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BMS SYSTEM OF
BOILER USING
PLC LADDER LOGIC
Authorised By
SANTOSH BHARADWAJ REDDY
Email: help@matlabcodes.com
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ABSTRACT
The problem of operation and safety posed by a Recovery Boiler is much
more than a conventional utility/Industrial Boiler. The Black Liquor
from Pulp Mill is acquired by Evaporator which is sent to Liquor Fired
Boiler.
Recovery Boiler is basically a chemical recovery process unit where the
organic material in the black liquor is burnt, while the sodium salt is
reduced and drained as molten smelt from the furnace bottom.
At the same time, Super Heated Steam which is the byproduct is utilized
for steam generation. Flue Gas is sent out through Chimney through I.D
Fan. The Green Liquor is sent to Causticizing Plant for Generation of
White Liquor.
The BMS System is a part of LIQUOR FIRED BOILER(LFB 5) of Soda
Recovery Plant. HoneyWell PLC is used to study the BMS System in
BOILER Plant..
In LFB5 the BMS system includes Primary, Secondary/Tertiary fans,
Liquor Guns, Oil Burner Valves, Induced Draft Fan, Electrostatic
Precipitator, Economizers, Steam/ Mud Drum, Furnace and Pumps to
circulate water .
In BMS system the Furnace is first Purged completely i.e., to flush the
Furnace with fresh air. In this duration of Purging (120ms) all valves
should be closed.
The BMS provides for the proper sequencing of equipment during the
normal startup operating and shut down procedures and provides for an
auxiliary fuel trip and/or an alarm during an adverse burner or unit
operating condition.
Stock Preparation
Coating
Rewinders Cutters
Plant
Wills Cutter
Market
BAMBOO WHITE LIQUOR
&
WOOD
STEAM
Pulp to Paper
Process
WBL :16-18%
EVAPORATOR
RECOVERY
BOILER
G/L
INTRODUCTI
ON
BMS stands for ‘BURNER MANAGEMENT SYSTEM’.
It is a part of Liquor Fired Boiler in Soda Recovery
Section.
The problem of operation and safety posed by a Recovery
Boiler is much more than a conventional utility/Industrial
Boiler.
It is basically a chemical recovery process unit where the
organic material in the black liquor is burnt, while the
sodium salt is reduced and drained as molten smelt from
the furnace bottom. At the same time, the heat released is
utilized for steam generation.
Though predominantly the heat for the process is obtained from
the burning of the black liquor, supplementary heat from oil
fired auxiliary fuel burners is required to start up the unit,
regulate the char bed , avoid blackouts and to augment
additional steam.
FLUE GAS ID
FURNACE ESP
FAN
PULP
WHITE
MILL LIQUOR
SMELT
DUST
WBL MUD
DISSOLVER WWL
ESP ASH TANK
STORAGE TANK
TANKS 87-95 DEG.C Na2SO4
PUMP G/L
SALT
CAUSTICIZING
CAKE
EVAPORATORS PLANT
MIXING TANK
THICK
BLACK LIQUOR
CBL
STORAGE TANKS SECONDARY INDIRECT HBL
HEATER HEATER
60-65 DEG.C
118 DEG.C 112 DEG.C 102 DEG.C
BMS SECTION
SUPER HEATED/ DRY STEAM to TURBINE
SATURATED STEAM
SUPER HEATER
S
T STEAM
E DRUM FLUE ESP ID
A GAS PLATES FAN
M
FLUE
HBL GAS
pump
SCMT
S
T
E
A
M
HAMMERS
FLUE
GAS DUST
SMELT
THEORY
of
BMS
FEATURES
• The BMS provides for the proper sequencing of equipment
during the normal startup operating and shut down procedures
and provides for an Auxiliary fuel trip and/or an Alarm during
an adverse burner or unit operating condition.
• This is accomplished through the use of pre-wired logic and
various Interlocks.
• The BMS is a local-manual relay system.
• Starting burners are started and stopped locally from their
associated local switch boxes while the various header trip
valves are opened and closed remotely from associated Push
Buttons on BOILER CONTROL DESK(BCD).
