Preferred Utilities Manufacturing Corp.

Burner
Management Systems
A Technical Discussion

Preferred Utilities Manufacturing Corp.

Introduction
Burner Management System Objectives
BMS Design Standards and Definitions
BMS Logic
BMS Strategies and Hardware

Types of Burner Management Systems

BMS Interface to SCADA Systems

Summary

Introduction
Burner Management
Systems..

..a starting point.

Introduction
What is a BMS?

A Burner Management System is defined as

the following:

A Control System that is dedicated to boiler safety,

operator assistance in the starting and stopping of
fuel preparation and burning equipment, and the
prevention of mis-operation of and damage to fuel
preparation and fuel burning equipment. 1

1. From NFPA 8501 Standard for Single Burner Boiler Operation

Burner Management Objectives

Sequence burner through safe start-up
Insure a complete pre-purge of boiler
Supervise safety limits during operation
Supervise the flame presence during
operation
Sequence a safe shutdown at end of cycle
Integrate with combustion control system
for proper fuel and air flows

BMS Design Standards

Each Burner Management System should be designed

in accordance with the below listed guidelines to
control and monitor all sequences of the start-up and
shutdown of the burner
National Fire Protection Association (NFPA 8501 /8502
or others)
Industrial Risk Insurers (IRI)
Factory Mutual loss prevention guidelines

Each burner management system should be designed

to accomplish a safety shutdown in the event of an
unsafe condition. (FAIL SAFE)

BMS Design Standards

U.S. National Fire Protection Association

(NFPA)

Governs safety system design on virtually all boilers

(regardless of the process to be used to combust the fuel)
Requires the separation of the Burner Management
System from any other control system
Requires the use of a hardwired backup tripping scheme
for microprocessor based systems
Requires that a single failure NOT prevent an appropriate
shutdown
Factory Mutual loss prevention guidelines.

NFPA 8501

NFPA 8501 Standard for Single Burner

Boiler Operation

Single Burner Boilers with fuel input greater than 12.5

mBTU/Hr (Approx. 250 BHP)
Single Fuel or Combination of Fuels (Common being
Natural Gas / No.2 Oil / No. 6 Oil)
Simultaneous Firing

NFPA 8502

NFPA 8502 Standard for Prevention of

Furnace Explosions / Implosions in Multiple
Burner Boilers

Multiple Burner Boilers with fuel input greater than

12.5 mBTU/Hr
Single Fuel or Combination of Fuels including
Pulverized Coal
Emphasis on implosion protection (larger boilers with
induced draft systems)

BMS Definitions

Furnace Explosions

Ignition of accumulated combustible mixture within

the confined space of a furnace or associated boiler
passes, ducts, and fans that convey gases of combustion
to the stack1
Magnitude and intensity of explosion depends on
relative quantity of combustibles and the proportion of
air at the time of ignition

1. From NFPA 8502 Prevention of Furnace Explosions / Implosions in Multiple Burner Boilers

BMS Definitions

Furnace Explosions can occur with any or a

combination of the following:1

Momentary loss of flame followed by delayed re-ignition

Fuel leakage into an idle furnace ignited by source of
ignition (such as a welding spark)
Repeated Light-off attempts without proper purging
Loss of Flame on one Burner while others are in operation
Complete Furnace Flame-out followed by an attempt to
light a burner

1. From NFPA 8502 Prevention of Furnace Explosions / Implosions in Multiple Burner Boilers

BMS Definitions

Furnace Implosions

More common in large Utility Boilers

Caused by any of the following:
Malfunction of equipment regulating boiler gas flow
resulting in furnace exposure to excessive induced
draft fan head capability
Rapid decay for furnace gas temperature and
pressure due to furnace trip

1. From NFPA 8502 Prevention of Furnace Explosions / Implosions in Multiple Burner Boilers

BMS Basic Definitions

Common Terminology

Supervised Manual
Manual Burner Lightoff with Interlocks

Automatic Recycling (Single Burner Only)

Automatic Burner Start and Stop based on preset
operating range (ie.. Drum pressure)

Automatic Non Recycling (Single Burner Only)

Automatic Burner Start and Stop based on Manual
command to start.

Types of Flame Scanners

Infrared (IR) Detectors

Ultra-Violet (UV) Detectors

Single Burner Applications

More Suitable with Oil Burning Flames
Multiple Burner Applications
More Suitable for Gas Burners and Combination Gas /
Oil Burners

Self Check Scanners

Flame Signal is interrupted at set intervals to verify

proper operation of scanner

Single Burner BMS Inputs

Low Low Drum Level

(D)

High Steam Pressure

(D)
(D)

Purge Purge Air Flow

(D)

Minimum Air Flow

OFF

BURNER
ON

R ESET

FUEL SELECT
GAS OIL

(D)

Flame / No Flame

Limits Made
Hold to Purge
SCRL

MODE

FD FAN
HAND O FF AUTO

(D)

Fuel Oil Temp Low

Fuel Oil Temp High
Fuel Oil Press Low
(A)
Fuel Oil Flow
Atomizing Medium Flow > Min

