control properly over their design range.

FUELS SYSTEM INSTRUMENTATION

O   7.1 Fired heaters with continuous pilots shall have the fuel instrumentation and controls shown in Figure 3
for each specified fuel, unless specified otherwise.
O 7.2 Pressure and flow indication of each main fuel supply to the fired heater, or each cell in multi-cell fired
heaters, shall be provided in the control house.
O  7.3 All main fuel systems and pilot gas systems shall have a high pressure and low pressure alarm
installed downstream of the fuel control valves. A pressure gauge shall also be installed on each fuel
header to the fired heater.
S   7.4 Pilot gas which is not supplied by a reliable gas source shall have a protective system which shuts off
all main fuels and pilot gas on low pilot gas manifold pressure.

THIS INFORMATION FOR AUTHORIZED COMPANY USE ONLY

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 IP 15-1-1 Instrumentation for Fired Heaters
Page 4 of 14 INTERNATIONAL
PRACTICE
Rev. 1 March 1998

S,E   7.5 Fired heater fuel systems using atomizing steam, and firing liquid fuels having a flash point of less than
or equal to 100F (38C) shall have the following pressure instrumentation installed downstream of the
atomizing steam control valve.
a. A differential pressure low cutout or pressure low cutout which causes its associated main fuel block
valve(s) to close.
b. An independent pressure or differential pressure low alarm.

PROTECTIVE SYSTEM
S  8.1 A hardwired emergency switch or pushbutton shall be provided in the control house and at the fired
heater local panel which closes all fuel and pilot gas protective system valves.
S 8.2 All air or hydraulically actuated main fuel and pilot gas valves in protective system service shall
close on loss of actuating medium.
S,O 8.3 Dampers associated with protective system action shall be provided with manual reset action located
at grade.
S 8.4 The fired heater protective system shall be standardized at each Owner's location. Deviations from the
most recent standard design shall be approved by the local Safe Operations Committee.
S,O  8.5 In fired heaters with one burner, continuous main flame verification using redundant detectors (such as
UV, IR or flame ionization rods) shall be provided. UV or IR sensors shall be self-checking type.
S  8.6 For fired heaters with more than one burner and continuous pilots, each pilot shall be equipped
with an ionization flame rod. These flame rods shall be connected to a permissive interlock system
which prevents any fuel gas protective system valve from opening during startup unless more than 50%
of the pilots are sensed. If a fired heater is divided into cells, either by refractory walls or tube rows, the
more than 50% of pilots lit criterion shall be applied to each cell and the resulting protective action shall
apply to the entire fired heater. For two burner fired heaters or cells, only one pilot must be sensed to
satisfy the more than 50% criterion. In addition:
a. The flame rods shall initiate the closure of all main fuel gas protective system valves during
fired heater startup when the pilot voting is "on" and 50% or less of the pilots are sensed.
b. A common alarm in the control house shall be provided to indicate when one or more pilots are
not sensed. This alarm shall have a "reflash" feature to alarm when subsequent pilots go out, after
the first.
c. Individual indicators for each pilot shall be provided on the local panel.
d. A "Voting Off" pushbutton shall be provided which allows the operator to deactivate the pilot voting
system when the fired heater is in stable operation.
e. A "Voting On" pushbutton shall be provided that allows the voting to be manually activated.
f. On the closure of all main fuel gas valve(s), the pilot voting system shall automatically be
reactivated such that the greater than 50% permissive is required before the main fuel gas valve(s)
may be opened again.
g. The fired heater local panel shall be provided with a key-lock bypass facility for this pilot voting logic.
S  8.7 Fired heaters which have a large number of small burners making pilots impractical shall
automatically shut off of all main fuel on main fuel low pressure. A separate low pressure pre-alarm shall
also be provided. These requirements are shown in Figure 4.