BMS PANEL
BURNER
1
BURNE BURNE OIL GUN HEA HEA ATOMISIN ATOMISING BURNER BURNER SCAVENG SCAVENG FLAME FLAME SCANNER
R ON R ENGAGE IGNITOR IGNITOR G V/V V/V E E SCANNER
V/V SHOWS NO
OFF D ADVANCED RETRACTE V/V CLOSED OPENED CLOSED V/V V/V SHOWS FLAME FLAME
D OPENED OPENED CLOSED
BURNER
2
BURNE BURNE OIL GUN HEA HEA ATOMISIN ATOMISING BURNER BURNER SCAVENG SCAVENG FLAME FLAME SCANNER
R ON R ENGAGE IGNITOR IGNITOR G V/V V/V E E SCANNER
V/V SHOWS NO
OFF D ADVANCED RETRACTE V/V CLOSED OPENED CLOSED V/V V/V SHOWS FLAME FLAME
D OPENED OPENED CLOSED
BURNER
3
BURNE BURNE OIL GUN HEA HEA ATOMISIN ATOMISING BURNER BURNER SCAVENG SCAVENG FLAME FLAME SCANNER
R ON R ENGAGE IGNITOR IGNITOR G V/V V/V E E SCANNER
V/V SHOWS NO
OFF D ADVANCED RETRACTE V/V CLOSED OPENED CLOSED V/V V/V SHOWS FLAME FLAME
D OPENED OPENED CLOSED
BURNER
4
BURNE BURNE OIL GUN HEA HEA ATOMISIN ATOMISING BURNER BURNER SCAVENG SCAVENG FLAME FLAME SCANNER
R ON R ENGAGE IGNITOR IGNITOR G V/V V/V E E SCANNER
V/V SHOWS NO
OFF D ADVANCED RETRACTE V/V CLOSED OPENED CLOSED V/V V/V SHOWS FLAME FLAME
D OPENED OPENED CLOSED
BOILER EMERGENCY
EMERGENCY DRAIN & TRIP
TRIP
AUXILIARY AUXILIARY
FUEL TRIP FUEL TRIP
PUSH PUSH
BUTTON BUTTON
ID SA/TA PA FAN BLACK ID FAN SA/TA PURGE START PURGE PURGE ALL ATOMIS ATOMISI
FAN FAN START LIQUOR RUNNING FAN READY PURGE IN COMPL EMERGEN ING NG
STAR STAR PERMI PUMP RUNNIN PUSH PROGR ETE CY DRAIN STEAM STEAM
T T T START G BUTTO ESS V/V S PRESS PRESSU
PER PERM PERMIT N CLOSED URE RE HIGH
MIT IT LOW
HO HO PRECIPITA PRECIPITAT FEED ALL AIR AIR DRUM DRUM FURNA FURNAC
PRESS TEMPE TOR OR WATER SCANNE FLOW FLOW LEVEL LEVEL CE E
URE RATUR OUTLET OUTLET SHUTOFF R <30% <30% VERY VERY PRESS PRESSU
LOW E TEMP. TEMP. SHOW LOW HIGH URE RE
VALVE
LOW >270 <270 DEG.C NO VERY VERY
CLOSED
DEG.C FLAME LOW HIGH
STEAM
DAY
SCAVENGE V/V FURNACE
OIL
TAN
K HOBV
HEATE
R
HORV
FURNACE OIL PUMP PRESSURE HOTV PRESSURE OIL
3 WAY
CONTROL V/V CONTROL V/V
V/V
15.0 Kg/cm2 8.0 Kg/cm2
AUXILIARY FUEL TRIP
• Any one of the conditions below will cause an auxiliary fuel
trip to occur,and results in the immediate shutdown of all of
the auxiliary fuel in service and necessitates completion of
another furnace purge cycle before any auxiliary fuel firing
may be reinstated.
• Evaporator outlet temperature greater than 525oF.
• Precipitator outlet temperature greater than 525oF.
• I.D. Fan not in service.
• Fans not in service.
• Primary Air Flow less than 30% of full load of flow.
• Furnace pressure greater than +4”W.G.
• Ignitor oil pressure not within controlled limits.(75% to 125%
of full load pressure).
• Ignitor air pressure greater than 75% of full load pressure.
• Main oil pressure below 75% of full load pressure .
• Starting burner oil header pressure above 125% of full load
pressure.
• Load carrying burner oil pressure above 125% of full load
pressure.
• Recirculation selector switch not in OPERATE position.
• A Boiler trip condition exists.
• Either of the local auxiliary fuel trip push button depressed.
• Both of the auxiliary fuel trip push buttons on the BCD
depressed.
LIQUOR SPRAY GUN
CBL
ESP DUST
TANK
Na2SO4
ESP
ASH PRESSUR
SCMT E INDIRE DIRE
TANK FLOW FURNA
CONTROL CT CT CE
V/V HEATE HEAT METE
CBL R ER R
PUMP HBL 102 DEG.C 112 DEG.C 118 DEG.C
ESP ASH HBL
ASH
TANK PUMP
PUMP
LEVEL
CONTROL
V/V
EMERGENCY DRAIN AND TRIP
• An emergency drain and trip procedure is initiated if water in
any amount is known to be entering the furnace and cannot be
stopped immediately or if any leaks external to the furnace
such as failure of gaskets, gage glasses etc.
