Application Solutions

Do programmable logic controllers offer better value

than distributed control systems in this application?
A vis-a-vis comparison of sequential operations, boiler availability, system
diagnostics, and alarming favors PLCs.

Two different microprocessor-based

(Fig. 1) or DCS platform. After considering

system platforms are currently available to

the requirements of a BMS and evaluating

handle a powerplants diverse system

the performance and cost of both

requirements - programmable logic

platforms, it is suggested here that the

controllers (PLCs) and distributed control

PLC platform provides more value.

systems (DCSs). To maximize system

performance and minimize capital
expenditures, plant engineers should
consider the functional requirements of
each boiler subsystem - combustion
control, burner management, balance of
plant, and data acquisition - before
selecting a hardware platform.
Leading manufacturers of both PLCs and
DCSs have field-proven interfaces that
support a seamless exchange of
information between system platforms.
Powerplants can select the most
advantageous control platform for each
boiler subsystem and still feature a
centralized data-storage device or CRTbased operator console. Platform
decisions made for one control subsystem
should not unduly influence other
subsystem platform decisions (see box).

Sequential Operations
PLCs were originally designed as easy-toprogram, flexible, low-cost replacements
for relay-based and solid-state hardwired
discrete logic systems. DCSs were
originally developed to replace electric
analog control systems and analog
manual/auto stations used for modulating
control applications.

Also, on further investigation, it can be

shown that PLC processors are able to

Since burner management is implemented

using discrete inputs and outputs (I/Os)
and requires only sequential logic
operations, hardware and programming
costs for a PLC-based BMS are
significantly less than for a similar DCSbased system. Typically, the installed cost
of PLCs is 30-60% lower than DCS-based
systems, depending on redundancy

update I/O tables and cycle through

sequential logic faster than DCS
processors. Typical scan rates for 128
discrete I/Os is 2 ms for a PLC, 20 ms for
a DCS. For a system architecture with
remote I/O, the difference between DCS
and PLC update times grows and the
hardware price increases for the DCS
platform.

requirements and I/O partitioning

schemes. Less hardware and software

These PLC advantages allow for the

Powerplants retrofitting obsolete or

complexity results in lower maintenance

implementation of additional features that

troublesome burner management systems

and spare-part costs over the useful life of

are usually cost-prohibitive or unavailable

(BMSs) with microprocessor-based

the system.

in a DCS platform. A well-partitioned

systems thus can choose between a PLC

Benefit: Real-Time Control, Communication and Visualization

system architecture and a detailed alarm

management package are two critical

pulverizer into a different processor limits

can be realized if remote I/O adapters can

features that can be cost-effectively

the number of burners impacted by a

locate the I/O modules closer to each

incorporated into a PLC-based BMS.

processor failure.

burner firing level or pulverizer.

Boiler Availability

The partitioning of logic into multiple

System Diagnostics, Alarms

BMS architecture with a PLC can increase

processors is cost-effective because the

A big advantage offered by

unit availability by minimizing the effects

leading suppliers of PLCs manufacture a

microprocessor-based PLCs is their

of a failed system component on overall

number of different processors for each

detailed diagnostic and comprehensive

boiler operations. I/O modules can be

product family. These processors range in

alarming capability. With proper

partitioned into functional groups, each of

memory size from 1 to 64K of words and

programming, a BMS is able to help

which is dedicated to a specific piece of

support a discrete I/O capability of

identify the location of a system hardware

process equipment. For example, the I/O

between 52 and 3072 points. DCS

fault, provide first-out cause-of-trip alarm

modules associated with one or two

manufacturers do not offer the range of

messages, indicate the cause of an

burners are designated as a functional

processor sizes, thus are not at a

attempted but restricted operator action,

group. This functional grouping of

competitive price disadvantage.

and identify any final-control-device

modules assures that the failure of any

single I/O module will only affect one or
two of the boilers burners and will not
jeopardize the entire units steam
production.

