Burner Management Burner Management – A Straightforward

Burner Management Burner Management ––A Straightforward A Straightforward Approach Using DeltaV Approach Using DeltaV SIS for Typical SystemsSIS for Typical SystemsSIS for Typical SystemsSIS for Typical Systems

David Sheppard, CFSE

– SIS, BMS, Why Implement BMS in a SIS

– State Transition Approach to BMS Design

– Review Example Design of a typical BMS System

– Show Function Blocks used in the Configuration

– Show An Example Operator Interface

Presentation:Presentation:Presentation:Presentation:

Emerson ConfidentialJune 30, 2009 – Slide 2

– Startup and Trip a Simulated BMS System

– Summary / Questions?

� By extending the Emerson digital PlantWeb architecture to safety systems, Smart SIS will provide unprecedented customer value by:

– enabling safer plants

– increasing availability

Emerson’s Emerson’s visionvisionEmerson’s Emerson’s visionvision


– increasing availability

– lowering lifecycle cost

– simplifying regulatory compliance

DEFINITION: SISDEFINITION: SIS(Safety Instrumented System)(Safety Instrumented System)DEFINITION: SISDEFINITION: SIS(Safety Instrumented System)(Safety Instrumented System)

� A SIS

– Takes a process to a safe state when predetermined (dangerous) conditions are violated (e.g. ESD)

– Permits a process to move forward in a safe mannerwhen specified conditions allow (e.g. BMS)

– Takes action to mitigate the consequences of an industrial hazard (e.g. FGS)


industrial hazard (e.g. FGS)

Related Definitions

• ESD - Emergency Shutdown

• ESS - Emergency Shutdown System

• SSD - Safety Shutdown Systems

• BMS - Burner Management System

• FGS – Fire & Gas Systemshutdown

valve

transmitter

logic

solver

What is What is the purpose of a the purpose of a BMS?BMS?What is What is the purpose of a the purpose of a BMS?BMS?

� To inhibit startup when unsafe conditions exist.

� To protect against the unsafe operating conditions and admission of improper quantities of fuel to the furnace.

� To provide the operator with status information – operator assistance

� To initiate a safe operating condition or shutdown


� To initiate a safe operating condition or shutdown interlock if unsafe condition exists.

� As per NFPA 85, “the BMS is a control system dedicated to boiler furnace safety and operator assistance……”

Why implement BMS in an SIS?Why implement BMS in an SIS?Why implement BMS in an SIS?Why implement BMS in an SIS?

� Increased safety

� Increased system availability

� Regulatory compliance


Is BMS a SIS?Is BMS a SIS?Is BMS a SIS?Is BMS a SIS?� Burners, furnaces and boilers are very critical and complex systems.

� There is evidence that OEMs and end users who wish to comply with standards (IEC/NFPA), or to meet certain insurance requirements, will have to classify burner management systems as safety-instrumented systems, to achieve certification by a third-party agency.

� In the process industry, a BMS is included in the IEC 61511 definition, although not by direct reference. There is also no exclusionary clause.


� Burner Management Systems (BMS) are defined as Safety Instrumented Systems (SIS) if they contain sensors, a logic solver and a final control element according to IEC 61511.

� All safety critical processes must be analyzed and their potential risk determined.

� By considering a BMS as a SIS, companies can ensure that these systems are designed, maintained, inspected and tested per both the applicable prescriptive standards (API, NFPA, etc.) as well as the latest SIS performance-based standards (ANSI/ISA, and IEC).

Is a BMS a SIS?Is a BMS a SIS?Is a BMS a SIS?Is a BMS a SIS?� Six (6) different codes, standards and / or recommended practices have been, or are currently

being developed, that mandate a BMS is a SIS until proven otherwise.

– The Black Liquor Recovery Boiler Advisory Committee (BLRBAC) has developed several guideline documents regarding design and operation of Recovery Boilers in the Pulp and Paper Industry. These documents invoke SIS requirements on the Recovery Boiler BMS.

