Elements of a

Successful Burner
Management Project
Presenters

 Kirk Adams

 David Sheppard
Introduction

– Details of the SRU BMS Project

– Proven Solution Using Best Tools Available
• State Transition Approach to BMS Design
• BMS Interface to Combustion Controls
– Engineered solution for Start-up and yearly testing
– Considerations for system requirements when the
unit is not running
– Summary / Questions?
Successful Project Considerations

Design
Yearly Testing
Down Time
BP SRU Project

 Over 600 SIS IO

 Majority of the safety related scope centered on
replacement of the burner management systems on
the eight fired equipment 4 Claus, 2 SCOT, and 2
incinerators
 DeltaV System used as Process Controls System
including Combustion Controls
 New Remote Instrument Enclosure
 Asset Management System
 SRU Unit never goes into full Turnaround
Presentation:
– Details of the SRU BMS Project
– Proven Solution Using Best Tools Available
• State Transition Approach to BMS Design
• BMS Interface to Combustion Controls
– Engineered solution for Start-up and yearly testing
– Considerations for system requirements when the unit is not
running
– Summary / Questions?
DeltaV SIS advanced function blocks
simplify configuration
 IEC 61508 certified modules
and functionality for BMS
– Cause and Effect Matrix (CEM)
– Step Sequencer
– State Transition
 Provides very efficient
configuration and powerful
application software.
 Available dynamos and
faceplates make the application
very transparent for the
operator.
Example BMS States
S03
Shutdown, S04
S02
Not Ready
Pre-Purge In Ignite Pilot
Shutdown, progress Purge Complete
S01
& Ready S05

Startup failure
Pilot only
S06
Running

Trips from States

5, 6, 7, 8, 9, 10, 12
Mixed firing, set
low fire position

S12
S07

S13

Cold Start, Set

Waste Gas Only S08 Low fire position
S10 S09

Ignite Main with

Mixed Gas Main without pilot, not at Pilot
Temp
3 Main Logic Part to a BMS System
In order to define a BMS you must know 3 fundamental items.
1. States & Transitions – When to move from one to another
2. Outputs – Valve Positions defined for each State
3. Trips – Including which is active during each State

Once these are defined, the DeltaV SIS logic can be programmed in
An easy to follow manner.

The following
Example is a
Single Burner-
Multi Fuel
with 13 states:
Outputs – Defined per State
 Once the States are defined, the position of each Output (Valve,
igniter, etc) is defined in each state in a simple table

