BURNER MANAGEMENT SYSTEM

Authorised By
SANTOSH BHARADWAJ REDDY
Email: help@matlabcodes.com
Engineeringpapers.blogspot.com
More Papers and Presentations available on above site

INTRODUCTION :
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 charbed , avoid blackouts
and to augment additional steam.

FEATURES :
Auxiliary fuel system is comprised of one level of starting burners (4
burners Oil fired with oil ignitors) at the hearth and one level of load
carrying burners at the secondary(famous)air registors.
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.

FUNCTION :
The following operations of the function are achieved in the BMS.
1. Boiler purge.
2. Main oil header trip valve open/close operation.
3. Ignitor oil header trip valve open/close operation.
4. Auxiliary fuel burner ignitor ‘ON/OFF’ operation.
5. Ignitor Flame scanning.
6. Auxiliary fuel burner start/stop operation.
 7. Auxiliary fuel trip production.
8. Emergency drain trip protection.

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).All the commands of
BMS are given from BCD and all the feed-back from BMS are indicated
in BCD.

FURNACE PURGE :
Before any auxiliary fuel can be introduced in the unit(initial or after an
auxiliary fuel trip)a satisfactory furnace purge cycle must first be
completed. To start a furnace purge cycle, proceed as follows:
1. Establish an (I.D. Fan Start,Permissive)by completing all of the
following conditions.
*1A. All Emergency drain valves are closed.
*1B. Main oil header trip valve and ignitor trip valve closed.
*1C. Feed Water shut off valve is open.
1D. Evaporator outlet temperature less than 525oF.
1E. Precipitator outlet temperature less than 525oF.
(*) Conditions preceded by an asterish are not required once the ID fan is
running.
2. Place I.D. Fan in service.
3. Place the F.D. Fan in service.
4. Adjust the primary air flow to maintain a minimum of 30% of full load
air flow.
5. See that all of the starting and all of the load carrying burner valves are
fully closed.
6. Reset the boiler trip by depressing the BOILER TRIP RESET Push
Button.
7. When the purge ready light comes on indicating that all of the purge
requirements have been completed depress the PURGE START PUSH
BUTTON.

TRIP VALVE OPERATION :

MAIN OIL HEADER TRIP VALVE:
Depressing the main oil header trip valve open push button once the furnace
purge is completed, will open the main oil header trip valve.

Depressing the main oil header trip valve close push button will close the
main oil header trip valve.

IGNITOR OIL HEADER TRIP VALVE :

Depressing the Ignitor Oil Header trip valve open push button once the
purge cycle has been completed and the main oil header trip valve is fully
opened, opens the ignitor oil header trip valve.

AUXILIARY FUEL START :-

STARTING BURNERS:

Prior to placing a starting burner or load carrying Burner in service the

operator must see the following condition s are established.
1. Ignitor oil header trip valve is fully opened.
2. The associated oil gun of each starting burner to be placed in service
is properly engaged in the firing position.
3. The oil temperature is above a minimum of 160oF.
4. Manual atomizing steam valve opened to establish a minimum of 5
Psi steam to oil differential pressure at each gun.
5. Manual oil shut off valve open at each gun.
6. Fuel air damper open.
7. Ignitor in engaged position.
When the above mentioned conditions have been established ,an individual
starting burner or load carrying burner may be placed in service at its local
control station as follows:
1. Turn the associated starting burner local control switch to the IGNITE
position. This will place the ignitor in service by opening the ignitor
oil and air valves and energizing the ignition transformer.
2. When the ignitor proves flame, indicated by the associated “Flame”
light coming on release the starting burner local control switch to the
“OPERATE” position. This will arm the holding coil of the associated
Burner manual reset valve.
3. Place the burner in service, by first opening the manual reset trip
valve. When the trip valve has been fully opened, slowly open the
manual shut off valve and establish flame by visual observation.
 OPERATION (SHUT DOWN)
AUXILIARY FUEL SHUT DOWN:
STARTING BURNER & LOAD CARRYING BURNER
An orderly shutdown of an individual burner takes place by turning the
associated starting burner local control switch to the TRIP GUN
POSITION which will close the burner shut-off valve. This will leave the
associated ignitor in service for manually scavenging the gun as follows:
1. Open the associated steam scavenge valve and scavenge the gun.
2. After scavenging for approximately one minute close the steam
scavenge valve.
3. Close the manual atomizing steam valve.
4. Place the associated burner local control switch to the OFF
position,this will shut down the ignitor.
5. Retract the oil gun from the firing position. However, it must be noted
that following a fuel trip the guns shall not be scavenged.
Any one of the following conditions being present, results in the
automatic shutdown of the burner oil gun:
*1. Associated ignitor fails to prove flame.
*2. Ignitor Oil Header trip valve not fully open.
*3. Auxiliary fuel trip.
4. Oil temperature below 160oF.
5. Steam to oil differential pressure below 5 PSIG.
6. Associated Oil gun not engaged in the firing position.
(*) Any of the conditions preceded by an asterisk will also trip the
associated ignitor.