ADDITIONAL REQUIREMENTS FOR FORCED DRAFT FIRED HEATERS,

BALANCED DRAFT FIRED HEATERS, AND FIRED HEATERS
WITH COMBUSTION AIR PREHEATERS
S  9.1 Induced draft fired heaters are considered special cases and protective instrumentation systems shall be
approved by the Owner's Engineer.
S,O  9.2 Forced draft fired heaters shall have additional cutouts with pre-alarms as shown in Figure 5 and as
given below:
a. Low combustion airflow.
 b. Loss of forced draft fan. The preferred measurement method is low fan speed. Other methods must
approved by the Owner's Engineer. No pre-alarm is required.

THIS INFORMATION FOR AUTHORIZED COMPANY USE ONLY

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 Instrumentation for Fired Heaters IP 15-1-1
INTERNATIONAL Page 5 of 14
PRACTICE Rev. 1 March 1998

ADDITIONAL REQUIREMENTS FOR FORCED DRAFT FIRED HEATERS,

BALANCED DRAFT FIRED HEATERS, AND FIRED HEATERS
WITH COMBUSTION AIR PREHEATERS (Cont)
c. Firebox high pressure. The firebox PH(CO) shall shut off all main fuels [and pilot, where the pilot
flame would be unstable at pressures above the PH(CO) set point] if high firebox pressure persists for
more than 10-15 seconds.
d. Loss of forced draft fan or low combustion air shall shut off all main fuels (and pilot, where the pilot
air is from same supply as main combustion air) if no facilities (i.e., per Subpar. 9.2e) have been
specified to permit fired heater to revert to a natural draft mode of operation.
 e. If the use of automatic air dropout doors with a forced draft fired heater with natural draft type
burners has been approved by the Owner's Engineer, the dropout doors shall open on either loss of
FD fan or low combustion air. Dropout doors shall have positive open position detection which shall
trip all main fuels and pilot gas should the doors not open within 10 seconds of the open command.
f. The forced draft fan shall not shut down on actuation of the pilot gas PL(CO) or main fuel PL(CO) or
any flame detector cutouts.
O 9.3 All fired heaters with preheaters and induced draft fans shall have additional cutouts and alarms as
shown in Figure 6 and as given below:
a. Low performance ratio alarm across the preheater (excluding circulating oil preheaters). This alarm
monitors the ratio of the decrease in flue gas temperature to the increase in the air temperature
across the air preheater as a means of fire detection.
(Temperature flue gas in) - (Temperature flue gas out)
Low Performance Ratio =
(Temperature air out) - (Temperature air in)
b. High flue gas temperature alarm and cutout, measured in the ducting upstream of the preheater.
High temperature cut-out shall bypass the air preheater by opening the pressure relief damper and
shutting down the ID fan.
c. High flue gas temperature alarm and cutout, measured in the ducting at the inlet of the ID fan. High
temperature cut-out shall shut down the ID fan and open the pressure relief damper.
d. Firebox PH(CO) shall also open the pressure relief damper.
S  9.4 In the event of an induced draft fan failure, sensed by a speed sensor on the fan side of the coupling
(preferred), the following actions should occur in sequential order:
a. Fan failure alarm. (No pre-alarm is required.)
b. The pressure relief damper shall open.
S  9.5 Induced draft fired heaters fitted with natural draft burners. If natural draft backup is not inherent in
the fired heater design, the heater shall be shut down on loss of the induced draft fan(s).

SUMMARY OF ALARMS AND SHUTDOWNS

I  10.1 Summary of alarms and shutdowns for natural draft fired heaters is provided in Table 2.
I  10.2 Summary of alarms and shutdowns for forced draft fired heaters, balanced draft fired heaters and
combustion air preheaters is provided in Table 3.

