Upload
dangngoc
View
229
Download
4
Embed Size (px)
Citation preview
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900E
T10 - Standards Review - Burner Management and Combustion Control
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
Industrial Combustion Team Overview
Background and Industry Experience
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
RA’s IC&PG Team History
The Story of Rockwell Automation’s
Industrial Combustion and Steam Generation Team
Rockwell Automation acquired Electronic Corporation of America (ECA) in the mid ‘80’s, who owned FIREYE
The FIREYE ‘Systems’ Team merged into Rockwell Automation’s solutions business
Have many years experience working with agencies like FM, NFPA, IEC, etc.
Since this initial merger Rockwell Automation has complimented this team with highly skilled individuals who have brought many years experience working for companies like ABB Bailey, Foxboro, Babcock & Wilcox, Combustion Engineering, Riley Stoker, Modicon, Cleveland Electric Illuminating, North American Manufacturing, Forney and others.
Over 900 systems provided worldwide in a wide variety of combustion applications.
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
4
RA’s IC&PG Team Expertise
Extensive experience working with Factory Mutual
Extensive Knowledge of Safety Standards and Guidelines
NFPA 85 Boiler & Combustion Code
NFPA 86 Furnace & Ovens
NFPA 87 Fluid Heaters (Chem. Plant Oil Heaters, vessels, etc.)
FM (7605) Approval Standard for PLC based BMS
CSA B149.3 (Canada)
BLRAC Recommended Good Practices
ANSI/ISA S84.00.011/IEC 61511 SIL Ratings for Systems
IEC 61508 SIL Ratings for Hardware
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
Industrial Combustion and Power Generation
Burner Management (BMS):
- Combustion “SAFETY” and operator assistance in safely starting, monitoring and stopping the fuel fired burners
- Used in conjunction with a combustion control system in any fossil fuel fired “industrial” combustion application.
Combustion Control (CCS):
- Regulates air/fuel ratio for stable flame and energy optimization
- Used in conjunction with a burner management system in any fossil fuel fired “industrial” combustion application.
Balance of Plant (BOP):
- A “catch-all” for common activities in a powerhouse that excludes, burner management and combustion control
- ESP, Plant Master, demineralizer control, feedwater control, coal/ash
handling, scrubber control, soot blower control, etc.
Combustion Control & Burner Management
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
Definitions
6
NFPA – National Fire Protection Association
FM Factory Mutual – Insurance Underwriter
SIL – Safety Integrity Level
Critical Input – Any Input that if lost will cause a trip
Critical Output – Any Outputs that drive fuel delivery devices
Fail Safe System – Inputs & Outputs - High is Normal / Low is Trip
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
Rockwell Automation IC&PG SIL Certification
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
Industrial Steam Generation
Large Central Power House (i.e. –
Paper Mill or Large Industrial Complex)
Boiler Steam Generation
Burner Management Systems
Combustion Control Systems
Balance of Plant Systems
Multiple Burners / Fuels including:
Natural Gas
Oil
Black Liquor
Bark/Wood Chips/Sawdust
Coal
Others
8
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
Any Industrial facility where steam or heat
is used in the manufacturing process
Burner Management & Combustion
(Temperature) Control Systems
Industrial Boilers
Non-Boiler Applications including:
- Furnaces - Ovens
- Dryers - Kilns
- Heaters - Oxidizers
9
Industrial & Process Heating
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
Safety Codes and Application Highlights
Survey of Applicable Codes for Fired Equipment
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION Copyri
ght ©
NFPA Standards
NFPA 85 – Boiler and Combustion Systems Hazards Code
(2011 Edition) (2015 due out in Jan)
NFPA 86 – Standards for Ovens and Furnaces (2015 Edition)
NFPA 87 – Recommended Practice for Fluid Heaters
(2015 Edition)
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION Copyri
ght ©
NFPA 85 Key Highlights
“The burner management system (BMS) shall be provided with independent logic, independent logic solving hardware, independent input/output systems, and independent power supplies and shall be functionally and physically separate device from other logic systems.”
“The BMS safety functions shall include, but shall not be limited to, purge interlocks and timing, mandatory safety shutdowns, trial timing for ignition, and flame monitoring.”
“Diagnostics shall be included in the BMS design to monitor processor logic function.”
“Logic shall be protected from unauthorized changes.”
“Logic shall not be changed while the associated equipment is in operation.”
“No single component failure within the logic system shall prevent a mandatory master fuel trip”
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION Copyri
ght ©
NFPA 86 Key Highlights
Programmable logic controller-based systems listed for combustion
safety service shall be used…..”
“Safety devices shall not be bypassed electrically or mechanically.”
“Output checking shall be provided for PLC outputs controlling fuel
safety shutoff valves and oxygen safety shutoff valves.”
