BURNER MANAGEMENT SYSTEM

R.R.Patel

Objectives
To ensure safe operation of combustion in heaters, furnaces, boilers, kilns, ovens, etc. To maintain safe operation during start up, operation & shutdown

System block diagram

In Field In PIB

DCS
FD FAN

Local Panel

BMS PLC ESD PLC

A general purpose PLC IEC 61131 A Safety PLC QMR / TMR TUV approved

Fuel gas

P T

Components of BMS
Local control panel

Ignition push buttons , lamp indications Ignition devices Pilot and main flame detectors Solenoids operated shutdown valves with proximity switches for open & close indications Pressure, Temperature, flow transmitters BMS & ESD PLC in PIB

Double block & bleed valve arrangement

BMS BMS +ESD PT

PILOT GAS

NITROGEN BMS BMS +ESD PT

FUEL GAS

Double Block valve arrangement

BMS BMS +ESD PT

FUEL OIL

ESD

Salient Features of BMS Design

Double block valves & vent valves for pilot & fuel gas For fuel oil, double block valves on supply header & single block valve on return header First block valve has two SOVs, one is controlled by ESD PLC and the other by BMS PLC Solenoid valve controlled by ESD has manual reset Second block valve & vent valve have one SOV each controlled by BMS PLC

Salient Features of BMS Design

Proximity switches for open and close indications on shutdown valves 2oo2 voting in ESD PLC, two transmitters for each trip input Ionisation rods for the detection of pilot flame IR scanners for the detection of main flame 2 nos. of hand isolation valves for each fuel line to the burners

Standards followed
NFPA 85 Boiler & combustion Control Systems
Hazards Code API 556 Instrumentation & Controls for Fired Heaters and Steam Generators ANSI/ISA S84.01 Application of Safety Instrumented Systems for the Process Industries IEC 61508

Safety PLC
Fail safe I/O circuits with built in diagnostics CPU with built in diagnostics for memory, CPU operation, watch dog timer and all communication systems QMR /TMR architecture IEC 61508 - SIL 2 Diverse architecture to avoid common cause failure - processor, software, logic family TUV approved

Heater shutdown logic in ESD PLC

Total Shutdown (Pilot Gas, Fuel Gas & Fuel Oil ): 1. Pilot Gas Pressure Very Low 2. ESD Push Button in control room / Field Fuel Gas Shutdown : 1. Fuel gas Pressure Very Low 2. Fire box Pressure Very High 3. Flue gas Temp at APH inlet Very High 4. Combustion Air Flow Very Low 5. Heater pass Flow Very Low 6. Other process conditions, if any

Heater shutdown logic in ESD PLC

Fuel Oil Shutdown : 1. Fuel oil Pressure Very Low 2. Steam/Fuel oil Differential Pressure Very Low 3. Fire box Pressure Very High 4. Flue gas Temp at APH inlet Very High 5. Combustion Air Flow Very Low 6. Heater pass Flow Very Low 7. Other process conditions, if any Shut off of both main fuel (gas & oil) or pilot burners in any one pass will shutdown main fuel in all the passes (Applicable for coker unit)

Troubleshooting Guidelines
a) 1ST OUT Sequence on DCS graphics Trip signal from ESD Change of close or open indication Proximity switch failure SOV loop failure b) SOE (sequence of event) in ESD During normal heater running, Vent valve can get opened 1) by ESD signal 2) Solenoid loop failure Block valve can get closed 1) by ESD signal 2) Loss of close indication of vent valve 3) Pilot voting logic if not overridden 4) Main flame failure 5) SOV loop failure

Pushbuttons on BMS Local Panel

1. System Start 2. Purge Start 3. Pilot Start (for each firing zone) 4. Fuel Gas Start (for each firing zone) 5. Fuel Oil Start (for each firing zone) 6. Heater in Operation 7. BMS Reset 8. Lamp Test 9. Emergency shutdown (Applicable for coker)