Common Alarm Output

Atomizing
Medium
Press Low

(D)

(D)
(D)

(D)

AE

TE

(D)

Remote Annunciator
(By Others)

FEEDWATER
PSH

STEAM

PSL
PT

PSH

FT

IGNITER
GAS

Safety Shut Off

& Vent Valves

LSLL

LSLL

Fuel
Gas
Press
Low

Fuel
Gas
Press
High

(D)

(D)

FT

PSL

ATOMIZING
MEDIUM

FT

GAS

PSL

PSL

OIL

PSL

TSH

TSL

FS

Control
Valve

Safety Shut Off

Valves

Control Valve &

Shut Off Valve

(D) - Descrete Signal Used By Flame Safeguard System

PSH

Safety Shut Off &

Vent Valves

Control
Valve

BMS Logic
Burner Management Systems can be broken
down into Interlock Groups
Typical BMS Interlock Groups:

Boiler Purge
Igniter Header Valve Management
Main Fuel Header Valve Management
MFT (Master Fuel Trip) Logic

Purge Interlocks
B O IL E R T R IP P E D

A ND

PU R GE /R ESET PB
S T A R T -U P
T IM E R

S TA RT FD FA N
P E R M IS S IV E S S A T IS F IE D :
- M A IN F U E L V A L V E S C L O S E D
-

NO FLA M E P RE S E N T
F D F A N R U N N IN G
M IN IM U M A IR F L O W S W IT C H M A D E
W A T E R L E V E L S A T IS F A C T O R Y
A T O M IZ IN G M E D IU M O N
FU E L S UP P LY P RE S S UR E N O T LO W

A ND

E N E R G IZ E F U E L R E L A Y
NO T

A ND

P U R G E S IG N A L T O C C S

P U R G E A IR
F L O W S W IT C H
M AD E

A ND

F D D A M P E R IN
FULL O PEN
P O S IT IO N

P U R G E T IM E R S E T

P UR G E C O M P LE TE
YE S

RE M O V E P URG E TO C C S

NO

S Y S T E M T R IP

Igniter Interlocks
P URG E C O M P LE TE

A IR D A M P E R IN L O W F IR E
P O S IT IO N

AND

F U E L V A L V E IN L O W F IR E
P O S IT IO N

E N E R G IZ E IG N IT E R A N D
IG N IT E R H E A D E R V A L V E S

10 SE C O ND D E LA Y

1 0 S E C P IL O T T R IA L
F O R IG N IT IO N

T IM E R C O M P L E T E
FLA M E
PRO VE N

NO T

AND

P E R M IT F O R M A IN
FLAM E

S Y S T E M T R IP

Main Flame Interlocks

IG N IT E R T IM E R
C O M P LE TE

FLAM E
PRO VEN

AND
E N E R G IZ E M A IN
FUEL VALVES
1 0 S E C M A IN F L A M E
T R IA L

T IM E R C O M P L E T E
NO T

AND

D E - E N E R G IZ E
IG N IT IO N
C O M P O NE N TS

RE LE A S E TO
M O D U LA TE TO C C S

S Y S T E M T R IP

Single Burner Main Fuel Trip

F O R O IL :

FOR GAS:

- LOW FU EL PR ESSU R E
- L O W T E M P E R A T U R E ( H E A T E D O IL S )
- L O S S O F C O M B U S T IO N A IR
- L O S S O F F L A M E O R F A IL T O E S T A B L IS H
- LO S S O F C O N TR O L S YS TE M E N E R G Y
- P O W E R F A IL U R E
- L O W W A T E R L E V E L (A U X L E V E L C O N T A C T )
- L O S S O F A T O M IZ IN G M E D IU M
- E X C E S S IV E S T E A M D R U M P R E S S U R E
- H IG H O IL T E M P E R A T U R E ( H E A T E D O IL S )

- L O W FU E L G AS P R E S S U R E
- H IG H G A S P R E S S U R E
- L O S S O F C O M B U S T IO N A IR
- L O S S O F F L A M E O R F A IL T O E S T A B L IS H
- LO S S O F C O N TR O L S YS TE M E N E R G Y
- P O W E R F A IL U R E
- L O W W A T E R L E V E L (A U X L E V E L C O N T A C T )
- E X C E S S IV E S T E A M D R U M P R E S S U R E

OR
OR

T R IP B O IL E R

T R IP IG N IT E R ,
IG N IT E R V A L V E S ,
O P E N IG N IT E R
VEN T

T R IP M A IN F U E L
VALVES,OPEN
VENT VALVE
(G A S O N L Y )

FU EL C ONTR OL
VALVE TO
C LOSED
P O S IT IO N

T R IP M F T R E L A Y

BMS System Types

Early Burner Management Systems

Microprocessor Based Systems

Hardwired Systems
Solid State Systems
Fireye E110 / Honeywell 7800 series with fixed
Logic.

PLC Based Systems

Programmable Logic Controller (PLC) Based

Powerful, versatile, expandable, more reliable.