– FM 7605 – Factory Mutual requires that any PLC listed for use in combustion safeguard service meet the SIS requirements contained in IEC 61508.

– TR84 – The ISA S84 committee has formed a BMS sub-committee to develop a document that clarifies how SIS concepts apply to a BMS. Examples being included in the document for each code or standard are:

• NFPA 85 – Single burner boiler


• NFPA 85 – Single burner boiler• NFPA 86 – Thermal oxidizer• API 14C – Process heater with multiple burners• API 556 – Glycol Reboilers

The goal of the S84 committee is for industrial users to properly follow the safety lifecycle to define the risk of every BMS to determine if it is a SIS.

– NFPA 86 Committee is planning to update this standard to reflect their agreement that an industrial BMS is a SIS and that a safety PLC should be used. It also will refer to ANSI/ISA 84.00.01-2004 as acceptable methodology.

– EN 50156-1 is a European standard covering electrical equipment for furnaces which invokes SIS requirements for a BMS.

– API 556 document governs design of BMS’s in the petroleum industry. It invokes SIS requirements on BMS’s.

Burners and boilers are very critical Burners and boilers are very critical and complex systemsand complex systemsBurners and boilers are very critical Burners and boilers are very critical and complex systemsand complex systems

Distance of boiler displacement = 50mDistance of boiler displacement = 50m


DeltaV SIS advanced function blocks DeltaV SIS advanced function blocks simplify configurationsimplify configurationDeltaV SIS advanced function blocks DeltaV SIS advanced function blocks simplify configurationsimplify configuration

� IEC 61508 certified modules

and functionality for BMS

– Cause and Effect Matrix (CEM)

– Step Sequencer

– State Transition

� Provides very efficient � Provides very efficient configuration and powerful application software.

� Available dynamos and faceplates make the application very transparent for the operator.

Example BMS StatesExample BMS StatesExample BMS StatesExample BMS States

S01

S02S03

S04Shutdown,

Not ReadyShutdown,

& Ready

Pre-Purge

In progressPurge

Complete

Ignite Pilot

Pilot only Startup failure

S05

S06Pilot only

Running

Ignite Main

with Pilot

Cold Start,

Set Low fire

positionS09S10

S12

Main without

pilot, not at Temp

Mixed Gas

Mixed firing,

set low fire

position

Waste Gas

Only

Trips from States

5, 6, 7, 8, 9, 10, 12

S07

S08

S13

In order to define a BMS you must know 3 fundamental items.1. States & Transitions – When to move from one to another 2. Outputs – Valve Positions defined for each State3. Trips – Including which is active during each State

Once these are defined, the DeltaV SIS logic can be programmed inAn easy to follow manner.

3 Main Logic Part to a BMS System3 Main Logic Part to a BMS System3 Main Logic Part to a BMS System3 Main Logic Part to a BMS System

The following Example is a Single Burner-Multi Fuel with 13 states:

BMS State Transition DiagramBMS State Transition DiagramBMS State Transition DiagramBMS State Transition Diagram

S01

S02

1) No Trip condition exists and all trips have been reset

S03

1) Operator initiates Purge hand switch.

S04

1) Total volume flow of nitrogen is confirmed at 200 SCFM for 5 min

1) Operator initiates pilot ignition with hand switch.

1) Pilot flame detected within 15 sec

Shutdown,

Not Ready

Shutdown,

& Ready

Pre-Purge In

progress Purge Complete

Ignite Pilot

Pilot only

Running

Startup failure

S05

S061) At least 15 seconds elapsed2) At least 6 hours of cold restart time is elapsed OR Operator over-rides this timer.3) Operator initiates "Light Main Burner" hand switch.