Lamps on BMS Local Panel

1. Pilot Gas Pressurisation Failed 2. Fuel Gas Pressurisation Failed 3. Leak Test in Progress (Flashing) / Complete (Steady) 4. Pilot Gas Leak Test Failed 5. Fuel Gas Leak Test Failed 6. Ready for Purge 7. Purging in Progress (Flashing) / Complete (Steady) 8. Pilot Gas valve discrepancy / energised 9. Fuel Gas valve discrepancy / energised 10. Fuel Oil valve discrepancy / energised 11. Heater in Operation 12. Flame ON for each pilot detector & IR scanner

Startup Permissive

No shutdown signal from ESD PLC All the block valves in closed & vent valves are in open condition No Pilot or Main flame is detected No valve discrepancy alarm

BMS Start up Sequence

Ensure startup permissive Press System Start Pressurisation - Leak test Depressurisation Purging (5 furnace volumes in 5 minutes) Pilot Start - press pilot ignition PB Fuel Gas Start - open manual valve

PILOT GAS SYSTEM

SYSTEM START

START PERMISSIVES 1. 2.
VENT VALVE

NO ESD SIGNAL BOTH BLOCK VALVES ARE CLOSED, VENT VALVE IS OPEN ALL PILOT & MAIN FLAMES ARE OFF NO LAMP ON LOCAL PANEL IS FLASHING
PRESSURE PRESSURE TRANSMITTER TRANSMITTER

3. 4.

TO BURNER TO BURNER

FIRST BLOCK VALVE

SECOND BLOCK VALVE

NOTE: PRESS SYSTEM START TO INITIATE LEAK TEST

PILOT GAS SYSTEM

SYSTEM START

START PERMISSIVES 1. 2.
VENT VALVE

NO ESD SIGNAL BOTH BLOCK VALVES ARE CLOSED, VENT VALVE IS OPEN ALL PILOT & MAIN FLAMES ARE OFF NO LAMP ON LOCAL PANEL IS FLASHING
PRESSURE PRESSURE TRANSMITTER TRANSMITTER

3. 4.

TO BURNER TO BURNER

FIRST BLOCK VALVE

SECOND BLOCK VALVE

NOTE: PRESS SYSTEM START TO INITIATE LEAK TEST

LEAK TEST IN PROGRESS

VENT VALVE

(AFTER 10 SECONDS) PRESSURISATION FAILED

TO BURNER

FIRST BLOCK VALVE

SECOND BLOCK VALVE

PILOT GAS SYSTEM

SYSTEM START

START PERMISSIVES 1. 2.
VENT VALVE

NO ESD SIGNAL BOTH BLOCK VALVES ARE CLOSED, VENT VALVE IS OPEN ALL PILOT & MAIN FLAMES ARE OFF NO LAMP ON LOCAL PANEL IS FLASHING
PRESSURE TRANSMITTER

3. 4.

TO BURNER

FIRST BLOCK VALVE

SECOND BLOCK VALVE

NOTE: PRESS SYSTEM START TO INITIATE LEAK TEST

LEAK TEST IN PROGRESS

VENT VALVE

(AFTER 10 SECONDS) PRESSURISATION IS SUCCESSFUL

> 0.375 kg/cm2

TO BURNER

FIRST BLOCK VALVE

SECOND BLOCK VALVE

LEAK TEST IN PROGRESS

VENT VALVE

(AFTER 20 SECONDS) LEAK TEST IS PASSED

> 0.3 kg/cm2

TO BURNER

FIRST BLOCK VALVE

SECOND BLOCK VALVE

LEAK TEST IN PROGRESS

VENT VALVE

2ND BLOCK VALVE OPENS FOR 8 SEC FOR DEPRESSURISATION > 0.3 kg/cm2

TO BURNER

Similar sequence takes place for Fuel Gas also, except that pressurisation test is done with nitrogen, hence instead of 1st block valve, nitrogen valve opens