Only isolated PLC contacts shall be used in the required safety circuits.”
Flow and pressure “transmitters” can be used in place of pressure
switches if the transmitter is dedicated to safety service.
“Access to the PLC and it’s logic shall be restricted to authorized
personnel.”
“An excess temperature limit controller shall be provided and interlocked
into the combustion safety circuitry…..”
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION Copyri
ght ©
NFPA 87 Key Highlights
“Does not apply to fired heaters in petroleum refineries and
petrochemical facilities that are designed and installed in accordance
with API560, Fired Heaters for General Refinery Service, API RP 556
Instrumentation and Controls for Fired heaters and Steam Generators,
and API RP2001 Fire Protection in Refineries.”
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION Copyri
ght ©
NFPA Equivalency Clause
NFPA 85, 86 and 87 will allow variations to it’s published codes and
standards through it “Equivalency” paragraph which states:
“Nothing in this standard is intended to prevent the use of systems,
methods, or devices of equivalent or superior quality, strength, fire
resistance, effectiveness, durability, and safety over those prescribed by
this standard.”
Local authority having jurisdiction has final say over what is acceptable
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION Copyri
ght ©
IEC Safety Standards
PROCESS SECTOR SAFETY INSTRUMENTED SYSTEM
STANDARDS
Safety Instrumented Systems Designers, Integrators & Users
IEC 61511
Manufacturers & Suppliers of Devices
IEC 61508
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION Copyri
ght ©
17
IEC 61508
This is a Basic International Standard that defines the requirement
that Electric/Electronic/Programmable Electronic devices must meet
when used in Safety applications.
Performance based Standard
Includes all activities related to the Safety Life Cycle
Covers possible hazards caused by Failure of the Safety Functions
Does not cover SIS with SIL requirements less than 1
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION Copyri
ght ©
IES 61511
A Process Sector Specific International Standard covering
Functional Safety for Safety Instrumented Systems
It defines the requirements that users must meet when designing,
implementing and maintaining a Safety Instrumented System in
Process Plants.
Performance based Standard
The document differentiates between Safety certified devices and
off the shelf general purpose devices.
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION Copyri
ght ©
ISA/ANSI S84.01
The Americanized version of IEC 61511.
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION Copyri
ght ©
IEC - Safety Integrity Levels (SIL) forSafety Instrumented Systems (SIS) Safety integrity is the probability that an SIS will perform its safety function(s) when the
process demands it.
Safety Integrity is specified as a discrete level, from 1 to 4 or Safety Integrity Level (SIL).
DEMAND MODE OF OPERATION
Safety IntegrityLevel (SIL)
Target AverageProbability of Failure on Demand
Target Risk Reduction
4 10-5
to <10-4
>10,000 to 100,000
3 10-4
to <10-3
>1000 to 10,000
2 10-3
to <10-2
>100 to 1000
1 10-2
to <10-1
>10 to 100
CONTINUOUS MODE OF OPERATION
Safety IntegrityLevel (SIL)
Target Frequency ofDangerous Failures to perform thesafety instrumented function (per
hour)
4 10-9
to <10-8
3 10-8
to <10-7
2 10-7
to <10-6
1 10-6
to <10-5
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
Copyright © 2008 Rockwell Automation, Inc. All rights 21
SIL Determination
.
D1
D2
D3
D4
A1
A2
A1
A2
E1
E2
E1
E2
P3 P2 P1
1 1
0
2 1
1
3 3
1
4 3
2
6
3
7
4
8
4
0
0
1
0
2
1
3
1
4 4
5
3
6
3
7
4
0 B
0
0 B
0
1 1
0
2 2
1
3
1
4
2
5
3
6
3
2
5 >4
3
DIN EN
IEC
Risk Parameters:
D - Extent of DamageD1: slight injuryD2: severe irreversible injury to one or more
persons or death of a personD3: death of several personsD4: catastrophic consequences, multiple
deaths
E - Exposure TimeE1: seldom to relatively frequentE2: frequent to continuous
A - Hazard Avoidance/MitigationA1: possible under certain conditionsA2: hardly possible
P - Occurrence ProbabilityP1: very low probabilityP2: low probabilityP3: relatively high probability
DIN VDE-19250 (AK) Fundamental safety aspects for measurement and control equipmentIEC 61508 (SIL) Functional safety of programmable electronic systems (PES)EN-954 (Category) Safety of machinery - Safety related parts of control systems
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION Copyri
ght ©
Summary
At Rockwell Automation the IC&PG Team uses the NFPA standards as
our base system design.
The code issue can be very confusing and are open a lot of different
interpretations.
The customer needs to advise what specific codes/standard that they
require to be applied to their application.