Ignite Main with

Pilot

Cold Start, Set

Low fire position

1) Low fire positions

confirmed

S09

1) Flame detectors confirm flame within 15 sec2) Additional 15 sec for flame stabilization

S10

1) Reached min temp

2) Operator initiates hand

switch to “Mixed Gas"

S12

1) Low fire positions confirmed

1) Operator initiates “Mixed Gas“ hand switch

1) Operator initiates "Waste Gas Only“

hand switchMain without

pilot, not at Temp

Mixed Gas

Mixed firing, set

low fire position

Waste Gas Only

Trips from States

5, 6, 7, 8, 9, 10, 12

S07

S08

S13

For Example: To move from State 2 – Shutdown and Ready to State 3 – Pre Purge in Progress The Operator Selects Cold Restart

The Built in DeltaV SIS Function Block - State Transition Block - is used to Easily Define the

State TransitionsState Transitions –– Defines What Allows the Logic to Defines What Allows the Logic to

move from one State to Anothermove from one State to Another

used to Easily Define the Transition Logic.

OutputsOutputs –– Defined Per StateDefined Per State

Once the States are defined, the position of each Output (Valve, ignitor, etc) is defined in each state in a simple table

State Output Control

Ou

tpu

t D

escri

pti

on

Descri

pti

on

Main

natu

ral gas

upstr

eam

blo

ck v

alv

e

Main

natu

ral gas

dow

nstr

eam

blo

ck v

alv

e

Main

com

bustion a

ir

valv

e s

ole

noid

#1

Main

com

bustion a

ir

valv

e s

ole

noid

#2

Trim

com

bustion a

ir

sole

noid

#1

Trim

com

bustion a

ir

sole

noid

#2

Pilo

t gas u

pstr

eam

blo

ck

valv

e

Pilo

t gas d

ow

nstr

eam

blo

ck v

alv

e

Waste

gas c

ontr

ol valv

e

sole

noid

1

Waste

gas c

ontr

ol valv

e

sole

noid

2

Oxy

gen t

o c

ontr

ol valv

e

Oxy

gen t

o c

ontr

ol valv

e

Oxy

gen t

o b

lock v

alv

e

Nitro

gen t

o b

lock v

alv

e

(FO

)

Pilo

t com

bustion a

ir

valv

e

Sour

Wate

r G

as C

ontr

ol

Valv

e S

ole

noid

Pilo

t Ig

niter

Burn

er

Sw

itch #

1 T

unin

g

Com

mand

Burn

er

Sw

itch #

2 T

unin

g

Com

mand

Tag

XY

XX

X1-1

XY

XX

X2-2

FY

XX

XX

-3

FY

XX

XY

-3

FY

XX

XY

-4

FY

XX

XX

-4

XY

XX

X1-5

XY

XX

X2-6

FY

XX

XX

-7

FY

XX

XY

-7

PX

XX

X-8

FY

XX

XX

-9

XX

XX

X-1

0

XY

XX

XX

-11

XY

XX

XX

-12

FY

XX

XX

-13

BY

XX

XX

-14

BX

XX

XX

1-1

5

BX

XX

XX

2-1

5

Outputs

Ou

tpu

t D

escri

pti

on

Tag

XY

XX

X1

XY

XX

X2

FY

XX

XX

FY

XX

XY

FY

XX

XY

FY

XX

XX

XY

XX

X1

XY

XX

X2

FY

XX

XX

FY

XX

XY

PX

XX

X

FY

XX

XX

XX

XX

X

XY

XX

XX

XY

XX

XX

FY

XX

XX

BY

XX

XX

BX

XX

XX

1

BX

XX

XX

2

No

tes

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

State Name StateD=De-Energize, E=Energize, C=BPCS to hold Closed, R=Release to BPCS Modulation, XX=Set the output % open