Nitrogen to block valve

XXXXX-10 Oxygen to block valve
Pilot gas downstream
valve

Main combustion air

Main combustion air

Trim combustion air

Trim combustion air

Pilot combustion air

Pilot gas upstream
downstream block

Waste gas control

Waste gas control

Tuning Command

Tuning Command
Oxygen to control

Oxygen to control
valve solenoid #1

valve solenoid #2

Burner Switch #1

Burner Switch #2
valve solenoid 2
Main natural gas
blockgas

valve solenoid 1

valve Gas
Control Valve
Description

solenoid #1

solenoid #2

Pilot Igniter
block valve

block valve

Solenoid
Main natural

Sour Water
valve

valve

valve

(FO)
Outputs

Output Description

upstream
State Output Control

XYXXXX-11

XYXXXX-12

BYXXXX-14
FYXXXX-13

BXXXXX1-

BXXXXX2-
FYXXXX-3

FYXXXY-3

FYXXXY-4

FYXXXX-4

FYXXXX-7

FYXXXY-7

FYXXXX-9
XYXXX1-1

XYXXX2-2

XYXXX1-5

XYXXX2-6

PXXXX-8
Tag

15

15
Notes

States
1

1
D=De-Energize, E=Energize, C=BPCS to hold Closed, R=Release to BPCS Modulation, XX=Set the
State Name State output % open
Shutdown, Not Ready S01 D D D D D D D D D D D D D D D D D D D
Shutdown & Ready S02 D D D D D D D D D D D D D E D D D D D
Pre Purge in Progress S03 D D D D D D D D D D D D D E D D D D D
Purge Complete S04 D D D D D D D D D D D D D E D D D D D
Ignite Pilot S05 D D D D D D E E D D D D D E E D E D D
Pilot Only Running S06 D D D D D D E E D D D D D E E D D D D
Cold start, set low fire positions S07 D D D D E E E E D D D D D E E D D D D
Ignite main with pilot S08 E E D D E E E E D D D D D E E D D D D
Main NG w/o Pilot, not at temp S09 E E D D E E D D D D D D D D D D D D D
Mixed Gas S10 E E E E E E D D E E D D D D D D D D D
Not Used S11
Mixed firing, set low fire positions S12 D D E E E E D D E E D D D D D D D D D
Waste gas Only S13 D D E E E E D D E E E E E D D E D E E
 Not Used
Ignite Pilot

Mixed Gas
State Name
States

Waste gas Only

Purge Complete

Pilot Only Running

Shutdown & Ready

Ignite main with pilot

Shutdown, Not Ready

Pre Purge in Progress

Outputs

State Output Control

Main NG w/o Pilot, not at temp

Cold start, set low fire positions

Mixed firing, set low fire positions

Output Description

S13
S12
S10
S09
S08
S07
S06
S05
S04
S03
S02

S11
S01
Notes Tag Description
Main natural gas

E
E
E

D
D
D
D
D
D
D
D
D
1 XYXXXX1-1 Main natural
upstream valve
blockgas
downstream block

E
E
E

D
D
D
D
D
D
D
D
D
1 XY206C2-2 valve
Main combustion air

E
E
E
D
D
D
D
D
D
D
D
D
1 FY2XXXX-3 valve solenoid #1
Main combustion air

E
E
E
D
D
D
D
D
D
D
D
D
1 FY205CY-3 valve solenoid #2
Trim combustion air

E
E
E
E
E
E
D
D
D
D
D
D
1 FY212CY-4 solenoid #1
Trim combustion air

E
E
E
E
E
E
D
D
D
D
D
D
State XX=Set the output % open
1 FY212CX-4 solenoid #2
Pilot gas upstream

E
E
E
E

D
D
D
D
D
D
D
D

1 XY202C1-5 block valve

Pilot gas downstream

E
E
E
E

D
D
D
D
D
D
D
D

1 XY202C2-6 block valve

Waste gas control

E
E
E
D
D
D
D
D
D
D
D
D

1 FY215CX-7 valve solenoid 1

Waste gas control

E
E
E
D
D
D
D
D
D
D
D
D

1 FY215CY-7 valve solenoid 2

Oxygen to control

E
D
D
D
D
D
D
D
D
D
D
D

1 PY237C-8 valve
Oxygen to control

E
D
D
D
D
D
D
D
D
D
D
D

1 FY240C-9 valve

E
D
D
D
D
D
D
D
D
D
D
D

1 XY250C-10 Oxygen to block valve

Nitrogen to block valve
E
E
E
E
E
E
E

D
D
D
D
D

1 XY224C-11 (FO)
Pilot combustion air
E
E
E
E

D
D
D
D
D
D
D
D

1 XY203C-12 valve
Outputs – Defined per State

E Sour Water Gas

D
D
D
D
D
D
D
D
D
D
D

1 FY216C-13 Control Valve Solenoid

E

D
D
D
D
D
D
D
D
D
D
D

States
1 BY217C-14 Pilot Igniter
Burner Switch #1
E
D
D
D
D
D
D
D
D
D
D
D

1 BX201C1-15 Tuning Command

Burner Switch #2
E
D
D
D
D
D
D
D
D
D
D
D

1 BX201C2-15 Tuning Command

D=De-Energize, E=Energize, C=BPCS to hold Closed, R=Release to BPCS Modulation,

Outputs
 
Trip Input Description

Trips

S11

S13
S12
S10
S09
S08
S07
S06
S05
S04
S03
S02
S01
State
Notes Tag Description
1 - Loss of