THIS INFORMATION FOR AUTHORIZED COMPANY USE ONLY

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.
 IP 15-1-1 Instrumentation for Fired Heaters
Page 6 of 14 INTERNATIONAL
PRACTICE
Rev. 1 March 1998

Revision Memo
9/68 Original Issue of Basic Practice 1/78 Revision 4
6/70 Revision 1 6/79 Revision 5
1/72 Revision 2 6/92 Revision 6
6/77 Revision 3
12/94 Revision 0 - Original Issue of International Practice
3/98 Revision 1
Complete editorial revision to rationalize this practice with the referenced standards and other IPs. Significant changes include:
Par. 1.1 deleted Table of Contents. Par. 2.1 added IP 3-12-1 to Table 1. New Par. 4.1 added to clarify minimum requirements for
natural draft heaters. Par. 4.2 delete specific requirement of device type and allowable differential pressure. Par. 5.1 eliminate
specifics on location of bridgewall draft reading to accommodate more options. Par. 5.3 clarify requirements for multi-cell heaters.
Par. 6.2 clarify that automatic pass flow control only required for coking services. New Par. 7.1 added to clarify fuel side
instrumentation requirements. Par. 8.6 clarify that requirement is more than 50% of pilots. Par. 9.4 deleted requirements for dual
ID fans since this is rarely done. Par. 10.1 moved table information into a separate Table 2. Several alarms changed from Priority
1 to Priority 2. Par. 10.2 moved table information into separate Table 3. Several alarms changed from Priority 1 to Priority 2.
Other changes to clarify/consolidate requirements shown. New Figure 1 added to clarify natural draft heater requirements.
Figure 2 changed figure number from 6 to 2. Figure 3 revised to clarify and limit content to fuel-related instrumentation only by
moving feed side instrumentation to new Figure 1. Changed figure number from 1 to 3. Figure 4 eliminated feed side controls
since now shown in new Figure 1. Changed figure number from 2 to 4. Figure 5 eliminated flue gas side instrumentation and
moved to new Figure 1. Changed figure number from 3 to 5. Figure 6 added stack TI. Changed figure number from 5 to 6.
Old Pars. deleted because requirement now in other Table 1 IP 5.2, 5.9, 8.1.
Old Pars. deleted because commonly accepted practice or no justification: 1.2, 1.4, 3.1, 3.5 to 3.9, 4.1, 4.3, 4.4, 4.5, 6.8.
Minor editorial changes: 3.1, 5.7, 6.5, 6.6, 6.10, 6.11, 7.3, 7.4, 7.5, 8.1, 8.7, 9.2, 9.3.
Paragraphs renumbered:
Old Par. No. New Par. No. Old Par. No. New Par. No.
1.3 1.2 5.10 5.8
3.2 3.1 6.9 to 6.12 6.8 to 6.11
3.3 3.2 7.1 to 7.4 7.2 to 7.5
3.4 3.3 8.2 to 8.8 8.1 to 8.7
5.3 to 5.8 5.2 to 5.7

© Exxon Research and Engineering Company, 1994, 1998

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 Instrumentation for Fired Heaters IP 15-1-1
INTERNATIONAL Page 7 of 14
PRACTICE Rev. 1 March 1998

TABLE 2
SUMMARY OF ALARMS AND SHUTDOWNS FOR NATURAL DRAFT FIRED HEATERS

Shut off all pilot gas (reliable or unreliable)

Alarm - Control Center Priority 1

Alarm - Control Center Priority 2

Shut off all liquid fuel (main fuel)
Shut off all gas fuel (main fuel)

Alarm - Local Panel(3)

ACTION
CAUSE

PROTECTIVE SYSTEM TRIP INITIATORS(1) Par.

Low Total Process Feed Flow (dp transmitter with 10-20 sec. delay) 6.3 X X X X

Shutdown System: Manual Emergency Pushbutton - Local Panel 8.1 X X X X X

Shutdown System: Manual Emergency Pushbutton - Control Center 8.1 X X X X X

Low Diff. or Low Atomizing Steam Pressure (Flash < 100oF or 38oC) at Oil Gun 7.5a X X X

Low Pilot Gas Pressure

(unreliable source only, i.e., pilot gas from main fuel supply) 7.3 X X X X X

Low Pressure on Main Fuel (for fired heaters with no pilots) 8.7 X X X X

Flamerod Logic: 50% or Less Pilots Lit (operational only during lightoff phase) 8.6 X X X

OTHER ALARMS(2) Par.