Shutdown, Not Ready S01 D D D D D D D D D D D D D D D D D D D

Shutdown & Ready S02 D D D D D D D D D D D D D E D D D D D

Pre Purge in Progress S03 D D D D D D D D D D D D D E D D D D D

Purge Complete S04 D D D D D D D D D D D D D E D D D D D

Ignite Pilot S05 D D D D D D E E D D D D D E E D E D D

Pilot Only Running S06 D D D D D D E E D D D D D E E D D D D

Cold start, set low fire positions S07 D D D D E E E E D D D D D E E D D D D

Ignite main with pilot S08 E E D D E E E E D D D D D E E D D D D

Main NG w/o Pilot, not at temp S09 E E D D E E D D D D D D D D D D D D D

Mixed Gas S10 E E E E E E D D E E D D D D D D D D D

Not Used S11

Mixed firing, set low fire positions S12 D D E E E E D D E E D D D D D D D D D

Waste gas Only S13 D D E E E E D D E E E E E D D E D E E

States

State Output ControlO

utp

ut

Descri

pti

on

Descri

pti

on

Main

natu

ral gas

upstr

eam

blo

ck v

alv

eM

ain

natu

ral gas

dow

nstr

eam

blo

ck

Main

com

bustion a

ir

valv

e s

ole

noid

#1

Main

com

bustion a

ir

valv

e s

ole

noid

#2

Trim

com

bustion a

ir

sole

noid

#1

Trim

com

bustion a

ir

sole

noid

#2

Pilo

t gas u

pstr

eam

blo

ck v

alv

eP

ilot gas d

ow

nstr

eam

blo

ck v

alv

eW

aste

gas c

ontr

ol

valv

e s

ole

noid

1W

aste

gas c

ontr

ol

valv

e

sole

noid

2O

xygen t

o c

ontr

ol

valv

eO

xygen t

o c

ontr

ol

valv

e

Oxy

gen t

o b

lock v

alv

eN

itro

gen t

o b

lock v

alv

e

(FO

)P

ilot com

bustion a

ir

valv

eS

our

Wate

r G

as

Contr

ol V

alv

e S

ole

noid

Pilo

t Ig

niter

Burn

er

Sw

itch #

1

Tunin

g C

om

mand

Burn

er

Sw

itch #

2

Tunin

g C

om

mand

Tag

XY

XX

XX

1-1

XY

206C

2-2

FY

2X

XX

X-3

FY

205C

Y-3

FY

212C

Y-4

FY

212C

X-4

XY

202C

1-5

XY

202C

2-6

FY

215C

X-7

FY

215C

Y-7

PY

237C

-8

FY

240C

-9

XY

250C

-10

XY

224C

-11

XY

203C

-12

FY

216C

-13

BY

217C

-14

BX

201C

1-1

5

BX

201C

2-1

5

No

tes

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

D=De-Energize, E=Energize, C=BPCS to hold Closed, R=Release to BPCS Modulation,

OutputsOutputs -- Defined per stateDefined per stateOutputsOutputs -- Defined per stateDefined per state

States

Outputs

State Name StateD=De-Energize, E=Energize, C=BPCS to hold Closed, R=Release to BPCS Modulation, XX=Set the output % open

Shutdown, Not Ready S01 D D D D D D D D D D D D D D D D D D D

Shutdown & Ready S02 D D D D D D D D D D D D D E D D D D D

Pre Purge in Progress S03 D D D D D D D D D D D D D E D D D D D

Purge Complete S04 D D D D D D D D D D D D D E D D D D D

Ignite Pilot S05 D D D D D D E E D D D D D E E D E D D

Pilot Only Running S06 D D D D D D E E D D D D D E E D D D D

Cold start, set low fire positions S07 D D D D E E E E D D D D D E E D D D D

Ignite main with pilot S08 E E D D E E E E D D D D D E E D D D D

Main NG w/o Pilot, not at temp S09 E E D D E E D D D D D D D D D D D D D

Mixed Gas S10 E E E E E E D D E E D D D D D D D D D

Not Used S11

Mixed firing, set low fire positions S12 D D E E E E D D E E D D D D D D D D D

Waste gas Only S13 D D E E E E D D E E E E E D D E D E E

The DeltaV SIS logic has a simple matrix that mirrors the table. It drives the outputs blocks

