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Safety Controls and Burner Management Systems (BMS) On Direct-Fired Multiple Burner Heaters
Safety Controls and Burner Management Systems (BMS) On Direct-Fired Multiple Burner Heaters
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Background
In the past, most heaters have operated on temperature control from the outlet
temperature to a control valve in the main gas line, with a single shut-off valve upstream
on the Control valve. This shut-off valve was either automatic with the plant ESD or
operated manually with an Operator action, with each company having various additions
to this basic concept.
The following is a list of new requirements that are common to various heater and BMS
codes.
1)
2)
3)
4)
5)
6)
7)
8)
Mandatory Purging.
Permissive Interlocks
Double Block and Bleed systems
Pilots and Ignition Systems
Dedicated Flame Monitoring Systems
High / Low Pressure, Temperatures and Flow.
Combustion Air and Draft Pressure Alarms and Controls
Dedicated Logic Solver
Each of these requirements have been developed due to incidents that have occurred
because of the lack of them.
Mandatory Purging
The most important function of the heater control system is to
prevent the possibility of an accumulation of combustible gas
followed by accidental or improper ignition sequence resulting in
an explosion. Correct pre-ignition purging of the heater is crucial
to the safe operation of the heater.
The normal practise for the purging of a natural draft heater has
been to allow a period of time for a heater to naturally purge.
Typically this would have been 20-30 minutes on a cold light off,
and would have been at the discretion of the operator. The
alternative is to purge with steam, if available. Caution must be
taken when doing so to prevent possible steam condensation from
affecting the operation of the ignition and flame monitoring
instrumentation.
The timed purge is to be proven. The codes imply that there has to
be a means to prove there has been four volumes changes or air in
the heater prior to light-off. It is not possible to measure the air
flowrate during a natural purge. Therefore the options available to
provide a proven purge are:
a) Purge Blower or Fan
b) Steam purge from radiant section
c) Induced Draft Purge (via Steam eductor in the Stack)
Furthermore, depending on the jurisdiction there may also be a
minimum purge flow rate that must be adhered to.
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Shut-off Valves
The safety shut-off valves are the key component in the BMS
to prevent the accumulation of an explosive mixture in the
heater. Standard practice is to provide automated safety shutoff valves installed in a double block and bleed configuration
on the main and pilot headers. An additional safety shut-off
valve should be located on each individual burner for multiple
burner systems. These shut-off valves must also be certified for
use safety shut-off valves.
In accordance with CSA
requirements these valves need to be certified to CSA 6.5
certified and per NFPA requirements these valves need to be
FM-7400 listed.
During normal operation the bleed is automatically closed on
light-off request and likewise opens automatically on shut
down. The vent valve is to be proven closed prior to opening
of the shut-off valve; on shutdown the upstream shut-off valve
is to be confirmed closed before the vent valve opens to
prevent fuel from being unnecessarily vented. The valves must
also be in their de-energized state and proven prior to heater
purge and start-up.
The configuration discussed above works well for a single
burner system but this cannot be applied to multiple burner
systems; unless they are all to operate in tandem. In order to
keep the heater running in the event of a single burner failure
the fuel gas must be isolated from the failed burner. Strict
adherence to the codes and guidelines would require two
separate safety shut-off valves piped in series for each burner.
An exception is provided in NFPA that would allow for the
shutdown of a single burner, provided that all burners fire into
a common combustion chamber and certain conditions are
met.
PLC Panel
The CSA code even goes one step further and requires a
double block and bleed arrangement on each main and pilot
burner. Although the code does not provide the same
exception afforded by NFPA a variance application can be
made to the authority having jurisdiction to implement a
similar valve train. The addition of more valves does not
necessarily equate to a safer heater from a reliability
standpoint.
CSA B194.3-05 Section 5.3 Safety Shut-off Valves
5.3.1: Safety shut-off valves shall not be bypassed
5.3.4: An appliance that has a maximum rated input in excess
of 10,000,000 Btu/h (3000 kW), up to and including
50,000,000 Btu/h (15 000 kW), with single burner or multiple
burner flame safeguard controls shall be equipped with not
less than two automatic safety shut-off valves piped in series
and wired in parallel that are certified in accordance with
ANSI Z21.21/CSA 6.5 and marked C/I.
