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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
Emerson ConfidentialJune 30, 2009 – Slide 3
– 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)
Emerson ConfidentialJune 30, 2009 – Slide 4
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
Emerson ConfidentialJune 30, 2009 – Slide 5
� 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
Emerson ConfidentialJune 30, 2009 – Slide 6
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.
Emerson ConfidentialJune 30, 2009 – Slide 7
� 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
Emerson ConfidentialJune 30, 2009 – Slide 8
• 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
Emerson ConfidentialJune 30, 2009 – Slide 9
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
S03 M M T M T T T T T T T T T M T
S04 M M T M T T T T T T T T T M T
S05 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
S07 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
S10 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
S13 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
S02 M M T M T T T T T T T T T M T
S03 M M T M T T T T T T T T T M T
S04 M M T M T T T T T T T T T M T
S05 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
S07 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
S10 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
S13 T M T T T T T T T T T T T M T
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
Emerson ConfidentialJune 30, 2009 – Slide 25
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
Emerson ConfidentialJune 30, 2009 – Slide 26
� 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?