FIRST BLOCK VALVE

SECOND BLOCK VALVE

READY FOR PURGE

LEAK TEST

COMPLETE

VENT VALVE

FD FAN START

TO BURNER FIRST BLOCK VALVE SECOND BLOCK VALVE

PURGE START

READY FOR PURGE

LEAK TEST

COMPLETE

VENT VALVE

PURGE AIR FLOW > 5 furnace volume in 5 minutes DCS SENDS PURGE PERMISSIVE TO BMS PLC

TO BURNER

FIRST BLOCK VALVE

SECOND BLOCK VALVE

READY FOR PURGE

PURGING IN PROGREE

PURGE TIMER FOR 5 MINUTES

VENT VALVE

TO BURNER

FIRST BLOCK VALVE

SECOND BLOCK VALVE

PURGING COMPLETED

PURGE TIMER FOR 5 MINUTES

VENT VALVE

TO BURNER

FIRST BLOCK VALVE

SECOND BLOCK VALVE

START PILOT LIGHT UP

PURGING COMPLETED AFTER PURGE COMPLETION, OPERATOR HAS 15 MINUTES TIME TO LIGHT UP ANY OF THE PILOTBURNERS, FAILING WHICH WILL RETURN THE SEQUENCE TO PURGE START

VENT VALVE

TO BURNER

FIRST BLOCK VALVE

SECOND BLOCK VALVE

( 30 MINUTE IGNITION TIMER STARTS.

VENT VALVE

AFTER 30 MINUTES AT LEAST (N-3) OUT OF TOTAL N PILOT BURNERS per zone SHOULD BE LIT (PILOT VOTING LOGIC)

TO BURNER

FIRST BLOCK VALVE

SECOND BLOCK VALVE

PRESS IGNITION PUSH BUTTON ONEAFTER ANOTER TO IGNITE THE PILOT BURNERS ENSURE THAT AT LEAST (N-3) BURNERS ARE LIT WITHIN 30 MINUTES TIME, N IS THE TOTAL PILOT BURNERS PER PASS

VENT VALVE

TO BURNER IGNITION PUSH BUTTON FOR EACH BURNER

FIRST BLOCK VALVE

SECOND BLOCK VALVE

AFTER 30 MINUTES, IF COUNT OF PILOT LIT DROPS BELOW (N-3), THE PILOT GAS IS SHUTOFF AND START UP SEQUENCE IS RETURNED TO HEATER STOP CONDITION
VENT VALVE

FIRST BLOCK VALVE

SECOND BLOCK VALVE

START FUEL GAS BURNER

PURGING COMPLETED AFTER PILOT BURNERS LIGHT UP, FUEL GAS (MAIN) BURNERS CAN BE LIT UP
VENT VALVE

FUEL GAS

TO BURNER

FIRST BLOCK VALVE

SECOND BLOCK VALVE

THE MANUAL VALVES ARE TO BE OPENED TO ESTABLISH MAIN FLAME

VENT VALVE

FUEL GAS

TO BURNER

FIRST BLOCK VALVE

SECOND BLOCK VALVE

MAIN FLAME HAS BEEN ESTABLISHED

VENT VALVE

FUEL GAS

FG IN

FIRST BLOCK VALVE

SECOND BLOCK VALVE

START FUEL OIL BURNER

PURGING COMPLETE

AFTER PILOT BURNERS LIGHT UP, FUEL OIL (MAIN) BURNERS CAN BE LIT UP

FUEL OIL
BMS BMS +ESD PT

ESD

FUEL OIL CIRCUATION FOR 10 MINUTES

FUEL OIL
BMS BMS +ESD PT

ESD

FUEL OIL CIRCUATION FOR 10 MINUTES COMPLETE

ENSURE ATOMISING STEAM

FUEL OIL
BMS BMS +ESD PT

ESD

FUEL OIL CIRCUATION FOR 10 MINUTES COMPLETE

ATOMISING STEAM

FUEL OIL
BMS BMS +ESD PT

ESD

MAIN FLAME HAS BEEN ESTABLISHED

FUEL OIL
BMS BMS +ESD PT

ESD