Low Pass Flow (one per pass) 6.2 X

High Firebox Pressure at Bridgewall (dp transmitter) 5.2 X

High Process Temperature (common coil outlet) 6.7 X

High Fuel Gas Pressure at Burners 7.3 X

Low Fuel Gas Pressure at Burners (for heater with pilots) 7.3 X

High Liquid Fuel Pressure at Burners 7.3 X

Low Liquid Fuel Pressure at Burners (for heater with pilots) 7.3 X

Low Diff. or Low Atomizing Steam Pressure at Oil (Flash > 100 oF or 38oC) Gun 7.5b X

High Pilot Gas Pressure at Burners (reliable or unreliable source) 7.3 X

Low Pilot Gas Pressure (reliable source case only) 7.3 X

Any one pilot flame not detected (flame rod logic) 8.6b X

Notes:
(1) All trip initiators shall be pre-alarmed on a Priority 1 basis per IP 15-7-2. Alarms indicated in table for trip
initiators are shutdown alarms only.
(2) All alarms shall be in accordance with IP 15-7-3.
(3) "First-Out" determination/indication shall be provided at the local panel unless the logic system can indicate first
out to the control center.

THIS INFORMATION FOR AUTHORIZED COMPANY USE ONLY

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 IP 15-1-1 Instrumentation for Fired Heaters
Page 8 of 14 INTERNATIONAL
PRACTICE
Rev. 1 March 1998

TABLE 3
SUMMARY OF ALARMS AND SHUTDOWNS FOR FORCED DRAFT FIRED
HEATERS, BALANCED DRAFT FIRED HEATERS, AND COMBUSTION AIR PREHEATERS

Open pressure relief damper (air preheater/ID fan case)

Same Action as for Natural Draft Fired Heaters

Shut off all pilot gas (reliable or unreliable)

Shut off all liquid fuel (main fuel)

Alarm - Control Center Priority 1

Alarm - Control Center Priority 2

Shut off all gas fuel (main fuel)

Shut Down Induced Draft Fan

Open Drop Out Doors

Alarm - Local Panel(3)

ACTION
CAUSE

PROTECTIVE SYSTEM TRIP INITIATORS(1) Par.

All Natural Draft Trip Initiators 10.1 X

Shutdown System: Manual Emergency Pushbutton - Local Panel 8.1 X X X X X X

Shutdown System: Manual Emergency Pushbutton - Control Center 8.1 X X X X X X

Low Combustion Air Flow Rate (if drop out doors provided) 9.2e X X X
(if no drop out doors provided to revert to natural draft operation) 9.2d X X X(4) X X

Loss of Forced Draft Fan (speed detection) (if drop out doors provided) 9.2e X X X
(if no drop out doors provided to revert to natural draft operation) 9.2d X X X(4) X X

High Firebox Pressure 10-15 sec. delay 9.2c X X X(5) X X

High Firebox Pressure (FD fans with APH/ID fan) 9.3d X X X

(if condition persists for more than 10-15 sec.) 9.2c X X X(5) X X

High Flue Gas Temperature Induced Draft Fan Inlet (air preheaters only) 9.3b X X X X

High Temperature Induced Draft Fan Inlet 9.3c X X X X

Loss of Induced Draft Fan (speed detection) 9.4a X X X

(if insufficient inherent natural draft backup exists) 9.5 X X X X X

Drop out doors not open within 10 seconds of loss of FD fan 9.2e X X X X X
or detection of low combustion air

OTHER ALARMS(2) Par.

All Natural Draft Alarms 10.1 X

Performance Ratio (air preheaters only) 9.3a X

Notes:
(1) All trip initiators (except for fan speed indicators) shall be pre-alarmed on a Priority 1 basis per IP 15-7-2. Alarms
indicated in table for trip initiators are shut down alarms only.
(2) All alarms shall be in accordance with IP 15-7-3.
(3) "First-Out" determination/indication shall be provided at the local panel unless the logic system can indicate first
out to the control center.
(4) Pilot gas shall be shut down only if its air is from same supply as main combustion air.
(5) Pilot gas shall be shut down only if pilot flame would be unstable at pressures above the PH(CO) set point.