OutputsStates

Trips

Tri

p In

pu

t D

es

cri

pti

on

De

sc

rip

tio

n

1 -

Lo

ss o

f m

ain

fla

me

sig

na

l

2 -

Lo

w N

atu

ral

Ga

s P

ressu

re

3 -

Hi H

i

co

mb

ustio

n a

ir

pre

ssu

re

4 -

Lo

w T

ota

l

Co

mb

ustio

n A

ir

Flo

w

5 -

Hi H

i le

ve

l in

Waste

ga

s K

O

dru

m

6 -

Hi H

i th

erm

al

rea

cto

r

tem

pe

ratu

re

7 -

Ma

nu

al E

SD

Bu

tto

n, R

IE

8 -

Ma

nu

al E

SD

Bu

tto

n, L

oca

l

9 -

Hi H

i le

ve

l in

hyd

roca

rbo

n

dru

m 1

10

-L

ow

le

ve

l in

hig

h p

ressu

re

str

ea

m d

rum

11

-H

i H

i le

ve

l in

hyd

roca

rbo

n

dru

m 2

12

-H

i H

i le

ve

l in

hyd

roca

rbo

n

dru

m 3

13

-H

i H

i le

ve

l in

hyd

roca

rbo

n

dru

m 4

14

-L

oss o

f p

ilot

fla

me

sig

na

l

15

-T

rip

on

So

ftw

are

Sh

utd

ow

n

Ta

g

BS

LX

XX

1/2

PT

7X

XX

/Y/Z

PT

XX

X1

/2/3

FT

XX

X1

/2/3

FT

XX

X1

/2/3

LT

XX

XX

/Y/Z

TT

XX

X

TT

XX

XX

HS

2X

XX

2

HS

XX

X3

LT

XX

X1

/2/3

LT

XX

X1

/2/3

LT

XX

X1

/2/3

LT

XX

X1

/2/3

LT

XX

X1

/2/3

BS

LX

XX

HS

XX

XX

Trip Matrix / Appropriate MaskingTrip Matrix / Appropriate MaskingTrip Matrix / Appropriate MaskingTrip Matrix / Appropriate MaskingDifferent Trip conditions should be masked during different states. For example, seeing Flame is Required when running, but it must be masked when not running

Tri

p In

pu

t D

es

cri

pti

on

Ta

g

BS

LX

XX

1/2

PT

7X

XX

/Y/Z

PT

XX

X1

/2/3

FT

XX

X1

/2/3

FT

XX

X1

/2/3

LT

XX

XX

/Y/Z

TT

XX

X

TT

XX

XX

HS

2X

XX

2

HS

XX

X3

LT

XX

X1

/2/3

LT

XX

X1

/2/3

LT

XX

X1

/2/3

LT

XX

X1

/2/3

LT

XX

X1

/2/3

BS

LX

XX

HS

XX

XX

No

tes

State "T" = Trip, "M"=Mask (no trip)S01 M T T M T T T T T T T T T M T

S02 M M T M T T T T T T T T T M T




S06 M T T M T T T T T T T T T T T


S08 T T T T T T T T T T T T T T T

S09 T T T T T T T T T T T T T M T


S11

S12 T M T T T T T T T T T T T M T


This cause needs to be “masked” in this state!

This cause has to be able to trip in this state.

