Burner Management System_RRP

BURNER MANAGEMENT SYSTEM

R.R.Patel

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

ObjectivesObjectives

System block diagramSystem block diagram

BMSPLC

ESD PLC

DCS

A general purpose PLC IEC 61131

A Safety PLC QMR / TMR TUV approved

LocalPanel

In PIBIn Field

FD FAN

PT

Fuel gas

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

Components of BMSComponents of BMS

PILOT GASPTBMS +ESD

BMS

FUEL GASPTBMS +ESD

BMS

NITROGEN

Double block & bleed valve arrangementDouble block & bleed valve arrangement

FUEL OIL

PTBMS +ESD

BMS

ESD

Double Block valve arrangementDouble Block valve arrangement

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 DesignSalient 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

Salient Features of BMS DesignSalient Features of BMS Design

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

Standards followed …Standards followed …

Safety PLCSafety 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

HeaterHeater shutdownshutdown logic in ESD PLClogic in ESD PLC Total Shutdown (Pilot Gas, Fuel Gas & Fuel Oil ):

1. Pilot Gas Pressure Very Low2. ESD Push Button in control room / Field

Fuel Gas Shutdown :1. Fuel gas Pressure Very Low2. Fire box Pressure Very High3. Flue gas Temp at APH inlet Very High 4. Combustion Air Flow Very Low5. Heater pass Flow Very Low6. Other process conditions, if any

Fuel Oil Shutdown :1. Fuel oil Pressure Very Low2. Steam/Fuel oil Differential Pressure Very Low3. Fire box Pressure Very High4. Flue gas Temp at APH inlet Very High 5. Combustion Air Flow Very Low6. Heater pass Flow Very Low7. 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)

Heater shutdown logic in ESD PLCHeater shutdown logic in ESD PLC

Troubleshooting GuidelinesTroubleshooting 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 failureBlock 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 PanelPushbuttons on BMS Local Panel

1. System Start2. Purge Start3. 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 Operation7. BMS Reset8. Lamp Test

9. Emergency shutdown (Applicable for coker)

Lamps on BMS Local PanelLamps on BMS Local Panel

1. Pilot Gas Pressurisation Failed 2. Fuel Gas Pressurisation Failed3. 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 Operation12. Flame ON for each pilot detector & IR scanner

Startup PermissiveStartup 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

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

BMS Start up SequenceBMS Start up Sequence

TO BURNER

VENT VALVE

FIRST BLOCK VALVE

SECONDBLOCK VALVE

START PERMISSIVES

1. NO ESD SIGNAL

2. BOTH BLOCK VALVES ARE CLOSED, VENT VALVE IS OPEN

3. ALL PILOT & MAIN FLAMES ARE OFF

4. NO LAMP ON LOCAL PANEL IS FLASHING

SYSTEM START

PRESSURETRANSMITTER

PILOT GAS SYSTEM

TO BURNER

PRESSURETRANSMITTER

NOTE: PRESS SYSTEM START TO INITIATE “LEAK TEST”

TO BURNER

VENT VALVE

FIRST BLOCK VALVE

SECONDBLOCK VALVE

START PERMISSIVES

1. NO ESD SIGNAL




SYSTEM START

PRESSURETRANSMITTER

PILOT GAS SYSTEM

TO BURNER

PRESSURETRANSMITTER


TO BURNER

LEAK TEST IN PROGRESS

(AFTER 10 SECONDS)PRESSURISATIONFAILED

FIRST BLOCK VALVE

SECONDBLOCK VALVE

VENT VALVE

TO BURNER

START PERMISSIVES

1. NO ESD SIGNAL




SYSTEM START

PRESSURETRANSMITTER

PILOT GAS SYSTEM

FIRST BLOCK VALVE

SECONDBLOCK VALVE

VENT VALVE


TO BURNER

> 0.375 kg/cm2

(AFTER 10 SECONDS)PRESSURISATION IS SUCCESSFUL

FIRST BLOCK VALVE

SECONDBLOCK VALVE

VENT VALVE


> 0.3 kg/cm2

(AFTER 20 SECONDS)LEAK TEST IS PASSED

TO BURNER


FIRST BLOCK VALVE

SECONDBLOCK VALVE

VENT VALVE

TO BURNER

> 0.3 kg/cm2

2ND BLOCK VALVE OPENS FOR 8 SEC FOR DEPRESSURISATION

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

SECONDBLOCK VALVE

VENT VALVE

TO BURNER

LEAK TEST COMPLETEREADY FOR PURGE

FD FAN START

FIRST BLOCK VALVE

SECONDBLOCK VALVE

VENT VALVE

TO BURNER

PURGE AIR FLOW > 5 furnace volume in 5 minutes

DCS SENDS PURGE PERMISSIVE TO BMS PLC

FIRST BLOCK VALVE

SECONDBLOCK VALVE

VENT VALVE

READY FOR PURGE LEAK TEST COMPLETEPURGE START

TO BURNER

PURGING IN PROGREE

PURGE TIMER FOR 5 MINUTES

FIRST BLOCK VALVE

SECONDBLOCK VALVE

VENT VALVE

READY FOR PURGE

TO BURNER

PURGE TIMER FOR 5 MINUTES

FIRST BLOCK VALVE

SECONDBLOCK VALVE

VENT VALVE

PURGING COMPLETED

TO BURNER

START PILOTLIGHT UP

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

FIRST BLOCK VALVE

SECONDBLOCK VALVE

VENT VALVE

PURGING COMPLETED

TO BURNER

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

FIRST BLOCK VALVE

SECONDBLOCK VALVE

VENT VALVE

TO BURNER

IGNITIONPUSH BUTTONFOR EACHBURNER

PRESS IGNITION PUSH BUTTON ONEAFTER ANOTER TO IGNITE THE PILOT BURNERS

FIRST BLOCK VALVE

SECONDBLOCK VALVE

VENT VALVE

ENSURE THAT AT LEAST (N-3) BURNERS ARE LIT WITHIN 30 MINUTES TIME, “N” IS THE TOTAL PILOT BURNERS PER PASS

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

FIRST BLOCK VALVE

SECONDBLOCK VALVE

VENT VALVE

TO BURNER

START FUEL GASBURNER

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

FIRST BLOCK VALVE

SECONDBLOCK VALVE

VENT VALVE FUEL GAS

PURGING COMPLETED

TO BURNER

THE MANUAL VALVES ARE TO BE OPENED TO ESTABLISH MAIN FLAME

FIRST BLOCK VALVE

SECONDBLOCK VALVE

VENT VALVE FUEL GAS

MAIN FLAME HAS BEEN ESTABLISHED

FG IN

FIRST BLOCK VALVE

SECONDBLOCK VALVE

VENT VALVE FUEL GAS

PTBMS +ESD

BMS

ESD

PURGING COMPLETESTART FUEL OILBURNER

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

FUEL OIL

FUEL OIL

FUEL OIL CIRCUATION FOR 10 MINUTES

PTBMS +ESD

BMS

ESD

FUEL OIL

FUEL OIL CIRCUATION FOR 10 MINUTES COMPLETE

ENSURE ATOMISING STEAM

PTBMS +ESD

BMS

ESD

FUEL OIL

FUEL OIL CIRCUATION FOR 10 MINUTES COMPLETE

ATOMISING STEAM

PTBMS +ESD

BMS

ESD

FUEL OIL

PTBMS +ESD

BMS

ESD

MAIN FLAME HAS BEEN ESTABLISHED

Documents

Burner Management System_RRP