Redundant processors are used in deenergize-to-trip systems to eliminate the

possibility of a single processor failure
tripping the entire boiler. Failure of the

failures. PLC processor speed in updating

I/O tables and executing the ladder logic
allows for timely capture of the following
events:

processor that controls the master-fuel-trip

Startup diagnostic messages help enhance

Functional grouping of I/O modules also

(MFT) logic and the boiler common I/O will

operator acceptance of a new BMS,

simplifies programming and

trip a unit off-line. To prevent this type of

especially if old benchboard controls are

troubleshooting. The burner logic for a

failure, the processor associated with the

being replaced with new CRT-based

functional group is created only once, then

MFT logic and boiler common functions is

stations. The messages indicate any

copied for the remaining identical pieces

backed up with a second hot processor.

permissives that are not satisfied when an

of process equipment. I/O assignments,

ladder logic, and wiring are identical for
all similar functional groups. Because of
the inexpensive hardware cost of PLCbased I/O modules, functional groups can
be cost-effectively generated for burners,
fans, feeders, and pulverizers.
Partitioning of logic into multiple
processors and the availability to
implement redundant processors can also
help to improve a boilers uptime. This is
especially true for large boilers with
multiple burner firing levels that operate
on a de-energize-to-trip (failsafe)
philosophy. Separating the logic and I/O
associated with each firing level or

Remote I/O, a common feature with PLC

platforms, is installed to reduce cable
routing costs. Using remote I/O adapter
modules to communicate with the master
processor, I/O modules can be located
next to the process equipment rather than
in a centralized rack in or near the control
room.
BMSs that adhere to a true power-to-trip
philosophy are particularly I/O intensive.
Typically, two input signals are required to
determine if a fuel valve is open or closed;
two output signals are also required to
open and close the valve. Thus,
substantial savings in field wiring costs

operator attempts to initiate a desired

sequence. For example, when an operator
depresses a burner start pushbutton, the
logic checks to see if all the burner
permissives are satisfied. Any missing or
dissatisfied permissive are displayed to
the operator. Starting diagnostics are
generally programmed for purge, opening
of header valves (Fig. 2), pulverizer starts,
and ignitor and burner light-off.
First-out-cause-of-trip alarms identify to
the operator the first input received by the
system that initiated a shutdown. Armed
with this information, maintenance
technicians can significantly reduce the
time it takes to diagnose the cause of a

trip, remedy the problem, and place the

system are abreast of the latest published

unit back on line after an unplanned

standards, are experienced in the startup

shutdown or trip.

and operating of similar boilers, and are

Final control device alarms alert the

operator to valve failures. All valves with
limit switches controlled by the BMS are

skilled system programmers. Good project

support plus the correct platform help
assure a safe, reliable system.

monitored by feedback inputs to verify

References

that their position agrees with the state

1 NFPA 85C Prevention of Furnace

commanded by the PLC processor. Any

Explosions/Implosions in Multiple

valve not so verified is alarmed to the

Burner Boiler-Furnaces, An American

operator.

National Standard, 1991 ed, 85C-11

System hardware alarms indicate I/O

module, processor, and/or system
communications failures. Alarm messages

2 Ibid, 85C-15
3 Ibid, 85C-25

indicating module type that failed, its

location in the system, and the exact input
or output channel that failed (Fig. 3). With
this type of detailed information,
maintenance technicians can quickly
identify and replace failed system
components.
The detailed hardware fault detection
described in the last two items requires
system I/Os in addition to those specified
for the field devices. Although
implementing detailed alarm management
in a DCS is possible, it is considerably
more expensive because of the higher
hardware costs associated with DCS I/O
modules.

A final note
Safety and reliability of a BMS rest on the
capabilities of system engineers. To gain
full benefits of any hardware platform
used to implement burner management,
plant owners and operators must be
assured that the engineers designing the

GMSE00-AP010B-EN-P July 2002

Supercedes Publication GMSE00-AP010A-EN-P September 2001

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