• An emergency drain is initiated by simultaneously depressing
the two “Emergency Drain push button” on the BCD panel.
• An emergency drain trip initiates the following.
• *1. Auxiliary fuel trip.
• *2. Fan trip.
• 3. Closing of the feed water valve.
• 4. Opening of the emergency drain valve.
• * Conditions preceded by an asterisk are the same trip
inputs .
BOILER TRIP
• A boiler trip condition exists when both the boiler trip
push buttons on the BCD pane are depressed or when
emergency drain is initiated. A boiler trip initiates the
following.
• a. Auxiliary fuel trip.
• b. P.A,S.A/T.A Fan trip.
• c. Black liquor pump trip.
• Depressing the two emergency drain push buttons results in an
instantaneous boiler trip. The feed water supply valve will not close,
however, until the following conditions are also satisfied.
– All trip valves closed OR
– Ignitor trip valve closed and
• All oil scanner valves closed.
• The emergency drain valves should not open until the feed-water
valve is closed (This is an externally interlocked circuit).
Alarms
3066
3051 3048 3053 3032 3033 3049 3050 115 3052 2301
2302
3002 3007 3018 3023
•The Scanner Film is present at Furnace through which the level, flow
are monitored. So, the I/Ps should remain active low.
B-1 HOBV B-2 HOBV B-3 HOBV B-4 HOBV B1-4 HOBV
CLOSED CLOSED CLOSED CLOSED CLOSED
•During Purge Ready initially the Furnace is Purged with fresh Air. So,
the Header Oil Burner v/vs B1-B4 should be closed.
INDUSTRIAL SPECIFICATIONS
• FURNACE TEMP. : 600deg.C(inlet),650deg.C
• FURNACE STEAM: 35TPH
• ECONOMISER TEMP. :
380deg.C(inlet) , 160deg.C(outlet)
• ESP TEMP. : 160deg.C(inlet),150deg.C(outlet)
• STEAM DRUM WATER LEVEL : 54%
• SUPER HEATED STEAM TEMP. : +/- 410 deg.C
• CHIMNEY TEMP. : 140 - 150 deg.C
• GREEN LIQUOR OUTLET : 1000 TPH/DAY
• STEAM PRESSURE O/L : 36kg/cm2
• STEAM TEMP. O/L : 410 – 415 deg.C
• STEAM FLOW O/L : 36 TPH.
IMPLEMENTATION
Level Control in a Reaction Vessel
PLC used in
LEVEL CONTROL
PLC WIRING
DIAGRAM
•The SIEMENS PLC specifications used for Level Control are :
•Software : STEP 7 LITE.
•MODEL : S7 300
•16 Digital Inputs
•4 Analog Inputs
•16 Digital Outputs
•9 Relay Outputs
•2 Analog Outputs
•Q1 : 24 V DC 0.5A MAX
•The Inputs and Outputs used in this project are Digital I/O ‘s only.
I0.0 I0.1 I0.2 I0.3 Q0.1 Q0.2 M3.1 M3.2 Q0.0
Q0.0 Q0.4
M3.0
M3.0
S
I0.0 I0.1 I0.2 I0.3 Q0.0 Q0.2 M3.1 M3.2 Q0.1
Q0.5
M3.0
I0.3 Q0.0 Q0.1 Q0.3 I0.0 R
M0.1
M0.1
M3.1
S
I0.0 M0.1 M0.5 M3.2 Q0.2
T1
M0.1 S_ODT M0.5
S Q
10s TV
M3.2
M3.4
50
NO AUXILLIAR HOTV AUXILLIAR PURGE PURGE
BOILER Y FUEL CLOSE Y FUEL COMPLET READY
TRIP TRIP D TRIP E
112 306 230 230 230 304 160 368 557
5 1 2 3 3
306
6
SA/TA FAN AIR PA FAN FURNACE FURNACE DRUM DRUM ID FAN ID FAN
RUNNING FLOW RUNNIN PRESSURE PRESSURE LEVEL LEVEL START RUNNING
>30% G VERY LOW VERY HIGH VERY LOW VERY HIGH PERMIT
305 3048 3053 3032 3033 3049 3050 115 3052 2301
1
2302
3002 300 301 3023
7 8
B-1 HOBV B-2 HOBV B-3 HOBV B-4 HOBV B1-4 HOBV
CLOSED CLOSED CLOSED CLOSED CLOSED