Trips

Tri

p In

pu

t D

es

cri

pti

on

De

sc

rip

tio

n

1 -

Lo

ss o

f m

ain

fla

me

sig

na

l

2 -

Lo

w N

atu

ral

Ga

s P

ressu

re

3 -

Hi H

i

co

mb

ustio

n a

ir

pre

ssu

re

4 -

Lo

w T

ota

l

Co

mb

ustio

n A

ir

Flo

w

5 -

Hi H

i le

ve

l in

Waste

ga

s K

O

dru

m

6 -

Hi H

i th

erm

al

rea

cto

r

tem

pe

ratu

re

7 -

Ma

nu

al E

SD

Bu

tto

n, R

IE

8 -

Ma

nu

al E

SD

Bu

tto

n, L

oca

l

9 -

Hi H

i le

ve

l in

hyd

roca

rbo

n

dru

m 1

10

-L

ow

le

ve

l in

hig

h p

ressu

re

str

ea

m d

rum

11

-H

i H

i le

ve

l in

hyd

roca

rbo

n

dru

m 2

12

-H

i H

i le

ve

l in

hyd

roca

rbo

n

dru

m 3

13

-H

i H

i le

ve

l in

hyd

roca

rbo

n

dru

m 4

14

-L

oss o

f p

ilot

fla

me

sig

na

l

15

-T

rip

on

So

ftw

are

Sh

utd

ow

n

Ta

g

BS

L2

01

C1

/C2

PT

72

9X

/Y/Z

PT

21

7C

1/2

/3

FT

20

5C

1/2

/3

FT

21

2C

1/2

/3

LT

21

1X

/Y/Z

TT

22

2C

TT

22

9C

HS

21

0C

2

HS

21

0C

3

LT

10

5C

1/2

/3

LT

20

3C

1/2

/3

LT

62

5C

1/2

/3

LT

62

5D

1/2

/3

LT

10

5D

1/2

/3

BS

L2

02

C

HS

XX

XX

No

tes

TripsTrips –– Including Masking Defined per StateIncluding Masking Defined per State

This Cause

is “masked” in this State!

State "T" = Trip, "M"=Mask (no trip)S01 M T T M T T T T T T T T T M T







S08 T T T T T T T T T T T T T T T



S11



The DeltaV SIS logic has a simple matrix that mirrors the table above that masks conditions based on the state the burner is in

States Outputs

Simple DocumentationSimple DocumentationSimple DocumentationSimple Documentation

State State Transition Diagram

Outputs TripsTransitions

Traditional GraphicTraditional GraphicTraditional GraphicTraditional Graphic

BMS Trips Graphics BMS Trips Graphics –– Normal StateNormal StateBMS Trips Graphics BMS Trips Graphics –– Normal StateNormal State

BMS Trips Graphics BMS Trips Graphics –– Trip StateTrip StateBMS Trips Graphics BMS Trips Graphics –– Trip StateTrip State

BMS Ring of Fire BMS Ring of Fire –– Step S02Step S02BMS Ring of Fire BMS Ring of Fire –– Step S02Step S02

BMS Ring of Fire BMS Ring of Fire –– Step S06Step S06BMS Ring of Fire BMS Ring of Fire –– Step S06Step S06

SummarySummarySummarySummary� The State Transition Diagram

approach is a very clear and systematic development process:

1. Define the states and transitions.

2. Define the outputs in each state.

3. Define the required trip signals.

4. Define per state if a trip is active or


4. Define per state if a trip is active or masked.

� Very good for developing functional requirements in an interdisciplinary team.

� The approach can also be used for other applications.

Safety lifecycle benefits:Safety lifecycle benefits:Reduced cost and improved safetyReduced cost and improved safetySafety lifecycle benefits:Safety lifecycle benefits:Reduced cost and improved safetyReduced cost and improved safety

� Analysis – a well defined approach and easily understandable.

� Implementation – can be easily implemented using standard function blocks and dynamos

� Operation – because failures can


� Operation – because failures can easily be located and removed.

� Verification – each state has clearly defined output signals and trip causes which can easily be tested and verified.

� Modification – the solution is unambiguous and can easily be modified.

Thank you…Thank you…

…any Questions?…any Questions?…any Questions?…any Questions?

Documents

Burner Management Burner Management – A Straightforward