Early Burner Management Systems

Hardwired Systems

Relay and Timer Driven. Found on older

installations
Typical of Late 50s, 60s

Solid State Systems

Solid State Processors and Relays

Found on Systems provided in the 70s and 80s
Proprietary Hardware (ie.. Forney and Peabody)
Spare Parts are extremely hard to find.

MicroProcessor Based Systems

Microprocessor Based System providing:

Burner Sequencing
Ignition
Flame Monitoring

Fixed Program with Limited Configuration

Changes
Components Selected Based on Requirements

Programmers, Flame Amplifiers, Message Displays

Fireye BMS Layout

E P P AR MO PG LR I FA IME RM E R

A U T O M A T IC P R IM A R Y S A F E T Y C O N T R O L

F IE L D W IR IN G

FLAM E
SC ANN ER

F IE L D W IR IN G

MicroProcessor Capabilities
Simple, Cost Effective
Features

Selectable Flame Amplifiers / Scanners

Remote Display
Remote Data Communications via Modbus Port
Modernization kits are available to integrate with older
systems
Spare Parts Normally Readily Available

When These Systems are Used

Simple Boiler Installations

Packaged Firetube / Watertube Boilers (Steam /

Hot Water)
Single Burner
One Fuel at a Time
No Flue Gas Re-Circulation
Upgrades from Previous MicroProcessor Based
Systems

PLC Based Burner Management Systems

PLC Based Features

NFPA 8501, 8502

Watchdog timer
UL 508 Certification

Redundant Scanners
Logic+ Message Center

Shows program status

Displays alarms
Prompts operator

PLC System Basic Design Features

Each PLC based burner management system should

incorporate a number of design techniques which
help detect and act upon unsafe failure modes which
can occur in any microprocessor based system.
These design features include the following:

Critical Input Checking

Critical output channel monitoring
Electro-mechanical Master Fuel Trip (MFT) Relay
Redundant Watchdog Timers
Low Water Cut-out Monitoring During Blow Down

PLC Based System Capabilities

Provision for Multiple Fuel Firing

Capped gas input during curtailment

Changeover from gas to oil at any load
Simultaneous firing of waste and fossil fuels

Redundant Scanners, change scanner with fuel

Single or Multiple Burner Applications
Integration of BMS with SCADA

PLC Based Operator Interfaces

Features

Clear Written Messages to indicate status,

required operator interaction, trip/alarm indication
High Visibility through two lines of display
Messages reduce time consuming troubleshooting
Prioritizes Messages
First Out Alarms
Warning / Alarm Messages
Status Messages / Prompts Operator

PLC System Layout (Typical)

D o o r M o u n te d L ig h t s / P u s h b u t to n s

L o g ic + M e s s a g e
D is p la y

S W IT C H

PLC CPU

I/O

I/O

I/O

S IL E N C E

L IG H T

I/O

C O M B U S T IO N
CO NTRO L SYSTEM
F L A M E A M P L IF IE R
(S IN G L E /
RED U N DAN T)
I/O E X P A N S IO N

I/O

F IE L D D E V IC E S

Benefits of PLC Based Systems

Flexibility / Reliability

Choice of PLCs

Programming Software allows changes to

system
GE / Modicon / Allen Bradley / Koyo

Choice of Flame Scanners

PPC / Fireye / Honeywell / Iris / Coen

Application Specific
Quantity of Burners / Fuels is not restricted

When to Use PLC Based Systems

Complex Boiler Installations

Larger Packaged Units / Field Erected Units

Multiple Burners
Multiple Fuels, On-line Fuel Changeovers
Flue Gas Re-Circulation
Replace Existing Relay Logic Systems
Requirement to maintain consistent control
platform (spare parts, etc..)

BMS SCADA Interface

BMS Systems can be integrated into a

SCADA System

Allows Remote Monitoring of Flame Status

Allows Remote Control of BMS
Events (ie.. Burner trip) can be routed to
Historical Portion of SCADA for fault
evaluation
Burner Operation can be trended over time

BMS SCADA Interface

Interface Methods:
SC AD A PC

M O D BU S
C O M M U N IC A T IO N
PR O TO C O L

M O D BUS
C O M M U N IC A T IO N
PR O TO CO L

C o m m u n ic a t io n
In te rfa c e
(If N e c e s s a ry )

PLC CPU

I/O

I/O

I/O

B M S L O G IC + S Y S T E M

I/O

F IR E Y E E 1 1 0 S Y S T E M

BMS SCADA Interface

Summary

Benefits Associated with New Burner

Management Systems

Help Improve plant safety

Help qualify for reduced insurance cost
Reduce Startup and Down Time with
comprehensive alarming and diagnostics

Summary
Review

of Topics Discussed

Objectives of Burner Management Systems

BMS Design Considerations
Basic BMS Logic
Types of Burner Management Systems
How BMS Systems can be integrated with
Plant Wide SCADA Systems

Preferred Utilities Manufacturing Corp

For further information, contact...

Preferred Utilities Manufacturing Corporation

31-35 South St. Danbury CT
T: (203) 743-6741 F: (203) 798-7313
www.preferred-mfg.com