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 Instrumentation for Fired Heaters IP 15-1-1
INTERNATIONAL Page 9 of 14
PRACTICE Rev. 1 March 1998

FIGURE 1
GENERAL INSTRUMENTATION AND CONTROLS FOR NATURAL DRAFT FIRED HEATERS

Feed
Inlet Note 3
XV
DG xxx

PI
TI From Draft Controls

Stack Control Damper

DG
TI

FL(CO) FAL AI AI
xxx xxx xxx xxx
FAL
O 2 and Combustibles
(CO) TI

PI
Note 2 TI
DG Bridgewall
I
PC PAH
xxx xxx

Firebox

To Draft Controls

Burner
DG
PI
TI TC
xxx xxx
Air Control Damper
TAH
From Excess xxx
XV
Air Controls
xxx

To
Firing
Controls
150101F1

Notes:
(1) Refer to IP 1-1-1 for explanation of symbology.
(2) Pressure gauge required only if in vaporizing service.
(3) Instrumentation shown except for combustion air control is also applicable for forced draft heaters. Refer to
Figure 5 for other forced draft heater requirements.

THIS INFORMATION FOR AUTHORIZED COMPANY USE ONLY

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 IP 15-1-1 Instrumentation for Fired Heaters
Page 10 of 14 INTERNATIONAL
PRACTICE
Rev. 1 March 1998

FIGURE 2
MINIMUM REQUIREMENTS FOR AIR-FUEL CROSSLIMITING CONTROL

CombustionAir Flow Element

See Note 2 FV
xxx
Load Set Point
Signal (COT. Steam Pressure, etc.)

FY
xxx

Ratio FFC
& Bias xxx

FY
Low Signal A
Selector

Set
Point
FY FC
B xxx
High Signal
Selector Set
Point

FC
yyy

FC
yyy

FV
See Note 2 yyy

Fuel (Gas or Oil) 150101F2

Notes:
(1) Refer to IP 1-1-1 for explanation of symbology.
(2) Where high fired heater reliability is a requirement, use dual transmitters for the combustion controls.

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 Instrumentation for Fired Heaters IP 15-1-1
INTERNATIONAL Page 11 of 14
PRACTICE Rev. 1 March 1998

FIGURE 3
FUEL INSTRUMENTATION AND CONTROLS FOR FIRED HEATERS WITH CONTINUOUS PILOTS

To Firing
Controls

I
See TC
Optional PV xxx
I Note 6
FI xxx PAH PAL
XV xxx xxx xxx PL(CO) PAL
xxx xxx (CO) I
Pilot
Gas

CSC PI
PAH BAL Bi
Alternate PAL xxx xxx LP
I
Reliable Source FC PI See
See Note 6 FV Note 4
XV xxx xxx xxx
xxx
Fuel
Gas Flame
Rod
CSC PI
PAH
FV PAL
I xxx
FC PI
xxx Fire
XV xxx
Box
xxx
Fuel
Oil

CSC PI
See Note 7
PDC DAL
PV
xxx xxx
xxx
Atomizing
Steam

PI
From Firing
Controls
See Note 3
PDL PDAL
I (CO)
(CO)
Feed
150101F3 See Note 8

Notes:
(1) Refer to IP 1-1-1 for explanation of symbology.
(2) Block and bypass valves around control valves; check, vent and drain valves; strainers in liquid fuel and pilot gas
lines; atomizing steam controls; Control Center instrumentation and protective system logic functions are not
detailed here.
(3) The signal from the Firing Controls sets the flow or pressure controller setpoint.
(4) One flame rod per burner with a common alarm in the Control Center.
(5) Figure 1 shows a combination of fuel gas and fuel oil with atomizing steam. Dedicated fuel gas or fuel oil
systems (with or without atomizing steam) can be derived by removing the appropriate process lines and their
respective instruments.
(6) If the pilot gas is from a reliable gas source, then the PL(CO) on the pilot gas may be eliminated.
(7) Steam PDC can also be PIC depending on atomizer type.
(8) PDL(CO) only required when liquid fuel flash point less than 100F (38C).

