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Fuel Gas Pressure Control Solutions for Fired Heaters and Boilers

Fuel Gas Pressure Control Solutions for Fired Heaters and Boilers
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Fuel Gas Pressure Control Solutions for Fired Heaters and Boilers - 1

Fuel Gas Pressure Control Solutions for Fired Heaters and Boilers Solutions for safer and more reliable operation of fired heater fuel gas systems. Process Management

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Fuel Gas Pressure Control Solutions for Fired Heaters and Boilers - 2

Prevent process downtime by keeping your critical heaters online. Fuel Gas Systems Fired heaters and boilers are essential components of most refineries, chemical plants and power generation facilities. Whether helping to power a steam turbine generator or the direct heating of hydrocarbons to make gasoline, the fundamentals of fuel gas pressure control are relatively standard across a wide range of fired heater applications. Power Generation Steam Steam Turbine Generator Electricity refining Process Fired Heater Distillation Tower

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Fuel Gas Pressure Control Solutions for Fired Heaters and Boilers - 3

Fuel Gas Pressure Control Challenges • Inadequate speed of response of pressure control devices causing unplanned shutdowns • Poor fuel gas quality or lack of routine maintenance leading to equipment failures • Poor pressure control caused by improper equipment selection Although natural gas is the fuel most commonly used in a fired heater, many refineries and chemical plants mix process waste gases into their fuel systems. These process gases may contain heavy hydrocarbons that can cause build-up in the fuel gas lines. For sites that use waste gas, a higher rate of residue build-up is...

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Fuel Gas Pressure Control Solutions for Fired Heaters and Boilers - 4

minimizing the dangers associated with equipment start-up is a top priority. Fuel Gas Solutions minimum Fire Pressure Control Complicated burner management systems can hinder your ability to start a heater safely and quickly. An API 556-recommended minimum fire pressure regulator is essential when the fuel gas control valve lacks sufficient turndown to light the first burner. This regulator not only helps minimize the complexity of the burner management system, but also reduces operator interaction during start-up. Simply set the regulator to the required setpoint during commissioning and...

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Fuel Gas Pressure Control Solutions for Fired Heaters and Boilers - 5

monitor Setup A monitor setup provides predictable control for certain pressure regulator failure modes without sacrificing pressure control performance. Commonly used in natural gas distribution by gas utilities, a monitor setup uses regulators in series to provide a layer of redundancy in the event the primary pressure regulator ceases to control downstream pressure. Monitor setups are recommended for use in fuel gas header and burner gas pressure control applications. Fired Heater Working Monitor Regulator Regulator Working Monitor Regulator Regulator Pressure Monitor Regulator Regulator...

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Fuel Gas Pressure Control Solutions for Fired Heaters and Boilers - 6

optional Features wireless Position Indication End users are often hesitant to use a pressure regulator, viewing it as a closed system that makes it difficult to determine if a regulator is working properly. Wireless position indicators can be used to detect and troubleshoot regulator problems on your existing control system before they impact your operation. They can be mounted on a variety of regulators to indicate real-time regulator performance, long-term degradation or a step change in process conditions. Slam-Shut The Emerson™ slam-shut valve is a mechanical device that will “slam...

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Fuel Gas Pressure Control Solutions for Fired Heaters and Boilers - 7

over 50% of unplanned shutdowns are related to human factors. minimize unscheduled down time by increasing your knowledge. rely on Emerson™ for expert assistance and training. Unparalleled Support Expert help when you need it the most. Emerson state-of-the art flow and materials labs provide an extensive worldwide network of engineers, application experts and sales professionals to help you size, select and troubleshoot your pressure regulators. Emerson test and evaluation teams provide flow, material and environmental testing under real-world operating conditions before you place them in...

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Fuel Gas Pressure Control Solutions for Fired Heaters and Boilers - 8

Top-rated Products for Boilers, Burners and Fuel Gas applications SElF-oPEraTEd rEGUlaTorS Type 912n Type y600a Body Size NPS 1/4 or 1/4 x 3/8 max Inlet 250 psig / 17.2 bar outlet range 3 in. w.c. to 5 psig / 7 mbar to 0.35 bar outlet range 4 in. w.c. to 7 psig / 10 mbar to 0.48 bar max Inlet 125 psig / 8.6 bar outlet range 4 in. w.c. to 2.2 psig / 10 mbar to 0.15 bar max Flowrate 4800 SCFH / 129 Nm3/h Type 66 Body Size NPS 1-1/4, 1-1/2 or 2 / DN 32, 40 or 50 outlet range 3.5 in. w.c. to 10 psig / 9 to 690 mbar outlet range 4 in. w.c. to 5 psig / 10 mbar to 0.35 bar outlet range 3.5 in....

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Fuel Gas Pressure Control Solutions for Fired Heaters and Boilers - 9

outlet range 2 in. w.c. to 60 psig / 5 mbar to 4.1 bar outlet range 5 to 500 psig / 0.34 to 34.5 bar Body Size NPS 3/4 or 1 / DN 20 or 25 max Inlet 200 psig / 13.8 bar outlet range 1 in. w.c. to 7 psig / 2 mbar to 0.48 bar outlet range 2 to 400 psig / 0.14 to 27.6 bar PrESSUrE loadEd/PIloT-oPEraTEd rEGUlaTorS 1098 Series outlet range 2 in. w.c. to 100 psig / 5 mbar to 6.9 bar outlet range 4 in. w.c. to 300 psig / 10 mbar to 20.7 bar minimum differential requirement minimum differential requirement outlet range 1 to 20 psig / 0.07 to 1.4 bar max Flowrate 17,600 SCFH / 472 Nm3/h recommended...

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Fuel Gas Pressure Control Solutions for Fired Heaters and Boilers - 10

Top-rated Products for Boilers, Burners and Fuel Gas applications PrESSUrE loadEd/PIloT-oPEraTEd rEGUlaTorS Ezl Series outlet range 3.5 in. w.c. to 60 psig / 9 mbar to 4.1 bar outlet range 7 in. w.c. to 300 psig / 17 mbar to 20.7 bar outlet range 14.5 to 1160 psig / 1 to 80 bar minimum differential requirement minimum differential requirement minimum differential requirement recommended Construction recommended Construction Fast open or fast closing Type 61 pilot option recommended Construction Dual registration using 3/4 in. piping outlet range 6 in. w.c. to 1000 psig / 15 mbar to 68.9 bar...

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Fuel Gas Pressure Control Solutions for Fired Heaters and Boilers - 11

Installation Tips Internal Sensing Units Piping should be a straight run for 8 to 10 pipe diameters downstream of the regulator Proper installation of a fuel gas application minimizes shutdowns and restarts and helps ensure safe equipment operation, with less burner and flame fluctuations. Best practices suggest that vent piping should be as large as the nominal size of the vent connection and increased one nominal pipe size for every 10 feet of linear pipe. (One elbow is equivalent to 3 feet of linear pipe.) 2. Verify the vent is oriented downward to protect it from the weather on...

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