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
Burner Management System (BMS)
Description: Burner Management System
A BMS is a SAFETY SYSTEM
A BMS is only for the safe start-up, monitoring and shutdown of a
combustion system.
Special Requirements:
Monitoring and testing of inputs and outputs
Boilers - NFPA 85 Standard
Ovens, Dryers, Furnaces, etc. - NFPA 86 Standard
Fluid Heaters – NFPA 87 Recommend Practices
Recovery Boilers - BLRBAC
Safety response – Fail-Safe Control of purge, ignition, shutdown
Factory Mutual Approval Standard (FM 7605) for PLC Based Burner Management Systems
ANSI/ISA S84.00.01/IEC 61511 - provides procedure for how to implement the SIL standards
Customer specific standards
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
24
Burner Management System Value
A new burner management system can
Improve availability by increasing the operator’s trouble-shooting
capability and accessibility of system information through enhance
diagnostics
Reduce normal startup time
Protects your combustion product equipment against damage
Uses standard Rockwell Automation hardware thus reducing or
eliminating the need for additional spare parts for existing RA
Clients.
Potential increase in overall safety
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
Design Documents (Non-SIL)
NFPA 85 for Boilers
NFPA 86 for Ovens and Furnaces
NFPA 87 for Fluid Heaters
Factory Mutual (FM)
IEC 7605 Approval Standard for Programmable Logic Control (PLC)
Based Burner Management Systems
BLRBAC (Recovery Boilers Only)
Customer Standards and Specifications
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
Design Documents for SIL
All of the applicable non SIL documents
IEC 615011 Functional Safety Instrument Systems
IEC 61508 Functional Safety of Electrical / Electronic / Programmable
Electronic Safety Related Systems
1756-RM001 Applying ControlLogix in SIL 2 Applications
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
What Makes a BMS Unique
Input Testing
Output Monitoring
External Watchdog
Hardwired Trip Circuit
No Online Edits system is operating
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION 28
Burner Management Design Features
A system watchdog, completely independent of the programmable controller, continually
verifies the controller’s timing function, as well as its ability to execute logic and control outputs
Input channels on each l/O module are periodically tested to verify their ability to detect
field device state changes to the “fail-safe” position.
Critical outputs are monitored by feeding back the status of the output as a separate input
signal and comparing it to the state demanded by system logic.
The use of software interlocks help guard against unauthorized modification of the
controller’s program.
A hardware trip circuit which allows the operator or the system watchdog to initiate a main
fuel trip
Start-up, first out, and system alarm/diagnostic messages.
Communication with other Rockwell programmable automation controllers or operator
terminals
Adaptable to any fossil fuel combustion applications with single or multiple burners
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
BMS Functions
Input Testing
Output Monitoring
External Watchdog
Hardwired Trip Circuit
Timer Preset Locking
No Online Edits
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
Input Testing
Detects Input Card Failure
Detects Input Circuit Shorted to Power
Detects Forced Inputs
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
Input Test Wiring
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
BMS Functions
Input Testing
Output Monitoring
External Watchdog
Hardwired Trip Circuit
Timer Preset Locking
No Online Edits
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
Output Monitor
Critical Outputs are wired to Inputs
Typical Outputs are to Fuel Valves & Ignition Transformer
Alarms if monitoring input Disagrees With Command
May Initiate Trip
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
Output Monitor Wiring
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
BMS Functions
Input Testing
Output Monitoring
External Watchdog
Hardwired Trip Circuit
Timer Preset Locking
No Online Edits
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
External Watchdog Trips
Processor Failure
MFT Relays Fail To De-energize
Processor Not In Run Mode (Controllogix)
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
External Watchdog Wiring
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
BMS Functions
Input Testing
Output Monitoring
External Watchdog
Hardwired Trip Circuit
Timer Preset Locking
No Online Edits
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
Hardwired Trip Circuit
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
BMS Functions
Input Testing
Output Monitoring
External Watchdog
Hardwired Trip Circuit
Timer Preset Locking
No Online Edits
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
Timer Preset Locking
Timer Presets can not be changed while the processor is running.
All Timer Preset Changes Must Be Made In Program Mode
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
BMS Functions
Input Testing
Output Monitoring
External Watchdog
Hardwired Trip Circuit
Timer Preset Locking
No Online Edits
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
Online Programming
NFPA does not allow program changes to be made to the processor while
the equipment is operating
If the processor is switched out of RUN mode, the System will MFT.
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
Procedure to Make Program Changes
44
Switch Processor to Program Mode
Make all Changes
Store Program to Non-volatile Memory (If installed)
Switch Processor Back To Run Mode
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC INFORMATION
Rockwell Automation
45
Questions?