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 IP 15-1-1 Instrumentation for Fired Heaters
Page 12 of 14 INTERNATIONAL
PRACTICE
Rev. 1 March 1998

FIGURE 4
FUEL INSTRUMENTATION AND CONTROLS FOR FIRED HEATERS WITHOUT PILOTS

Fire Box

PAL
xxx
I
PAH PI
xxx xxx
I

FC PL(CO) PAL
xxx xxx (CO)
XV FV
xxx xxx

Fuel Gas
or
Fuel Oil
CSC
From
Process 150101F4
Controls

Notes:
(1) Refer to IP 1-1-1 for explanation of symbology.
(2) Block and bypass valves around control valves; check, vent and drain valves; strainers in liquid fuel and pilot gas
lines; atomizing steam controls; Control Center instrumentation and protective system logic functions are not
detailed here.

THIS INFORMATION FOR AUTHORIZED COMPANY USE ONLY

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.
 Instrumentation for Fired Heaters IP 15-1-1
INTERNATIONAL Page 13 of 14
PRACTICE Rev. 1 March 1998

FIGURE 5
ADDITIONAL INSTRUMENTS REQUIRED FOR FORCED DRAFT PROCESS FIRED HEATERS

Bridgewall
PH(CO)
xxx

PAH
(CO)
Firebox To Excess
Air Controls

I
Burner

FC FAL I
Air xxx xxx
Plenum

PI FL(CO)
Forced xxx
Draft
FAL
PI Fan
(CO)
See Note 2

SL(CO) SAL
I
150101F5 xxx (CO)

Notes:
(1) Refer to IP 1-1-1 for explanation of symbology.
(2) Combustion air control via fan speed or FD louvers/dampers associated controls and gauges not shown.

THIS INFORMATION FOR AUTHORIZED COMPANY USE ONLY

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.
 IP 15-1-1 Instrumentation for Fired Heaters
Page 14 of 14 INTERNATIONAL
PRACTICE
Rev. 1 March 1998

FIGURE 6
ADDITIONAL INSTRUMENTS REQUIRED FOR FIRED HEATERS WITH FLUE GAS/AIR PREHEATERS

TI
TAH Flue Gas
(CO) I Bypass Damper
(Pressure Relief)
TH(CO) Tl TAH Tl Stack
I
xxx xxx
XV

TH(CO) TAH SL(CO) SAL

I I (CO)
xxx (CO) xxx

DG

TI
gi DG DG Induced
TI TAL Draft Fan
go xxx See Note 3
Air
Preheater TAH
See Note 6 xxx
Fired Heater
PI PI
TI
TI
al

Forced
TI Draft Fan
ao

See Control
Note 4 Damper Bypass

See Notes 2 & 3 150101F6

Notes:
(1) Refer to IP 1-1-1 for explanation of symbology.
(2) Instruments required in Figure 5 are also required here.
(3) FD and ID fan louvers/dampers associated controls and gauges are not shown.
(4) The temperature measurements must be downstream of the air preheater air bypass.
(5) The temperature sensors used for performance ratio monitoring have subscripts where their loop numbers
would normally be (per IP 1-1-1). This is done here only to clarify to which temperature sensors the text is
referring.
Tai - Temperature Air In Tgi - Temperature Flue Gas in
Tao - Temperature Air Out Tgo - Temperature Flue Gas Out
(6) If the heater is specified with a waste heat recovery device other than an air preheater, the instrumentation on the
flue gas side shall be as shown here and the forced draft fan instrumentation shall be as shown in Figure 5.

THIS INFORMATION FOR AUTHORIZED COMPANY USE ONLY

EXXON RESEARCH AND ENGINEERING COMPANY — FLORHAM PARK, N.J.