T
T
T
T
T
M
M
M
M
M
M
M
main flame
BSLXXX1/2 signal
2 - Low

T
T
T
T
T
T

M
M
M
M
M
Natural Gas
PT7XXX/Y/Z Pressure

This
3 - Hi Hi

T
T
T
T
T
T
T
T
T
T
T
T
combustion air
PTXXX1/2/3 pressure

M cause
4 - Low Total

T
T
T
T
T
M
M
M
M
M
M
M
FTXXX1/2/3 Combustion
FTXXX1/2/3 Air Flow

this
needs
5 - Hi Hi level

T
T
T
T
T
T
T
T
T
T
T in Waste gas
LTXXXX/Y/Z KO drum

state!
6 - Hi Hi
thermal

T
T
T
T
T
T
T
T
T
T
T
T

TTXXX reactor
TTXXXX temperature
7 - Manual

T
T
T
T
T
T
T
T
T
T
T

ESD Button,

toT be “masked”
HS2XXX2 RIE
8 - Manual

T
T in T
T
T
T
T
T
T
T
T
T
T

ESD Button,
HSXXX3 Local
9 - Hi Hi level
in

T
T
T
T
T
T
T
T
T
T
T

hydrocarbon
LTXXX1/2/3 10 -drum level
Low 1
in high
T
T
T
T
T
T
T
T
T
T
T

pressure
"T" = Trip, "M"=Mask (no trip)

stream
LTXXX1/2/3 11 level
- Hi Hidrum
in
T
T
T
T
T
T
T
T
T
T
T

hydrocarbon
LTXXX1/2/3 12 -drum
Hi Hi 2level
this

in
Trip Matrix / Appropriate Masking

T
T
T
T
T
T
T
T
T
T
T

hydrocarbon
LTXXX1/2/3 13 -drum
Hi Hi 3level
state.

in
T
T
T
T
T
T
T
T
T
T
T

hydrocarbon
T ThisTcauseThas toT be able

LTXXX1/2/3 drum 4
14 - Loss of
T
T
T

M
M
M
M
M
M
M
M

pilot flame
T to trip

BSLXXX signal
15 - Trip on
Different Trip conditions are be masked in different states.

T
M in T
T
T
T
T
T
T
T
T
T
T

Software
HSXXXX Shutdown
 Trip Input Description

Trips

S11

S13
S12
S10
S09
S08
S07
S06
S05
S04
S03
S02
S01
State
Notes Tag Description

T
T
T
T
T
M
M
M
M
M
M
M
1 - Loss of main
BSL201C1/C2 flame signal

T
T
T
T
T
T

M
M
M
M
M
M
2 - Low Natural
PT729X/Y/Z Gas Pressure
3 - Hi Hi

T
T
T
T
T
T
T
T
T
T
T
T
combustion air
PT217C1/2/3 pressure
4 - Low Total

T
T
T
T
T
M
M
M
M
M
M
M
FT205C1/2/3 Combustion Air
FT212C1/2/3 Flow
5 - Hi Hi level in

T
T
T
T
T
T
T
T
T
T
T
T
Waste gas KO
LT211X/Y/Z drum
6 - Hi Hi thermal

T
T
T
T
T
T
T
T
T
T
T
T
TT222C reactor
TT229C temperature

T
T
T
T
T
T
T
T
T
T
T
T

7 - Manual ESD
HS210C2 Button, RIE

T
T
T
T
T
T
T
T
T
T
T
T

8 - Manual ESD
HS210C3 Button, Local
9 - Hi Hi level in

States

T
T
T
T
T
T
T
T
T
T
T
T

hydrocarbon
LT105C1/2/3 drum 1
10 - Low level in

T
T
T
T
T
T
T
T
T
T
T
T

high pressure
"T" = Trip, "M"=Mask (no trip)

LT203C1/2/3 stream drum

11 - Hi Hi level in
State!