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.
1. Evaporator outlet temperature greater than 525oF.
2. Precipitator outlet temperature greater than 525oF.
3. I.D. Fan not in service.
4. F.D. Fan not in service.
5. Primary Air Flow less than 30% of full load of flow.
6. Furnace pressure greater than +4”W.G.
 7. Ignitor oil pressure not within controlled limits.(75% to 125% of full
load pressure).
8. Ignitor air pressure greater than 75% of full load pressure.
9. Main oil pressure below 75% of full load pressure.
10. Starting burner oil header pressure above 125% of full load pressure.
11.Load carrying burner oil pressure above 125% of full load pressure.
12.Recirculation selector switch not in OPERATE position.
13.A Boiler trip condition exists.
14.Either of the local auxiliary fuel trip push button depressed.
15.Both of the auxiliary fuel trip push buttons on the BCD depressed.

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. F.D.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 :
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.
1. All trip valves closed OR
2. 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).
The emergency drain condition will remain, “Scaled in ” until the circuit is
reset by means of a reset push button on the BCD panel. This action is to be
taken by responsible personnel after assessing the particular situation which
warranted the emergency drain trip initially.

Alarms :
The following alarm conditions will cause an annunciator alarm to sound if
the appropriate terminals on the BCD panel are connected to the customers
annunciators. The contacts are normally open for the alarm conditions.
1. Furnace pressure greater than +4”W.G.
2. Air flow less than 30%.
3. Ignitor oil pressure less than 75%.
4. Ignitor air pressure less than 75%.
5. Main oil pressure less than 75%.
6. Starting Burner Oil pressure greater than 125%.
7. Boiler trip.
8. Auxiliary fuel trip.
9. I.D. Fan not running.
10.F.D. Fan not running.
11.Precipitator outlet temperature greater than 525oF.
12.Feedwater shut off valve not open.
13.Emergency drain valves not closed.
14.Evaporator outlet temperature greater than 525oF.
15.Emergency drain and trip.