5.3.5: An appliance that has a maximum rated input in excess
of 10,000,000 Btu/h (3000 kW), up to an including
100,000,000 Btu/h (30 000 kW), with multiple burners that
have multiple burner flame safeguard controls shall be
equipped with not less than two automatic safety shut-off
valves per burner, certified in accordance with ANSI
Z21.21/CSA 6.5 and marked C/I, one of which shall be in the
common valve train and may be of the fast opening type.
The downstream valve shall be provided with a mandatory
manual-reset function to open.
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Operating philosophy
Burner Management
Systems
Power On
Continue Check
Permissives
Check
Permissives
Start
Purge
Complete
Purge
Burner
Management
System
Hand
to DCS
Confirm
Burner(s)
Ignite Pilot(s)
Light
Burner(s)
Prove
Pilots
The main function of the BMS is to allow and ensure the safe start-up, operation, and shutdown of the Fired Heater. Once the
logic is configured and the system properly commissioned the BMS will provide a safe and consistent operating sequence. The
human interface will guide the operator so that the heater may be safely operated, and if needed, be quickly and safely restarted.
The following sequence of operation is typical for most Fired Heaters.
1) Initially, the PLC will check that all the permissives and interlock are in place to allow start up.
2) Start Purge. The PLC will check that the permissives are at their correct status. The system will typically wait for the
operator to request the heater to start, although all permissives are met and the the heater is ready to purge. Once the
heater start/purge is requested a pre-set timer will commence. Assuming the timing is not interrupted by an Interlock
activation, it will continue until complete. Once finished, it will notify the operator that Purge Complete has been
accomplished.
3) Ignite Pilots. Once the purge is completed, the operator will be notified that the system is ready to start the pilots. The
pilot header double block and bleed valves will energize. Instantaneously, the individual local pilot firing valves will open
and the ignition transformers will be energized. The pilot valves and the ignition transformers will only be energized for a
maximum of 10 seconds. If the pilot flame is not detected within this time the individual pilot isolation valve will close.
4) Prove Pilots. Each pilot has its own dedicated flame detector, which in most cases is via a flame rod. Once proven, the
individual pilot valve will hold in and continue to burn, in the event a pilot is not lit.
5) Light Main Burners. Before the main burners are lit, the PLC will continue to check the permissives to ensure it is safe to
light the main burners. The two main permissives are that there is sufficient flow in the process coils and the the pilot
burners are proven. The system then proceeds to energize the main header vent and shut-off valves. The first burner will
light at the minimum fire rate. A five second trial for ignition is provided from the time the individual isolation valve is
opened until the detection of the flame. If the flame is not detected, the individual main burner isolation valve is deenergized.
6) Confirm Main Burner Status. Once this is achieved the system is ready to be ramped up to operating conditions. This is
usually performed manually until the process variable is close to the operating set point, then the temperature and gas
flow/pressure controllers can then be switched to auto mode.
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Conclusion
There are a number of codes and guidelines pertaining to the safety control and burner management system for direct
fired heaters. The controlling code within Canada is CSA B149.3, but the most common guideline referred to around the
world is NFPA 86. Due to changing government legislation as well as safety and insurance concerns, there is an increase
in the necessity to upgrade or install the heater safety systems (BMS) to comply with published codes and guidelines.
These codes and guidelines are specific when in regards to the valve train and certain safety instrumentation. There is
little aid when incorporating the safety and operability aspects of the overall heater and BMS unit. Unlike boilers, there
are a variety of configurations and process fluids that a direct fired heater may be designed for. As such, there are many
safety interlock and operation permissives that must be reviewed on a case-by-case basis.
Adherence to the published codes and guidelines is a great start and will create a good foundation for the heaters safety
system. In order to design the system for maximum reliability and operability, each system should be reviewed
individually and the safety controls designed accordingly.