T
T
T
T
T
T
T
T
T
T
T
T

hydrocarbon
LT625C1/2/3 drum 2
This Cause is
“masked” in this

12 - Hi Hi level in
T
T
T
T
T
T
T
T
T
T
T
T

hydrocarbon
LT625D1/2/3 drum 3
13 - Hi Hi level in
T
T
T
T
T
T
T
T
T
T
T
T

hydrocarbon
LT105D1/2/3 drum 4
Outputs
T
T
T

M
M
M
M
M
M
M
M
M

14 - Loss of pilot
BSL202C flame signal
15 - Trip on
T
T
T
T
T
T
T
T
T
T
T
T

Software
HSXXXX Shutdown
Trips –Including Masking Based on State
Presentation:
– Details of the SRU BMS Project
– Proven Solution Using Best Tools Available
• State Transition Approach to BMS Design
• BMS Interface to Combustion Controls
– Engineered solution for Start-up and yearly testing
– Considerations for system requirements when the unit is not
running
– Summary / Questions?
Interface with Combustion Controls
 Typical Systems use many flags or Bits.
1. Go To Min Fire
 Only One Parameter
2. Open Valves for Purge was Required.
3. Set Valves to Ignite Pilot The State.
4. Set Valves to Ignite Main Burner
5. Main Light, Release to Modulate  It Resets Itself.

 These items have to be Set / Reset / tested

Presentation:
– Details of the SRU BMS Project
– Proven Solution Using Best Tools Available
• State Transition Approach to BMS Design
• BMS Interface to Combustion Controls
– Engineered solution for Start-up and yearly testing
– Considerations for system requirements when the unit is not
running
– Summary / Questions?
Projects Remember Customer Needs

 Project teams consider start-up time, but sometimes

forget the yearly testing.
 Operations is the final customer!
 Successful projects consider entire Life Cycle!

 Used existing tools effectively to deliver a better

result.
AMS and Quickcheck
Consistent / Complete / Repeatable
Testing
Ensure Each Step is Tested

Step 1 – Sets All Transmitters to Normal

Step 2 – FT101 Vote to Trip
Step 3 – FT101 & FT102 Vote to Trip
Step 4 – Resets All Transmitters to Normal
Step 5-7 – Tests FT102 & FT103
Step 8 – Tests FT101 Over-range
Step 9 – Tests FT101 Under-range
Step 10-16 – Tests other Transmitters
Testing Considerations – Loss of Flame
Trips Graphic
Bypass Considerations
Presentation:
– Details of the SRU BMS Project
– Proven Solution Using Best Tools Available
• State Transition Approach to BMS Design
• BMS Interface to Combustion Controls
– Engineered solution for Start-up and yearly testing
– Considerations for system requirements when the unit is not
running
– Summary / Questions?
Allow Stroking of any BMS Valve during
Down Time
Presentation:
– Details of the SRU BMS Project
– Proven Solution Using Best Tools Available
• State Transition Approach to BMS Design
• BMS Interface to Combustion Controls
– Engineered solution for Start-up and yearly testing
– Considerations for system requirements when the unit is not
running
– Summary / Questions?
Summary / Results
 Utilized Advance Function Blocks in a
State Transition Diagram approach
 Simplified Interface with Combustion
Controls
 Consideration for Yearly Testing
using AMS and Quickcheck
 Consideration for stroking Valves
during Turn-around
 The approach can also be used for
other applications in Safety Logic
Solvers or DeltaV Controllers
 Successful Startup
 Testing of all Trips was done very
quickly and systematically
 Thank you…

…any Questions?

David.Sheppard@Emerson.com
WWW.EasyDeltaV.Com