ECONOMIZER:
 In boilers, economizers are heat exchange devices that heat fluids,
usually water, up to but not normally beyond the boiling point of that
fluid.
 Economizers are so named because they can make use of the enthalpy
in fluid streams that are hot, but not hot enough to be used in a boiler,
thereby recovering more useful enthalpy and improving the boiler's
efficiency. They are a device fitted to a boiler which saves energy by
using the exhaust gases from the boiler to preheat the cold water used
to fill it (the feed water).
DIGITAL I/P’s :
1. OIL GUN ENGAGED
2. HOBV CLOSED
3. SCNR FLM
4. IGNITOR
5. FURNACE PRESSURE
6. HO PRESSURE
7. ATOM STEAM PRESSURE
8. HO TEMPERATURE
9. HORV OPEN
10.HORV CLOSE
11.HOTV OPEN
12.HOTV CLOSE
13.EP O/L TEMP
14.AIR FLOW
15. DRUM LEVEL
16. SA/TA FAN RUNNING
17. ID FAN RUNNING
18. PA FAN RUNNING
19. FW SHUT OFF VLV OPEN
20. FW SHUT OFF VLV CLOSE
21. EMERGENCY TRIP
22. EM DRAIN & TRIP
23. AUXILIARY FUEL TRIP
24. PURGE START
25. SCANNER FAN-A ST/SP
26. SCANNER FAN-B ST/SP
DIGITAL O/P’s :
1. ATOMISING STEAM V/V
2. HOBV OPENED
3. SCAVENGE V/V
4. HEA IGNITOR
5. HOTV OPEN CMD
6. HOTV CLOSE CMD
7. HORV OPEN CMD
8. HORV CLOSE CMD
9. SCANNER FAN-A START
10.SCANNER FAN-B START
11.NO BOILER TRIP
12.SA/TA FAN START PMT
13.PA FAN START PMT
14.ID FAN START PMT
15.BL PMP
16.EP ASH PUMP
17.AFT
18.PURGE COMPLETE NO AFT
19.EP O/L TEMP
20.FW SHUT OFF V/V CLOSE
21. TRIP SA/TA FAN
22.TRIP PA FAN
23.STM-BL V/V
24.STARTUP V/V
25.EMRG DRN V/V
PLC used in BMS :

HONEYWELL 620LCS AND MOELLER IPC620 PLCS

Powerful, modular easy to use system with a vast range of expansion
options

Honeywell 620LCS - Moeller IPC620

The Honeywell 620LCS is an extremely versatile, modular PLC

system offering high speed control of both discrete and analogue
applications.
Also marketed by Klockner-Moeller as the IPC620PLC, the system
features many special purpose modules for enhanced network
communications and functionality. The 621 series universal
I/O expands the 620 to build systems of up to 2040 I/O points in any
mix of analogue or digital.
CNC & PTP applications are handled by the Honeywell 622 motion
control system which integrate seamlessly into the 620 rack to give up
to 6 axis of servo control.
The entire 620 range is programmed using the 623-60 loader suite
which has a comprehensive instruction set including full floating point
maths and user definable function blocks. Pre-tested function blocks
are also available to download. WinLoader, a windows based version of
the programming suite is now available for use with Windows XP.
uses

 PLC used is TATA HONEYWELL.

 CPU : IPC 620-35.
 SOFTWARE : 620 WINLOADER,VERSION 5.4
 DC POWER SUPPLY
 DI’S : 352, DO’S : 512.
 INPUT : 110V/220V or 240V,5.5A Max.
 OUTPUT : 25V DC,20A.
 FREQUENCY : 50 HZ.
 PLC SPECIFICATIONS :-
 32K EXPANDABLE MEMORY.
 PLC used is a Redundant System.
 I/O Handling Capacity : 2048 Real IO’s.
 Scan Rate : 50msec.

 PLC consists of 5 Modules:

• Memory module
• Register module
• System Control module
• Processor module
• I/O Control module.
 The PLC is Redundant type.
 Redundant system has Running mode and Standby mode slots.
 If Running mode won’t work then Standby mode is used by PLC for
functioning.
  A Key is present in the PLC.
• It has four modes:
1. Program
2. Disable
3. Run/Prog.
4. Run

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.

Conclusion:-

• The main theme of this project is Purging the Furnace at initial stage
and activating the Emergency Trip and Drain valves during abnormal
conditions while continuous running of process.
• This project can be used for better functioning of Boiler plant without
any malfunctions by continuously monitoring the Industrial
parameters and protecting the Boiler from destruction

• Authorised By
• SANTOSH BHARADWAJ REDDY
• Email: help@matlabcodes.com
• Engineeringpapers.blogspot.com
• More Papers and Presentations available on above site